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Kingfisher Plus+ Hardware Manual
KINGFISHER PLUS+ Modular RTU Hardware Reference Manual 7.15
Kingfisher Plus+ Hardware Manual
Document Control
Copyright Copyright 2000 - 2014 Semaphore Australia Pty Ltd. ABN 35 006 805 910 www.servelec-semaphore.com, info.kingfisher@servelec-semaphore.com
Kingfisher Plus+ Hardware Manual
Revision History
Version Number Date Summary
7.0 7.1 7.12
28/10/2011
Update: adaptor ADP-22B (include Wavecom extend) Update: temp sensor is white / white with a black strip Update: power requirements of T option board Update: power calculation tables Update: Comms option boards selection table Update: safety warnings Update: Lenses for PS-12 and PS-22 Update: Lens for MC-31 Proposed ‘Linked Backplane Example’ chapter removed Update: Various errors found in first release
7.13 3/9/2012
Corrected IO-5 power consumption Added CP-12 power consumption Added CP-30/MC-30/MC-31 to compatibility chapter Corrected various spelling and grammatical mistakes Outlined A3 / T3 simultaneous master and slave limitation in rare use-cases Added IO-5 Power Consumption Corrected RJC-ADP30 Diagram, RJ45 wiring error corrected Updated T3 temp range Added block diagrams for all IO Modules Added Option Board installation guide PS-x2 nominal voltage at low temperatures extended to 15°C after further testing Logo updated
7.14 24/10/2014
Added new modules. Added block diagrams for various modules. Modules specifications reviewed and updated. Safety warnings updated. Non-operational hyperlinks updated. Logo and the document style updated. Various corrections and updates.
7.15 18/11/2014
MC-10/11/30 modules added. PS-11 and PS-21 modules added. Option Board T2 added. Various corrections and updates.
Kingfisher Plus+ Hardware Manual
CONTENTS 1. INTRODUCTION......................................................................................... 7
2. B ACKPLANES ........................................................................................... 8 2.1 Overview ........................................................................................................................... 8 2.2 BA-x-PLUS Backplanes .................................................................................................... 9
2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor .................................................... 9 2.2.2 BA-40-PLUS: 4-slot Backplane................................................................................. 10 2.2.3 BA-6-PLUS: 6-slot Backplane................................................................................... 11 2.2.4 BA-12-PLUS: 12-slot Backplane .............................................................................. 12
2.3 BP-x-PLUS Backplanes .................................................................................................. 13 2.4 Connectors ...................................................................................................................... 18 2.5 Linking Backplanes ......................................................................................................... 19
2.5.1 Creating Racks.......................................................................................................... 19 2.5.2 Backplane Cables ..................................................................................................... 20 2.5.3 Setting Bus Terminators ........................................................................................... 21 2.5.4 Setting Rack Number ................................................................................................ 21 2.5.5 Setting Slot Number Range ...................................................................................... 24
3. POWER SUPPLY MODULES .................................................................... 26 3.1 Overview ......................................................................................................................... 26 3.2 PS-x2 and PS-x1 Power Supply Modules ...................................................................... 26
3.2.1 Overview ................................................................................................................... 26 3.2.2 Options and Ordering Info ........................................................................................ 29 3.2.3 Theory of operation ................................................................................................... 30 3.2.4 Battery Charging ....................................................................................................... 31 3.2.5 Module LEDs............................................................................................................. 32 3.2.6 PS-x2 Specifications ................................................................................................. 35 3.2.7 PS-x1 Specifications ................................................................................................. 37 3.2.8 Wiring Diagrams........................................................................................................ 39
3.3 PSU-x AC Power Supply Unit ......................................................................................... 43 3.4 Calculating Power Requirements ................................................................................... 47
3.4.1 Total Current Consumption....................................................................................... 47 3.4.2 5 V Rail Overload Check........................................................................................... 49 3.4.3 Total Power Load ...................................................................................................... 51 3.4.4 Battery Backup .......................................................................................................... 51
4. PROCESSOR MODULES .......................................................................... 52 4.1 Overview ......................................................................................................................... 52 4.2 PC-1: Power & Processor Module .................................................................................. 53
4.2.1 Overview ................................................................................................................... 53 4.2.2 Part Numbers ............................................................................................................ 54 4.2.3 PC-1 Module LEDs ................................................................................................... 55 4.2.4 PC-1 Specifications................................................................................................... 56 4.2.5 PC-1 Pinout ............................................................................................................... 58
Kingfisher Plus+ Hardware Manual
4.3 CP-12 Processor Module ................................................................................................ 59 4.3.1 Overview ................................................................................................................... 59 4.3.2 CP-12 Reset Procedures .......................................................................................... 59 4.3.3 CP-12 Module LEDs ................................................................................................. 60 4.3.4 CP-12 Specifications................................................................................................. 61 4.3.5 CP-12 Ports............................................................................................................... 62
4.4 CP-30: High Performance Processor Module ................................................................ 63 4.4.1 Overview ................................................................................................................... 63 4.4.2 CP-30 Options and Ordering Info ............................................................................. 63 4.4.3 Backup Battery / Reset to Factory Defaults ............................................................. 64 4.4.4 CP-30 Module LEDs ................................................................................................. 67 4.4.5 CP-30 Specifications................................................................................................. 70 4.4.6 CP-30 Ports............................................................................................................... 71
5. COMMUNICATIONS MODULES ................................................................ 72 5.1 Overview ......................................................................................................................... 72 5.2 MC-10/11/30 Communications Modules ........................................................................ 73
5.2.1 Overview ................................................................................................................... 73 5.2.2 MC-10/11/30 Module LEDs ...................................................................................... 73 5.2.3 MC-10/11/30 Specifications ...................................................................................... 74 5.2.4 MC-10/11/30 Block Diagram..................................................................................... 75 5.2.5 MC-10/11/30 Ports .................................................................................................... 75
5.3 MC-12 Communications Module .................................................................................... 76 5.3.1 Overview ................................................................................................................... 76 5.3.2 MC-12 Module LEDs................................................................................................. 77 5.3.3 MC-12 Specifications ................................................................................................ 78 5.3.4 MC-12 Ports .............................................................................................................. 79
5.4 MC-31 Communications Module .................................................................................... 80 5.4.1 Overview ................................................................................................................... 80 5.4.2 MC-31 Options and Ordering Info ............................................................................ 80 5.4.3 MC-31 Module LEDs................................................................................................. 81 5.4.4 MC-31 Specifications ................................................................................................ 84 5.4.5 MC-31 Ports .............................................................................................................. 85
6. COMMUNICATIONS OPTION BOARDS ..................................................... 86 6.1 Overview ......................................................................................................................... 86 6.2 Installing and removing Option Boards........................................................................... 86 6.3 Option Board I: Isolated serial ........................................................................................ 89
6.3.1 Overview ................................................................................................................... 89 6.3.2 Serial Option Board Connections ............................................................................. 90
6.4 Option Board F: Fibre Optic Serial Board....................................................................... 92 6.5 Option Board D: 33.6 kbps Dial Option Board................................................................ 93 6.6 Option Board L: Line/Analogue Radio Interface............................................................. 95
6.6.1 Line Board Connections............................................................................................ 95 6.6.2 Connecting a Radio .................................................................................................. 96 6.6.3 2-Wire Line, point-to-point ........................................................................................ 97 6.6.4 2-Wire Line, multi-drop.............................................................................................. 97
Kingfisher Plus+ Hardware Manual
6.6.5 4-Wire Line, point-to-point ........................................................................................ 98 6.6.6 4-Wire Line, multi-drop.............................................................................................. 98
6.7 Option Board H: HART Interface .................................................................................. 101 6.7.1 HART Board Connections ...................................................................................... 101
6.8 Option Boards T3 & T2: 10/100 Ethernet Controller .................................................... 104 6.9 Option Board A3: Fibre Optic Ethernet ......................................................................... 105 6.10 Option Board R2: Australian Spread Spectrum Radio ............................................... 106 6.11 Option Board R3: International Spread Spectrum Radio ........................................... 108 6.12 Option Board R4: US/Canada Spread Spectrum Radio ............................................ 110
7. PC-1 OPTION BOARDS...........................................................................112 7.1 PC-1 Serial Option Board ............................................................................................. 112 7.2 PC-1 Modem Board PL: Two Wire Line ....................................................................... 113 7.3 PC-1 Modem Board: Analogue Radio Interface ........................................................... 114
8. COMPATIBILITY .....................................................................................115
9. AN ALOGUE INPUT MODULES ................................................................116 9.1 AI-1: 8 Channel Analogue Current Input Module ......................................................... 116
9.1.1 Overview ................................................................................................................. 116 9.1.2 AI-1 Module LEDs ................................................................................................... 118 9.1.3 AI-1 Specifications .................................................................................................. 119 9.1.4 AI-1 Wiring Diagram................................................................................................ 120
9.2 AI-10: 8 Channel High Impedance Analogue Input Module......................................... 122 9.2.1 Overview ................................................................................................................. 122 9.2.2 AI-10 Module LEDs ................................................................................................. 125 9.2.3 AI-10 Specifications ................................................................................................ 126 9.2.4 AI-10 / AI-10-V Wiring Diagram .............................................................................. 127
10. AN ALOGUE OUTPUT MODULE .............................................................129 10.1 AO-3: Analogue Output Module.................................................................................. 129
10.1.1 Overview ............................................................................................................... 129 10.1.2 AO-3 Module LEDs ............................................................................................... 131 10.1.3 AO-3 Specifications .............................................................................................. 132 10.1.4 AO-3 Wiring Diagram ............................................................................................ 133
11. DIGITAL INPUT MODULES....................................................................135 11.1 Overview ..................................................................................................................... 135 11.2 DI-5: DC Input 16 Channel Digital Input Module ........................................................ 135
11.2.1 Overview ............................................................................................................... 135 11.2.2 DI-5 Module LEDs................................................................................................. 136 11.2.3 DI-5 Specifications ................................................................................................ 137 11.2.4 DI-5 Wiring Diagram ............................................................................................. 138
11.3 DI-10: AC or DC Input, 16 Channel ............................................................................ 140 11.3.1 Overview ............................................................................................................... 140 11.3.2 DI-10 Options and Ordering Info .......................................................................... 141 11.3.3 Theory of operation ............................................................................................... 142
Kingfisher Plus+ Hardware Manual
11.3.4 Configurable Functions ......................................................................................... 143 11.3.5 Sequence of Events Recording ............................................................................ 144 11.3.6 GPS Time Synchronisation (Optional) ................................................................. 144 11.3.7 DI-10 Module LEDs............................................................................................... 146 11.3.8 DI-10 Specifications .............................................................................................. 148 11.3.9 DI-10 Wiring Diagram ........................................................................................... 151
12. DIGITAL OUTPUT MODULES ................................................................153 12.1 Overview ..................................................................................................................... 153 12.2 Switching Inductive Loads .......................................................................................... 153 12.3 DO-1: 8 Channel Isolated Relay Output Module ........................................................ 154
12.3.1 Overview ............................................................................................................... 154 12.3.2 DO-1 Module LEDs ............................................................................................... 156 12.3.3 DO-1 Specifications .............................................................................................. 157 12.3.4 DO-1 Wiring Diagram............................................................................................ 158
12.4 DO-2: 16 Channel Relay Output Module.................................................................... 160 12.4.1 Overview ............................................................................................................... 160 12.4.2 DO-2 Module LEDs ............................................................................................... 162 12.4.3 DO-2 Specifications .............................................................................................. 162 12.4.4 DO-2 Wiring Diagram............................................................................................ 163
12.5 DO-6: 16 Channel Open Drain Output Module .......................................................... 165 12.5.1 Overview ............................................................................................................... 165 12.5.2 DO-6 Module LEDs ............................................................................................... 166 12.5.3 DO-6 Specifications .............................................................................................. 166 12.5.4 DO-6 Wiring Diagram............................................................................................ 167
13. RELAY EXPANSION BOARDS ...............................................................169 13.1 Overview ..................................................................................................................... 169 13.2 TEL REL 002: SPDT Relay Board.............................................................................. 171
13.2.1 Overview ............................................................................................................... 171 13.2.2 TEL REL 002 Specifications ................................................................................. 171 13.2.3 TEL REL 002 Wiring Diagram .............................................................................. 172
13.3 TEL REL 003: SPST Relay Board .............................................................................. 174 13.3.1 Overview ............................................................................................................... 174 13.3.2 TEL REL 003 Specifications ................................................................................. 174 13.3.3 TEL REL 003 Wiring Diagram .............................................................................. 175
13.4 TEL REL 004: DPDT Relay Board ............................................................................. 177 13.4.1 Overview ............................................................................................................... 177 13.4.2 TEL REL 004 Specifications ................................................................................. 177 13.4.3 TEL REL 004 Wiring Diagram .............................................................................. 178
14. COMBINATION IO MODULES ................................................................180 14.1 IO-2: Combinational Digital IO Module ....................................................................... 180
14.1.1 Overview ............................................................................................................... 180 14.1.2 IO-2 Module LEDs ................................................................................................ 182 14.1.3 IO-2 Specifications ................................................................................................ 182 14.1.4 IO-2 Wiring Diagram ............................................................................................. 183
14.2 IO-3: Combinational Analogue/Digital IO Module ...................................................... 185
Kingfisher Plus+ Hardware Manual
14.2.1 Overview ............................................................................................................... 185 14.2.2 IO-3 Module LEDs ................................................................................................ 187 14.2.3 IO-3 Specifications ................................................................................................ 188 14.2.4 IO-3 Wiring Diagram ............................................................................................. 190
14.3 IO-4: Combinational Analogue / Digital IO Module .................................................... 192 14.3.1 Overview ............................................................................................................... 192 14.3.2 IO-4 Module LEDs ................................................................................................ 194 14.3.3 IO-4 Specifications ................................................................................................ 195 14.3.4 IO-4 Wiring Diagram ............................................................................................. 197
14.4 IO-5: Combinational Analogue / Digital IO Module .................................................... 199 14.4.1 Overview ............................................................................................................... 199 14.4.2 IO-5 Module LEDs ................................................................................................ 202 14.4.3 IO-5 Specifications ................................................................................................ 203 14.4.4 IO-5 Wiring Diagram ............................................................................................. 205
15. AD APTORS AND CABLES ....................................................................207 15.1 Overview ..................................................................................................................... 207 15.2 RTU Test Cables......................................................................................................... 209 15.3 Device Cables and Adaptors ...................................................................................... 210
16. ACCESSORIES .....................................................................................221 16.1 MBR-3: 19” Rack Mounting for BA-12 ........................................................................ 221 16.2 TEL-RAK-002: 19” Rack Mounting for BA-4/6/40 ...................................................... 222 16.3 Battery Bracket: 7 Ah Battery Mounting Bracket ........................................................ 223
17. GLOSSARY...........................................................................................224
18. APPENDIX A: SYSTEM INSTALLATION ............................................................225
Kingfisher Plus+ Hardware Manual
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1. INTRODUCTION A Kingfisher Plus+ Remote Terminal Unit (RTU) is a highly configurable device that can monitor and control a wide range of equipment.
This manual details the specifications for each type of module, option board, cable and accessory available for use with a Kingfisher Plus+ Modular RTU.
There are three types of Kingfisher Plus+ modular RTUs identified by the processor module they contain: PC-1, CP-12 or CP-30.
PC-1 CP-12 CP-30
Modular RTUs support up to 64 modules and 1008 IO (input/output) points. Each modular RTU has at least one backplane, a power supply and a processor module.
A PC-1 RTU is powered using an external AC/DC power supply. A PC-1 processor module is only used on a BA-4 PLUS backplane (4 slot).
A CP-12 or CP-30 RTU is powered using a power supply module (or modules) and utilizes one of three backplanes: a BA-40 PLUS (4 slot), a BA-6 PLUS (6 slot) or a BA-12 PLUS (12 slot). A Powered Backplane (BP-x-PLUS) can also be used.
IO (input/output) modules can be added to the RTU in any combination as required. To obtain more communications ports, one or more communications modules can be added to the RTU.
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2. BACKPLANES
2.1 Overview The purpose of a backplane is to host all Kingfisher Plus+ modules that make an RTU and to allow the processor module to communicate with all other modules within the same RTU. The backplane also distributes power to each module. Some backplanes can be linked together to create an RTU containing up to 64 modules.
There are two families of Kingfisher Plus+ backplanes available:
• BA-x / BA-x-PLUS – passive backplanes that require a power supply module to be installed in one of the slots to make the RTU working. These backplanes range is a flexible solution for creating medium- to large-scale RTUs of any desired configuration.
• BP-x-PLUS – backplanes with an integrated 5 V power converter that require only one external +12 VDC power supply to run the RTU. These backplanes have limited expansion and configuration capabilities and mainly aimed for building small-scale low-cost RTUs.
Seven versions of backplanes are available in total:
BA-4 / BA-4-PLUS 4-slot backplane for use with PC-1 processor module
BA-40 / BA-40-PLUS 4-slot backplane
BA-6 / BA-6-PLUS 6-slot backplane
BA-12 / BA-12-PLUS 12-slot backplane
BP-2-PLUS 2-slot backplane with integrated 5 V power supply
BP-4-PLUS 4-slot backplane with integrated 5 V power supply
BP-6-PLUS 6-slot backplane with integrated 5 V power supply
Note: Where the number of slots is not important, the backplanes will be referred to as ‘BA-x-PLUS’ (for all passive backplanes) and ‘BP-x-PLUS’ (for all backplanes with a built-in power supply) further in this document. The part numbers with the ‘-PLUS’ suffix use the green pluggable terminal blocks for the inter-rack data connectors, while the old (will be referred to as ‘BA-x’) backplanes use black crimp connectors (Harwin Datamate M80) for that purpose.
All Kingfisher Plus+ backplanes are designed to be surface mounted. Mounting brackets (2 pieces) are supplied for user fitting. The backplanes can also be mounted in a 19" rack (see “Accessories” chapter for details).
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2.2 BA-x-PLUS Backplanes
2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor A BA-4-PLUS backplane is designed to be used with a PC-1 power and processor module. The PC-1 is installed into the leftmost slot and any other modules can be installed in the remaining 3 slots.
Please use a BA-40-PLUS backplane if requiring a 4-slot backplane for use with a CP-xx processor and a PS-xx power supply.
BA-4-PLUS backplane
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2.2.2 BA-40-PLUS: 4-slot Backplane A BA-40-PLUS backplane is identical to a BA-4-PLUS backplane but with the J6 Power Connector and the PC-1 Power Connector are removed.
This backplane is designed to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.
BA-40-PLUS backplane
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2.2.3 BA-6-PLUS: 6-slot Backplane A BA-6-PLUS six-slot backplane is designed to support any power supply, IO or communications module in any slot position. This backplane is intended to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.
BA-6-PLUS backplane
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2.2.4 BA-12-PLUS: 12-slot Backplane A BA-12-PLUS twelve-slot backplane is designed to support any power supply, IO or communications module in any slot position. It is intended to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.
BA-12-PLUS backplane
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2.3 BP-x-PLUS Backplanes BP-x-PLUS backplanes are available as two-, four- and six- slot versions (BP-2-PLUS, BP-4-PLUS and BP-6-PLUS correspondingly).
The BP-x-PLUS backplanes serve the same purpose as the BA-x-PLUS backplanes, the main difference is that these backplanes have an integrated 5 VDC / 5 A power converter on board and, as a result, do not require a PS-xx power supply for the RTU to work. In order to operate, the BP-x-PLUS backplanes need only be powered from a single external 12 VDC power source. If a backup power source is required then a 12 V lead-acid battery can be connected in parallel with an input power supply with its output adjusted to 13.8 V level. The BP-x-PLUS backplanes do not provide any battery charging means by themselves.
BP-2-PLUS backplane
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BP-4-PLUS backplane
BP-6-PLUS backplane
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The BP-x-PLUS backplane provides switchable 12VAUX output for powering extra circuits (e.g. an external radio) with its voltage derived directly from the BP-x-PLUS input and therefore not regulated. The output is in ON-state by default and can be controlled by the Toolbox software or user logic (implementation pending).
The status of BP-x-PLUS power rails is indicated by corresponding LED indicators shown on the figure below.
BP-x-PLUS LED Indicators
5V-rail status (top row of LEDs):
• Green (left) LED — 5 VDC power is normal. • Red (right) LED — 5 VDC level is out of range due to overload or circuit fault.
12VAUX-rail status (bottom row of LEDs):
• Green (left) LED — 12 VDC AUX power is turned ON and is normal. • Red (right) LED — 12 VDC AUX level is out of range due to overload or circuit fault. • Both LEDs OFF — 12 VDC AUX power is turned OFF.
The BP-x-PLUS backplanes offer the following protection features:
• Input is protected from overvoltage and reverse polarity (crowbar protection level set to 18 VDC), and from overcurrent (a polyfuse rated at 6 A @ 25 °C).
• 5 VDC output is protected from overload (5 A maximum output current).
• 12 V AUX output is protected from overload (2 A maximum output current).
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Note that the crowbar protection circuit will latch when its voltage is either below -0.5 V or above +18.5 V (approximately). It will clamp the input power rail voltage to a very low value: ± (0.5 – 2.5) V depending on the clamp current supplied by a power source. If the power source can provide current exceeding a polyfuse trip current (3-24 A depending on the ambient temperature), it may trip also, limiting the clamp current to several milliamperes.
To recover protective circuit after tripping, the input voltage should be removed completely. A 5-10 s pause before re-applying input power may be required to allow for the polyfuse to cool down if it has tripped.
WARNING. Install BP-x-PLUS as close to the power source as practically possible. To avoid tripping of the overvoltage / reverse polarity protection circuit, that may occur due to voltage overshoots caused by the parasitic inductances of the long wires, the power wires length should not exceed 3 m. Install a 330 - 1000 µF (rated 25 V minimum) capacitor as close as practical to the input power terminals of the BP-x-PLUS backplane if high levels of electromagnetic interferences may be present at the installation site.
There are no adjustable or serviceable parts on the BP-x-PLUS backplanes. Since these backplanes are not configurable, their rack number is always fixed to #1 and their slot numbering always starts from 1. Therefore, only one BP-x-PLUS backplane can be used in the RTU. However, Power and/or Data Connectors to extend the RTU using BA-x-PLUS backplanes are available.
Block-diagram of the BP-x-PLUS backplanes is shown in the figure below.
BP-x-PLUS backplane Block Diagram
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Specifications of the BP-x-PLUS backplanes are summarised in the table below.
PARAMETER VALUE COMMENT
Operating Temperature Range -40 to +85 °C
Input Power Rating 10-16 VDC; 5 A
Output Power Rating (5V output)
5 VDC ± 5%; 5 A max
Derated at high temperatures, refer to the “BP-x-PLUS 5V Output Derating Curve” graph below for details.
Output Power Rating (12V AUX output)
10-16 VDC; 2 A max
Non-regulated. The output is ON by default but can be controlled by processor software.
Rack Number 1 Not configurable.
Slot Numbers
1 - 2 2-slot version (BP-2-PLUS). Not configurable.
1 - 4 4-slot version (BP-4-PLUS). Not configurable.
1 - 6 6-slot version (BP-6-PLUS). Not configurable.
BP-x-PLUS 5V Output Derating Curve
The BP-x-PLUS backplanes are fully compatible with all other Kingfisher Plus+ modules except Power Supply units (PS-xx). Although accidental installation of PS-xx module into a powered backplane will not cause any damage, this is not recommended as the BP-x-PLUS modules are intended to supply power independently and not designed to share power with other power sources.
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2.4 Connectors There are several connectors located at the right-hand side of the Kingfisher Plus+ backplanes which are used for wiring power and/or signals outside of a backplane. The type and quantity of the connectors depend on the model of the backplane. Please refer to the pictures of the backplanes shown earlier in this chapter and/or the connector reference designators to determine which connectors exist on your backplane. All connectors are described in the table below.
DESIGNATOR CONNECTOR TYPE CONNECTOR PINOUT
J14 6-pin 4.2 mm male header (white).
Molex P/N 39-28-8060 (mating part P/N 39-01-2065).
Note: the ‘24V’ pin may be used for other purposes such as time-synchronisation between backplanes.
J13, J15* 7-pin 3.5 mm male header (green).
Phoenix P/N 1843651 (mating part P/N 1840418).
J6 9-pin 5.08 mm male header (orange).
Weidmuller P/N 1520260000 (mating part P/N 1716390000).
J5 4-pin 3.5 mm male header (green).
Phoenix P/N 1843622 (mating part P/N 1840382).
* - J15 for BA-x-PLUS backplanes only; not present on BP-x-PLUS units.
It is recommended to cover all unused backplane connectors in harsh environmental conditions (e.g. by fitting the mating connector). The parts suitable for the Power and Data connectors are listed in the table above. The suitable mating parts for the 32-pin module slot connectors are listed below:
1. Oupiin P/Ns: 9001-3532 / 9001-3520 / 9001-3732 / 9001-3720.
2. Harting P/Ns: 09 22 132 7922 / 09 22 132 6922 / 09 22 132 2922 / 09 22 132 7921 / 09 22 132 6921 / 09 22 132 2921.
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2.5 Linking Backplanes
2.5.1 Creating Racks A single RTU can consist of up to 64 modules by using a six-bit number adopted in the Kingfisher Plus+ systems:
In order to organise connection of up to 64 modules into one RTU, backplanes should be linked together into ‘racks’. Each rack can have a maximum of 16 slots. A single RTU can support up to 4 racks thus providing a total of 64 module slots.
The figure below shows one full rack (16 slots) consisting of a BA-40-PLUS linked to a BA-12-PLUS.
The BA-x-PLUS backplanes have an IN and an OUT connectors (J13 and J15 described earlier) linking them to the RTU data bus. The BP-x-PLUS backplanes have only one (OUT) connector linking them to the RTU data bus (J13). The reason for this is that the BP-x-PLUS backplane must always be the first in an RTU.
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2.5.2 Backplane Cables While building an RTU, it may become necessary to organise signals and/or power connections between backplanes. To implement the required interconnections the cables will be required that can be either assembled (based on the data on the backplane connectors provided above) or ordered from your Kingfisher supplier. The following cables are available for order:
Order Code Description To be used with Backplanes (Connectors)
POWER CABLES
BPC-01 Interrack 6-way Power Cable, 0.6 m All (J14 to J14)
BPC-02 Interrack 6-way Power Cable, 1.1 m All (J14 to J14)
COMM CABLES
BAC-01 Interconnect cable, 0.5 m, 8-pin clip on both ends
BA-x (J13/J15 to J13/J15)
BAC-02 Interconnect cable, 1.0 m, 8-pin clip on both ends BA-x (J13/J15 to J13/J15)
BAC-INT-01 Interconnect cable, 0.5 m, 8-pin clip to 7-pin terminal plug
BA-x (J13/J15) to BA-x-PLUS (J13/J15) BA-x (J13/J15) to BP-x-PLUS (J13)
BAC-INT-02 Interconnect cable, 1.0 m, 8-pin clip to 7-pin terminal plug
BA-x (J13/J15) to BA-x-PLUS (J13/J15) BA-x (J13/J15) to BP-x-PLUS (J13)
BAC-PLUS-01 Interconnect cable, 0.5 m, 7-pin terminal plug on both ends
BA-x-PLUS (J13/J15 to J13/J15) BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)
BAC-PLUS-02 Interconnect cable, 1.0 m, 7-pin terminal plug on both ends
BA-x-PLUS (J13/J15 to J13/J15) BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)
SPECIAL CABLES
BPC-02-GPS
Interrack 2-way Cable, 1.1 m (24V / SYNC and GND pins only) To distribute GPS time-sync pulse across racks without power distribution
All (J14 to J14)
BPC-SPLIT BPC Splitter Cable, 6-way, 0.1 m All (J14) to 2x BPC-0x / BPC-02-GPS cables
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2.5.3 Setting Bus Terminators Each BA-x-PLUS backplane has data bus terminators (resistors) that can be Enabled or Disabled by the first six switches of the DIP-switch installed on the backplane PCB (please refer to the information printed on the backplane board surface for exact details on possible switch configurations). A chain of backplanes requires the terminators to be switched ON (Enabled) for the first and the last backplane in the chain. All intermediate backplanes must have terminators switched OFF (Disabled). The BP-x-PLUS backplanes have their terminating resistors always enabled as they are designed to be the first backplane in a rack.
IO-bus terminators control switches CM-bus terminators control switches
2.5.4 Setting Rack Number While the rack number value of the BP-x-PLUS backplanes is always fixed (and equal to #1), the BA-x-PLUS backplanes allow that their rack number to be configured with the switches #7 and #8 of the on-board DIP-switch (please refer to the information printed on the backplane board surface for exact details on possible switch configurations).
Rack Number control switches
The following table outlines the DIP switch configuration required for the most recent hardware revisions of the BA-backplanes (v2.x and v3.x). For previous hardware versions please refer to the Superseded Products manual available on Semaphore Helpdesk.
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Tota l Number of Racks in RTU
Sw itch Se ttings 1 Rack 2 Racks 3 Racks 4 Racks
1st Rack
2nd Rack
3rd Rack
4th Rack
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Backplane Switch Configuration Example (revision 2.x and 3.x):
Note that supplementary to the data bus connections shown, each backplane requires either a Power Supply Module installed or a power cable connected to J14.
For previous backplane hardware revisions please refer to the Superseded Products Manual.
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2.5.5 Setting Slot Number Range Backplanes have hard-coded slot numbers which, for the BA-x-PLUS modules, can be set to four different ranges determined by the rack number (please refer to the ‘Setting Rack Number’ section of this chapter for details). The BP-x-PLUS backplanes slot numbering range is not configurable and always starts from #1.
The BP-x-PLUS, BA-6-PLUS and BA-12-PLUS backplanes occupy the start of each rack, while the BA-4-PLUS (and BA-40-PLUS) occupies the last four slot numbers in each rack (e.g. #13 to #16 in Rack 1). Starting from v3.3, the BA-4-PLUS / BA-40-PLUS backplanes can be used in the beginning of the rack as well. To achieve this, the BA-4-PLUS / BA-40-PLUS backplanes are equipped with an extended 10-way DIP-switch. Switches #9 and #10 are used to configure the desired slot numbering range (see the figure below for possible switch configurations).
Slots numbered from 1 to 4 (for Rack 1) Slots numbered from 13 to 16 (for Rack 1)
Slot Number Range control switches (BA-4-PLUS & BA-40-PLUS only)
The configuration when both #9 and #10 switches are turned ON (factory default setting) is equal to the left picture above (Slots are numbered from 1 to 4 for Rack 1) but increases current consumption from the 5V rail by 3 mA approximately. The configuration with both #9 and #10 switches turned OFF should not be used as the slot numbering setting becomes undefined.
An example of the possible RTU configuration, explaining rack and slot numbering sequence, is shown on the picture below.
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3. POWER SUPPLY MODULES
3.1 Overview The Kingfisher Power Supply Modules allow real time monitoring of currents, voltages and temperatures supplied to the RTU and the backup battery. The monitoring capability also allows the RTU to determine when a supply has failed if in a redundant configuration.
If fitted, auxiliary supplies can be overridden manually or by logic to allow for external equipment or sensor loops to be shut down or reset.
3.2 PS-x2 and PS-x1 Power Supply Modules
3.2.1 Overview • Monitoring of rail voltages, supply & battery currents and temperature • AC or DC input • Support for redundancy (several supplies per backplane) • Isolated DC output • Sealed Lead Acid battery connection with charging/monitoring and low voltage
protection • Software controlled power to the Backplane and Aux Outputs
Note: PS-x1 is a SUPERSEDED product and is not being manufactured currently.
Fire Risks
A supply voltage outside the specified limits may cause fire.
Risques d'Incendie
Une tension d’alimentation en dehors des limites spécifiées peut provoquer un incendie.
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Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide
appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit
breaker, depending on installation) before performing any operation on this product.
Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
L’alimentation secteur doit être raccordée conformément aux règles et réglementations nationales de câblage locales. Les
équipements du bâtiment doivent assurer une protection appropriée contre les courts-circuits.
Toujours enlever la tension d’alimentation (en débranchant le cordon d’alimentation de la prise d’alimentation secteur ou en
coupant le disjoncteur externe en fonction de l’installation) avant d’effectuer toute opération sur ce produit.
Débranchez le cordon d’alimentation du module d’alimentation avant le câblage, le retrait ou l’entretien.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves du personnel ou même la mort.
Warning
The Earth Terminal in the mains power inlet provides only FUNCTIONAL EARTH connection.
It cannot be relied upon for safety purposes.
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Avertissement de Sécurité
Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE.
On ne peut pas compter sur lui pour assurer la sécurité.
The PS-x2/PS-x1 modules provide AC-DC (PS-12 and PS-11 only) or DC-DC conversion from mains power into 12 VDC and 5 VDC for the backplane, as well as 12 VDC and optional 24 VDC auxiliary outputs. Both auxiliary outputs can be controlled by the RTU logic configuration.
The PS-x2/PS-x1 is supplied with an internal temperature sensor to monitor its PCB temperature and an optional external temperature sensor to monitor a backup battery. When the battery is connected, the supplied external sensor should be mounted in the vicinity of the battery negative terminal to ensure correct temperature compensation. If readings from the external temperature sensor are out of range, internal sensor data is used. Boost charge is disabled when external temperature sensor is faulty, not connected or if the battery temperature is out of range. Please note the charge circuitry is designed for float operation and short term boost of batteries already charged and in good condition. Use of this supply on flat or fully discharged batteries may cause damage to the module.
The 12V Rail Voltage, Supply Current, Battery Current, internal and, optionally, external temperature monitoring circuits, various status and controls registers enable the RTU to monitor and to control all functions of the PS-x2/PS-x1 module. The Processor Module has access to many of these values as analogue and digital points in the system.
If the Mains power interrupted and the system is powered from the backup battery, the PS-x2/PS-x1 enters Low Battery Shutdown when battery voltage drops below 10.6 V. All outputs are switched OFF for battery preservation, including Backplane power as well – effectively meaning that the whole RTU will be shut down. PS-x2/PS-x1 switches itself to the lowest power consumption mode possible, further preserving the battery from deep discharge. PS-x2/PS-x1 checks rail voltage regularly, and the Backplane power will be restored when +12V_RAIL voltage rises above 12.4 V (if no Mains present) or 11.2 V (if Mains present).
Besides various hardware protection features, PS-x2/PS-x1 firmware provides additional protection from overload. If output power exceeds its maximum specified power, the Switch-mode Power Supply (SMPS) will enter an Overload Mode. Its output voltage will be ramped down and, if overload still persists when it reaches 10.0 V (minimal output voltage), it will switch all outputs off, similar to Low Battery Shutdown. PS-x2/PS-x1 will attempt to switch the Backplane ON again regularly. RTU power will be restored permanently when overload condition is removed.
Several Power Supply modules of any type can be installed on a backplane thus providing redundant and alternative power source configurations.
PS-x2/PS-x1 modules can be swapped while RTU is running, providing that there is an alternative power source in the system for the RTU to be powered during such swap – e.g. another (redundant) PS-xx module.
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3.2.2 Options and Ordering Info Since PS-x1 modules are superseded, this section does not contain ordering information for PS-11 and PS-21 modules.
Unless explicitly noted, all hardware versions of PS-x2 modules are described in this manual. The newer PS-x2 version (v1.5) has some differences in the module features and specifications comparing with its predecessor (v1.3); in particular the available current for the 5V rail has increased from 3 A to 5 A and the operating temperature range has been extended to -40 °C to +85 °C.
The PS-x2 modules with ‘-C’ suffix in their Order Code have an additional isolated DC-DC converter board DC-10 installed / plugged in to the main PS-x2 board. It provides isolated 24 V power to the 24VAUX output.
PS-x2 options, ordering info and main specification differences are summarised in the table below:
Order Code H/W version
Ma ins Input
Pow er
24VAUX pow er
5 V max current, A
Opera ting tempera ture , °C
3.0 5.03 -20 - +70 -40 - +85
PS-12-0 v1.31
100–240 V, 50-60 Hz
or 96-340 VDC
v1.52
PS-12-C v1.31
v1.52
PS-22-0 v1.31
20-60 VDC
v1.52
PS-22-C v1.31
v1.52
Notes: 1) And earlier versions (here and further in this Manual). 2) And later versions (here and further in this Manual). 3) Linearly derated to 4.0 A from +60 °C to +85 °C.
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3.2.3 Theory of operation A combined block-diagram of the PS-x2 and PS-x1 modules is shown on the picture below.
PS-x2/PS-x1 Block Diagram
When Mains power is supplied to the SMPS, it generates a DC output voltage on the internal +12V_RAIL of the PS-x2/PS-x1. Voltage level on this rail is controlled by the microcontroller (MCU). Supply Current Sensor is used to measure current supplied by the SMPS.
When 12VBP SWITCH is activated, power from the internal rail is fed to the backplane and to the 5VBP converter that powers 5VBP rail on the backplane, providing power to all modules installed there. Both 12VBP and 5VBP outputs are connected to the backplane outputs via ideal diodes that allow for redundant connection of the PS-x2/PS-x1 modules.
24VAUX ISOLATED Converter (option ‘-C’ only) and 12VAUX SWITCH can be switched ON and OFF with user logic, providing power to the corresponding outputs of the field connector as required.
Any device connected to the ‘B’ terminals of the Field Connector (J22 for PS-x2; ), including a battery, is connected directly to the internal +12V_RAIL of the PS-x2/PS-x1. Battery Current Sensor is used to measure current flowing to or from ‘B’ terminals. Assuming that a battery is connected to these terminals, positive current flows into the battery when it is charged and negative current flows out of the battery when it supplies power to the RTU.
The PS-x2/PS-11 battery input has a crowbar protection circuit with series polyfuse to protect it from over-voltage and reverse-polarity connection. The crowbar protection circuit will latch when its voltage is either below -0.5 V or above +18.5 V (approximately). It will clamp the input power rail voltage to a very low value: ± (0.5 – 2.5) V depending on the clamp current supplied by a power source. If the power source can provide current exceeding a polyfuse trip current (2-16 A depending on the ambient temperature), it may trip also, limiting the clamp current to several milliamperes. To recover protective circuit after tripping, the input voltage should be removed completely. A 5-10 s pause before re-applying input power may be required to allow for the polyfuse to cool down if it has tripped.
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3.2.4 Battery Charging PS-x2/PS-x1 power supply modules are designed with provisions for the backup battery charging and monitoring. They can charge 12 V Sealed Lead Acid (SLA) batteries with the capacity from 6 Ah to 25 Ah connected to the ‘B+’ and ‘B-’ terminals. SLA batteries of higher capacity or unsealed (wet) lead-acid batteries can be used if required but the PS-x2/PS-x1 will not be able to fully charge them and to maintain / properly calculate its internal charge level (required for making correct decisions by charging control algorithms). As a result, their performance cannot be guaranteed.
When more than 100 mA is drawn out of (or is supplied to) ‘B’ terminals (e.g. when a battery is connected), the PS-x2/PS-x1 logic assumes that a fully discharged battery has just been connected and starts its Boost charge. Boost charge is not possible if external temperature sensor is not connected, or it is faulty, or when battery temperature is below -20 °C or above +60 °C. After boost charging the battery for the estimated time (3-10 hours, BATT DET and BATT BST LEDs ON, see below for details), the power supply will switch to Float charging (BATT DET and BATT FLT LEDs ON).
PS-x2/PS-x1 maintains an estimated charge level of the attached battery and this value is used for making a decision for switching to the Boost charge when the battery charge level drops below 40% of its nominal capacity. For this algorithm to work properly, a correct battery capacity should be provided to the PS-x2/PS-x1 via the Toolbox / RTU configuration setup. When battery is initially detected, it is assumed to be fully discharged. Boost charging time mentioned earlier is calculated based on the provided battery capacity value. Estimated battery charge level is increased by integrating measured charge current flowing into the battery over the time till it reaches the stated battery capacity. When battery current becomes negative (for instance, if Mains power is out and the RTU runs from the battery), this current is integrated over the time and subtracted from the estimated battery charge level till it reaches zero.
Please note that PS-x2/PS-x1 is not able to distinguish between the real battery connection and the connection of any other (generic) load or power source to the battery terminals, as it detects such connections only by measuring the Battery Current. As a result, all battery status related LEDs may exhibit several various patterns depending on kind of load / source connected to the ‘B’ terminals.
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3.2.5 Module LEDs
PS-x2 LEDS
PS-12-x PS-22-x
LED Sta te Description
OK
ON Module operating normally.
960 ms ON, 80 ms OFF No communications with RTU Processor Module.
OFF Power off or Module fault.
VIN ON Mains present / SMPS running1,2.
OFF Mains not present / SMPS not running.
OVLD
65 ms ON, 450 ms OFF
In Overload Mode. Output voltage is being ramped down (when powered from Mains).
OFF PS-x2 is not in Overload Mode.
Tx ON The PS-x2 is sending data to Processor Module via Backplane.
OFF No data being sent to Processor Module.
Rx ON Any RTU module sends data via Backplane.
OFF No data being sent by other modules.
BATT (Battery) LEDs
DET ON Battery or load or DC source connected to B terminals.
OFF No battery nor load nor DC source connected to B terminals3.
FLT ON Battery is slow (float) charging.
OFF Battery is not in Float Charge mode.
BST
ON Battery is fast (boost) charging.
10 ms ON, 2.0 s OFF
Boost charge is not possible (either external temperature sensor not connected or it is faulty or battery temperature is out of -20 °C to +60 °C).
OFF Battery is not in Boost Charge mode.
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LED Sta te Description
SUPP ON Battery sources current of more than 0.1 A4 to the PS-x25.
OFF Battery does not supply current to the PS-x2.
LOW
ON +12V_RAIL voltage has fallen below 11.5 V5.
40 ms ON, 5.0 s OFF Battery Low Shutdown.
OFF +12V_RAIL voltage has raised above 12.4 V5.
OUT (Outputs) LEDs
12BP ON Backplane power is switched ON.
OFF Backplane power is switched OFF (either start-up or shutdown).
5BP ON Backplane power is switched ON.
OFF Backplane power is switched OFF (either start-up or shutdown).
12AUX ON 12VAUX is switched ON.
OFF 12VAUX is switched OFF.
24AUX ON 24ViAUX is switched ON.
OFF 24ViAUX is switched OFF.
FAULT LEDs
12BP ON Backplane power is switched ON and 12VBP is below 9 V5.
OFF Backplane power is switched OFF or it is ON and 12VBP is above 9 V5.
5BP ON Backplane power is switched ON and 5VBP is below 2 V5.
OFF Backplane power is switched OFF or it is ON and 5VBP above 2 V5.
12AUX ON 12VAUX is switched ON and it is below 9 V5.
OFF 12VAUX is switched OFF or it is ON and above 9 V5.
24AUX ON 24ViAUX is switched ON and it is below 18 V5 (or no DC-10 / Option –C
module installed).
OFF 24ViAUX is switched OFF or it is ON and above 18 V5.
Notes: 1) May keep switching ON and OFF intermittently at a very light or no load (v1.3 only). 2) May keep switching ON and OFF intermittently at very heavy loads (hardware hick-up mode). 3) Short flashes every 2 s may indicate that PS-x2 is trying to detect battery. 4) Current value given to the Processor Module is negative. 5) Approximate values.
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PS-x1 LEDS
PS-11-x PS-21-x
LED Sta te Description
OK1
ON Module operating normally.
960 ms ON, 80 ms OFF No communications with RTU Processor Module.
OFF Power OFF or Module fault.
Vsup1,2 ON Mains present / SMPS running
OFF Mains not present / SMPS not running.
Vb1 ON Battery detected (the current into or out of the battery exceeds 100 mA)
2.0 s ON, 40 ms OFF
No battery nor load above 100 mA nor DC source connected to B terminals.
5V1 ON Backplane power is switched ON.
OFF Backplane power is switched OFF (either start-up or shutdown).
Vaux1 ON Auxiliary 24 V supply is installed, switched ON and output voltage is OK
OFF Auxiliary 24 V supply is either not installed or switched OFF or output voltage is out of range
BATT CHG1
ON Battery is being charged (current into battery > 100 mA)
OFF Battery is not being charged (current into battery < 100 mA or negative)
FL1 ON Battery is in slow charging (Float Charge) mode.
OFF Battery is not in Float Charge mode.
BO1 ON Battery is fast (Boost Charge) charging mode.
OFF Battery is not in Boost Charge mode.
LO1 ON Battery voltage has reached discharge condition (< 11.5 V ± 0.2 V)
OFF Battery voltage has reached charged condition (> 12.4 V ± 0.2 V)
Notes: 1) Redundant Power Supply will have all LEDs turned ON when the Power Supply module is switched OFF. 2) If the input supply source is disconnected from the redundant Power Supply, the Vsup LED will go OFF.
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3.2.6 PS-x2 Specifications PS-12 and PS-22 Pow er Supply Modules Specifica tions
Mains Power
Input PS-12-x PS-22-x
AC Rated Voltage Range (Maximum Input Current)
100 - 240 V, 50 - 60 Hz (1.5 A) Not applicable
DC Rated Voltage Range (Maximum Input Current)
96 - 340 VDC (1.5 A)
20 - 60 VDC (4.0 A)
Power Inlet
Connector PS-12-x PS-22-x
Terminal Block Plug (7.62 mm) Phoenix PC 4/3-ST-7.62
Dinkle EC762V-03P Phoenix GMSTBA 2.5/3-G-7.62
Cable Housing (optional) Phoenix KGG-PC 4/3 Not available
PCB Header (7.62 mm) Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P
Phoenix GMVSTBR 2.5/3-ST-7.62
‘B’ Input / Output
DC Rated Voltage Range (Maximum Input Current)
12.0 – 16.0 VDC (4.5 A)
Backup Battery Type Sealed Lead-Acid (SLA)
Maximum Battery Capacity 25 Ah1
Output Power
Total Rated Output Power 60 W
Output Voltage Range Maximum Current
Protection Logic Control
12 V Backplane2 10.5 - 15.6 V 4.5 A Firmware No
5 V Backplane 5 V ± 5% 3.0 A (v1.3) / 5.0 A (v1.5)3
Electronic No
Battery2 10.5 - 15.6 V 4.5 A
Polyfuse with crowbar over-voltage and reverse polarity
protection
No
12 V aux2 10.5 - 15.6 V 2.0 A Polyfuse (v1.3) / Electronic (v1.5) Yes
24 V Isolated aux 24 V ± 5% 0.25 A Polyfuse Yes
Field Connector
Terminal Block Plug (5.0 mm) WECO 120-M-111/07
Phoenix MSTB 2.5/7-G
PCB Header (5.0 mm) WECO 120-A-111/07
Phoenix MSTB 2.5/7-ST
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PS-12 and PS-22 Pow er Supply Modules Specifica tions
Monitoring
Parameter Range Accuracy
Rail Voltage (12 VBP, Battery, 12 VAUX)
9.0 - 15.6 V ± 2%
Supply Current 0.0 - 4.0 A ± 10%
Battery Current4 ±4.0 A ± 10%
External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Internal Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Safety Isolation / Maximum Working Voltage
Primary (Mains) to Secondary (Backplane, Field, Functional Earth) isolation
3.0 kVRMS / 4.2 kVDC In accordance with IEC 60950
Maximum Working Voltage on any contact of the Field Connector
42.4 VPEAK / 60 VDC relative to system (backplane) ground
Environment
Operating Temperature -20 to +70 °C (v1.3) -40 to +85 °C (v1.5)
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes: 1) Batteries exceeding quoted maximum capacity can be used. However, full charging and estimated battery charge level cannot be guaranteed. 2) Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and are controlled by the PS-x2 module when charging a battery. They will depend only on backup battery voltage when RTU runs from the battery (e.g. when there is a Mains outage). 3) Linearly de-rated to 4.0 A from +60 °C to +85 °C. 4) Negative: current flows from the battery (battery supplies power)
Positive: current flows to the battery (battery is charged).
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3.2.7 PS-x1 Specifications PS-11 and PS-21 Pow er Supply Modules Specifica tions
Mains Power
Input PS-11-x PS-21-x
AC Rated Voltage Range (Maximum Input Current)
100 - 240 V, 50 - 60 Hz (1.5 A) Not applicable
DC Rated Voltage Range (Maximum Input Current)
96 - 340 VDC (1.5 A)
20 - 60 VDC (4.0 A)
Power Inlet
Connector PS-11-x PS-21-x
Mains Connector Plug Phoenix PC 4/3-ST-7.62 Dinkle EC762V-03P
JST VHR-3M (housing) JST SVH-41T-P1.1 (contact)
Cable Housing (optional) Phoenix KGG-PC 4/3 Not available
Mains Connector PCB Header Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P
JST S3P-VH
‘B’ Input / Output
DC Rated Voltage Range (Maximum Input Current)
12.0 – 15.0 VDC (4.5 A)
Backup Battery Type Sealed Lead-Acid (SLA)
Maximum Battery Capacity 25 Ah1
Output Power
Total Rated Output Power 60 W2
Maximum total current 4.5 A
Output Voltage Range Maximum Current
Protection Logic Control
12 V Backplane3 10.2 - 14.4 V 4.5 A PS-11 : Electronic PS-21 : No
No
5 V Backplane 5 V ± 5% 3.0 A Electronic No
Battery3 10.8 - 15.0 V 4.5 A Polyfuse4 No
12 V Auxiliary3 10.8 - 15.0 V 4.0 A PS-11 : Electronic PS-21 : No
Yes
24 V Auxiliary Isolated 24 V ± 5% 0.25 A Polyfuse Yes
Field Connector
Terminal Block Plug (5.0 mm) WECO 120-M-111/07 Phoenix MSTB 2.5/7-G
PCB Header (5.0 mm) WECO 120-A-111/07 Phoenix MSTB 2.5/7-ST
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PS-11 and PS-21 Pow er Supply Modules Specifica tions
Monitoring
Parameter Range Accuracy
Rail Voltage (12 VBP, Battery, 12 VAUX)
9.0 - 15.6 V ± 2%
Supply Current 0.0 - 4.0 A ± 10%
Battery Current5 ±4.0 A ± 10%
External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Internal Temperature 0 to +80 °C ± 2 °C typ @ 25 °C
Safety Isolation / Maximum Working Voltage
Primary (Mains) to Secondary (Backplane, Field, Functional Earth) isolation
3.0 kVRMS / 4.2 kVDC In accordance with IEC 60950
Maximum Working Voltage on any contact of the Field Connector
42.4 VPEAK / 60 VDC relative to system (backplane) ground
Environment
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes: 1) Batteries exceeding quoted maximum capacity can be used. However, full charging
and estimated battery charge level cannot be guaranteed. 2) For ambient temperatures for up to +50 °C. 3) Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and are
controlled by the PS-x1 module when charging a battery. They will depend only on backup battery voltage when RTU runs from the battery (e.g. when there is a Mains outage).
4) In addition to polyfuse, the PS-11 module has a crowbar over-voltage and reverse polarity protection. The battery input of the PS-21 module does not have auto-resetting protection against reverse-polarity. Please ensure the battery is connected correctly.
5) Negative: current flows from the battery (battery supplies power) Positive: current flows to the battery (battery is charged).
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3.2.8 Wiring Diagrams
Safety Warning
Ensure that the power cord is disconnected from the power source before uncoupling it from the PS-x2/PS-x1 mains power inlet.
Disconnect power cord from the PS-x2/PS-x1 before wiring, removing or servicing the module.
Connect PS-x2/PS-x1 to Mains supply in accordance with the relevant requirements of national wiring regulations.
Mains connections of PS-x2/PS-x1 must comply with all installation requirements listed in this Manual.
Avertissement de Sécurité
Assurez-vous que le cordon d’alimentation est débranché de la source d’alimentation avant de le débrancher de l’entrée
alimentation secteur du module PS-x2/PS-x1.
Débranchez le cordon du module PS-x2/PS-x1 avant le câblage, le retrait ou la réparation du module.
Connectez le module PS-x2/PS-x1 à l’alimentation secteur en respectant toutes les règles applicables des réglementations et
normes électriques locales.
L’alimentation secteur connexions du module PS-x2/PS-x1 doit se conformer à toutes les exigences d'installation répertoriées dans ce
manuel.
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Power Supply with battery backup
PS-x2/PS-11 Wiring Diagram
PS-21 Wiring Diagram
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Notes: 1. AC mains power can be supplied to the PS-12 and PS-11 modules only. WARNING. Supplying AC mains power to a PS-22 or PS-21 module will destroy it. 2. DC mains power to the PS-12 and PS-11 modules can be supplied in any polarity. 3. DC mains power to the PS-22 and PS-21 modules can be supplied only as shown on the diagrams above. WARNING. Supplying DC mains power to the PS-22 or PS-21 module in reverse polarity may severe damage the modules, as there is no protection against reverse polarity on this input. 4. External temperature sensor should be installed directly onto the battery near its negative terminal. Connect the negative sensor wire to B- or R- contact of the Field Connector. WARNING. Connecting the temperature sensor in reverse polarity will cause permanent damage to the sensor. 5. The polarity of the temperature sensor wires are colour-coded. One of the following colour pairs will be supplied based on availability:
Positive Terminal (+) connected to TS
Negative Terminal (-) connected to B- or R-
Black striped White Black
Grey Black
White Black
Red Black
Black Black striped Grey
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Powered from 12 – 16 VD C Supply:
PS-x2/PS-x1 Wiring Diagram
Notes: 1. A battery, a solar system or any other low voltage DC supply can be connected to the ‘B’ terminals to power the PS-x2/PS-x1 module.
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3.3 PSU-x AC Power Supply Unit The PSU-x AC to DC power supply module is intended to be used as a standalone unit to provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-x units do not have any power monitoring functions. Power monitoring is performed by the PC-1 processor module.
The range of supplied PSU-x modules consists of three unit types (PSU-3, PSU-4 and PSU-5), specifications of each are shown below.
Fire Risks
A supply voltage outside the specified limits may cause fire.
Risques d'Incendie
Une tension d’alimentation en dehors des limites spécifiées peut provoquer un incendie.
Warning
The Earth Terminal in the mains power inlet provides only FUNCTIONAL EARTH connection.
It cannot be relied upon for safety purposes.
Avertissement de Sécurité
Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE.
On ne peut pas compter sur lui pour assurer la sécurité.
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Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide
appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit
breaker, depending on installation) before performing any operation on this product.
Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
L’alimentation secteur doit être raccordée conformément aux règles et réglementations nationales de câblage locales. Les
équipements du bâtiment doivent assurer une protection appropriée contre les courts-circuits.
Toujours enlever la tension d’alimentation (en débranchant le cordon d’alimentation de la prise d’alimentation secteur ou en
coupant le disjoncteur externe en fonction de l’installation) avant d’effectuer toute opération sur ce produit.
Débranchez le cordon d’alimentation du module d’alimentation avant le câblage, le retrait ou l’entretien.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves du personnel ou même la mort.
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Specifications
PSU-x Power Supply Modules Specifications
Parameter PSU-3 PSU-4 PSU-5
Input Supply 90 to 260 VAC 50/60 Hz, 125 to 370 VDC
Output Voltage Adj. Range 13.5 to 16.5 VDC
Output Voltage (factory preset) +13.8 VDC
Max Output Current* 2.8 A 4 A 5 A
Load Capacity* 40 W 60 W 70 W
Isolation (AC input to DC output) 3 kVAC
Isolation (AC input to Functional Earth) 1.5 kVAC 2 kVAC 1.5 kVAC
Connector Screw Terminals
Operating Temperature* -10 to +60 °C -25 to +70 °C
Storage Temperature (at 10 – 95 % RH) -20 to +85 °C -40 to +85 °C
Operating Humidity 20 to 90 % RH (non-condensing)
Weight (without mounting bracket) 440 g 510 g 410 g
*) Refer to the “PSU-x Output Derating Curve” graph below.
PSU-x Output Derating Curve
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PSU-x Block Diagram The block diagram of the PSU-x modules is shown below.
PSU-x Block Diagram
PSU-x Mounting
PSU-x Mounting and Connections
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3.4 Calculating Power Requirements This chapter aims to assist you in selecting an appropriate power supply module/s and backup battery for your RTU. It also allows the power requirements of the RTU to be checked to ensure the power supplies are not overloaded.
Note that there is an Excel™ spreadsheet that can perform the following calculations automatically available from “Kingfisher RTU Power Budget, Backup Battery and Solar Panel Calculator”.
3.4.1 Total Current Consumption
PS-22 Typical current consumption at various DC voltages (mA)
Input Voltage 20 V 40 V 60 V
Basic Module, no options 34 20 19
24 VDC Aux Converter Installed 49 27 25
PS-12 Typical efficiency at various AC supply voltages
Input Voltage 100 V 170 V 240 V
Efficiency 85% 87% 88%
Note: No DC-DC converter installed.
Communications/Processor Modules current consumption (mA at 13.8 VDC)
Item CP-12 / MC-12 CP-21 CP-30 / MC-31
Basic Module, no options 70 147 135
PC-1 Typical current consumption (mA at 13.8 VDC)
Bare Module 24 V Aux Converter
Installed Option S Board
Installed Option R Board
Installed Option P Board
Installed
54 +53 59 62 59
For Communications Option Boards please refer to the 5 V Rail Overload Check chapter.
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IO Module typical current consumption (mA at 13.8 VDC)
Part number
24 V Converte r
OFF
24 V Converte r
ON
Ex tra current
per Ana logue Input ON
Ex tra current
per Ana logue
Output ON
Ex tra current
per Digita l
Input ON
Ex tra current
per Digita l Output
ON
Absolute max imum
current draw
AI-1 11 80 +50 [+0] - - - 480
AI-10 v1.x 25 185 +62 [+3] - - - 681
AI-10 v2.x 15 50 +38 [+0] - - - 354
AO-3 5 180 - +50 - - 380
DI-5 23 - - - +7 [+2] - 135
DI-10 40 - - - +11 [+5] - 216
DO-1 7 - - - - +31 255
DO-2 7 - - - - +13 215
DO-5/6 3 - - - - +1 19
IO-2 5 - - - +7 [+3] +12 157
IO-3 10 53 +46 [-1] +42 +10 [+1] +12 367
IO-4 8 44 +44 [-2] - +9 [+1] +12 228
IO-5 13 97 +89 [0] +42 +14 [2] +12 389
Note: Values shown are for inputs powered by the IO module itself when power is available from the 13.8 VDC supply. Values in square brackets ‘[ ]’ denote current consumption when inputs are powered by an external supply.
Relay Output Modules power consumption:
Item Per Output Maximum Consumption
TEL-REL 02 530 mW 8.5 Watts
TEL-REL 03 800 mW 12.8 Watts
TEL-REL 04 530 mW 8.5 Watts
Superseded Communications Modules current consumption (mA at 13.8 VDC)
Item CP-11 / MC-11 / MC-30
Basic Module, no options 165
Superseded IO Module typical current consumption (mA at 13.8 VDC)
Part number
24 V Converter
OFF
24 V Converter
ON
Extra current per Analogue
Input ON
Extra current per Analogue Output ON
Extra current per Digital Input ON
Extra current per Digital Output ON
Absolute maximum
current draw
AO-2 11 115 - +55 - - 335
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MC-xx / CP-xx Option Board typical 5 V Rail consumption (mA at 13.8 VDC)
Option Board Type Port label Consumption
A3 Fibre Optic Ethernet Board A3 272
Dial (PSTN) D 75
Fibre Optic Serial F 23
HART H 9
Isolated Serial (RS-232) I 32
Private Line or Analogue Radio Interface L 9
2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving
R3
41 35
900 MHz (1 W) Spread Spectrum Radio: Transmitting Receiving
R2 / R4
275 41
T3 Ethernet Option Board T3 136
3.4.2 5 V Rail Overload Check The PS-12 and PS-22 modules supply 5 VDC to the backplane for powering modules. A maximum of 3 Amps can be drawn on the 5 VDC rail from each power supply module.
Please ensure that this limit is not exceeded by totalling the 5 V current requirements for your RTU.
CP-xx and MC-xx typical 5 V Rail current consumption (mA from 5 VDC)
CP-11 MC-11 MC-30
CP-12 MC-12 CP-21 CP-30
MC-31
310 150 360 290
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CP-xx and MC-xx Option Boards typical 5 V Rail consumption (mA from 5 VDC)
Option Board Type Port labe l Consumption
ACTIVE
A3 Fibre Optic Ethernet A3 600
Dial (PSTN) D 165
Fibre Optic Serial F 50
HART H 20
Isolated Serial (RS-232) I 70
Private Line or Analogue Radio Interface L 20
2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving
R3
100 85
900 MHz (1 W) Spread Spectrum Radio: Transmitting Receiving
R2 / R4
670 100
T3 Ethernet T3 300
SUPERSEDED
10/100 Base-T Ethernet ENET-T 130
100 Base-FX (Fibre Optic) Ethernet ENET-A 650
10/100 Base-T Ethernet ENET-T2 310
10/100 Base-T Ethernet ENET-E 0 idle / 850 max
Serial (RS-232) SER-S 5
Line (original version) L(1) 120
Image Capture J 1000
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IO Module 5 V Rail current consumption (mA from 5 VDC) Module All IO inactive All IO active and powered by module
AI-1 22 27
AI-10 15 66
AO-2 22 28
AO-3 9 30
DI-5 6 40
DI-10 54 85
DO-1 15 27
DO-2 9 39
DO-5/6 48 39
IO-2 10 37
IO-3 26 36
IO-4 23 37
IO-5 37 151
3.4.3 Total Power Load The total current required to power the RTU is as follows:
𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝑇𝑇𝑇𝑇𝐿𝐿 = 𝐼𝐼𝑃𝑃𝑃𝑃𝑇𝑇𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑇𝑇𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝑀𝑀𝑀𝑀−𝑥𝑥𝑥𝑥 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑇𝑇𝐿𝐿𝑀𝑀𝑇𝑇𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 Total Power load is therefore:
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑃𝑃𝑇𝑇𝑃𝑃𝑃𝑃𝑃𝑃 [𝑊𝑊𝑇𝑇𝑇𝑇𝑇𝑇𝑊𝑊] =13.8 [𝑉𝑉] × 𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝑇𝑇𝑇𝑇𝐿𝐿 [𝑚𝑚𝑚𝑚]
1000
• The Total Current Load for a PS-12/22 should not exceed 4.5 Amps. • The Total Current Load for a PC-1 should not exceed 4 Amps. Loads greater than 4
Amps will require a PS-12/22 supply to be installed. • Users should be mindful of the current draw on the 5 VDC rail. See the “5 V Rail
Overload Check” chapter for more details.
3.4.4 Battery Backup To maximise the service life of the battery, the depth of its discharge should not exceed 50% of available capacity. E.g. for a 7 Ah battery, there is 3.5 Ah of backup power. Therefore the battery can supply 3.5 Amps for 1 hour or 1 Amp for 3.5 hours etc. The size of the backup battery required depends on how long the RTU needs to be able to run without mains power. In addition to the Total Current Load above, a backup battery will also need to power the PS-12/22 if present (not applicable if using a PC-1 processor).
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4. PROCESSOR MODULES
4.1 Overview The processor module is the core part of any RTU. It is responsible for running user logic and facilitating inter-module interactions (via backplane) and communications with the SCADA system and other RTUs and various 3rd party devices (via communications ports) as required. The amount of memory, speed, and flexibility of an RTU is determined by the processor module selected.
There are three processor modules available in the Kingfisher Plus+ modular RTU range. Each of them has one resident communications port, with an ability to add up to two additional communications ports as.
Processor modules summary:
Parameter / Fea ture PC-1 CP-12 CP-30
Processor Speed 16 MHz 40 MHz 166 MHz
Flash Memory 128 KB 512 KB 16 MB
SDRAM - - 32 MB
NV RAM 256 KB 512 KB 512 KB1
Port 1 (resident) RS-232 RS-232 10BASE-T / 100BASE-TX Ethernet
Optional Ports 12 23 23
Programming Languages Ladder Logic Ladder Logic Structured Text, Ladder Diagram, Function Block Diagram, Instruction List, Sequential
Function Chart and Flow Chart
Notes: 1) 128 KB for CP-30 v1.x. 2) See PC-1 Option Boards for available options. 3) See chapters Communications Options Boards and Compatibility for available options.
Lithium Battery
This product contains a lithium battery. Risk of explosion if battery is replaced by an incorrect type. Dispose of used batteries in accordance with local regulations or return to the supplier.
Pile au Lithium
Ce produit contient une pile au lithium. Il y a un risque d’explosion si la pile est remplacée par un modèle incorrect. Jetez les piles
usagées conformément aux réglementations locales ou retournez-la au fournisseur.
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4.2 PC-1: Power & Processor Module
4.2.1 Overview • Monitoring of battery and input supplies • Isolated DC Outputs • 16 MHz Processor • DC Input Supply • Up to two communications ports • Low Voltage Battery Protection • 256 KB SRAM
The PC-1 is one of the best supported processors available to a kingfisher RTU. It is well suited to small and mid-size installations as it features an integrated power supply, reduces the system complexity by negating the need for additional power supply modules.
With remote installations in mind the PC-1 was designed to be capable of running from a backup battery, and has a fully isolated low power DC output for external equipment.
To configure the PC-1, a PC running the Toolbox 32 software is required. The Toolbox 32 software allows the user to implement ladder logic.
The PC-1 can only be installed in the first slot of a 4-slot backplane (BA-4) and operates from a nominal +12 VDC supply (typically 13.8 VDC). The module has one fixed RS-232 port and one option port.
A PC-1 has two links that can be accessed from the rear of the module as shown below.
The SRAM battery is enabled at shipping time by the factory. The user can clear the SRAM by removing the SRAM link for five minutes. This will clear the RTU configuration and ladder logic.
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4.2.2 Part Numbers The PC-1 is available with 3 options (A, P, M) as detailed below.
PC - A P M
Device: 24 V 10 W Auxiliary Supply Converter
Port 2 Option Board Type
Memory
Part Number: 0 = Not Fitted C = Fitted
0 = Not Fitted R = Radio, V.23 FSK* P = 2-Wire Line, V.23 FSK S = Serial RS-232/RS-485
0=128 KB RAM (obsolete) 1=256 KB RAM (standard)
* Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait radios. Please indicate which Radio you are using when ordering a radio option card.
Example: PC-1-CR1 is a PC-1 with 24 VDC auxiliary converter, radio option port and extra RAM.
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4.2.3 PC-1 Module LEDs
Both of the communications ports have Tx, Rx, RTS and CD LEDs in a vertical group as shown above.
PC-1 LED Description
OK ON when module is functioning OK
DC +5V ON when the internal 5 V supply is OK. This LED should always be on
+12V ON when the internal 12 V supply is OK. This LED should always be on (software controlled)
T1 Test LED 1. Flashes during Power Down mode.
+Vs ON when the Auxiliary 24 V supply is OK (will only display if the 24 V converter is installed).
BATT CHG*
ON when the battery is being charged
DIS* ON when the battery is being discharged
LO ON when the battery voltage is low (For a PC-1 this occurs when the supply voltage is less than about 11.2 VDC)
T2 Test LED 2. Not currently used.
Tx ON when port is transmitting
Rx ON when port is receiving
RTS Request to send. Set ON to begin transmitting
CD Carrier detect: ON while a communications signal is detected.
WD Processor Watchdog Timer. Set ON when the processor is reset.
* The battery charging (BATT CHG) and battery discharging (DIS) LEDs will sometimes flicker on and off when the battery is charged to the optimum level or if no battery is connected.
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4.2.4 PC-1 Specifications PROCESSOR SPECIFICATIONS
Processor Type Intel 80C188
Word Size 16 Bit internal data bus 8 Bit external data bus
Clock Speed 16 MHz
BIOS Yes
Flash Memory 128 KB Total. 28 KB for firmware drivers.
SRAM 256 KB
Real-t ime Clock Accuracy 1 minute per month (± 20 ppm)
Watchdog Timer Yes
Status Indicat ion Yes
Bat tery Type Lithium. Not rechargeable.
Bat tery Life (module unpowered) 7 years @ 25°C
Communicat ions Ports 2
Port 1 (RS-232) Serial, 300 to 115200 Baud
Port 2 (Opt ional) Serial, Analogue Radio Interface, 2-Wire Line or 4-Wire Line 300 to 115200 Baud (depending on port type)
Modem Port 2 CCITT V23 (Opt ional)
1200 Baud
Configurat ion Software Toolbox 32
Diagnost ics Software Yes
Bas ic Configurat ion Auto on power-up
RTU Address Range 1 – 249
Communicat ions Protocol Kingfisher, DNP3, Modbus, plus many more…
Analogue Block Process ing Yes
PID Block Process ing Yes
Redundant Power Supplies Not supported
Redundant Processors Not supported
Redundant Communicat ions Yes
Internal Power Consumpt ion 120 mA from +5 VDC
I/O Bus Data Rate 250 kbps
CM Bus Data Rate 83 kbps
Cyc lic Redundancy Port 1 and 2
Operat ing Temperature -20 to +70 °C
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Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Hot Swap Not supported. Removing the PC-1 will power down the RTU.
PC-1 POWER SUPPLY SPECIFICATIONS
Input Supply to PC-1 11.5-15 VDC / 4 A maximum (60 W) Typically 13.8 VDC if backup battery connected
Outputs From PC-1
+5 VDC / 1 A maximum (5 W) to Backplane +12 VDC / 4 A maximum to Backplane* +12 VDC / 2 A maximum to Vr* +24 VDC / 400 mA (10 W) Optional Auxiliary Output (3 kV Isolation)#
Backup Bat tery 12 V
Deep Discharge Protec t ion RTU Shutdown at 10.6 V RTU Start-up at 11.8 V
Supply Fuse 7 A (Maximum Current into the PC-1)
Bat tery Fuse 7 A (Maximum Current into or out of battery)
Combined Vr and 24 VD C Fuse 3 A Polyfuse
Monitoring
Parameter Accuracy
Battery Current PC-1 Supply Voltage PC-1 Supply Current
PC-1 Temperature
± 10% ± 5% ± 10% ± 5%
* Note: backplane rail voltages are dependent on power supply to the PC-1. Most PC-1s are powered using the 40 W PSU-3 Power Supply set to 13.8 VDC when using a 12 VDC backup battery. # the +24 V converter is optional and must be ordered with the PC-1.
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4.2.5 PC-1 Pinout
Port 1 Pins Direction RS-232 signal
1 OUT DTR
2 OUT +12 V low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXD
8 OUT TXD
Please refer to the PC-1 Option boards for more information regarding port 2 option boards.
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4.3 CP-12 Processor Module
4.3.1 Overview • Support for Processor and Communications Redundancy • Up to 3 communications ports • 40 MHz x86 CPU
The CP-12 processor module has up to three independent communications ports. Ports 2 and 3 can house option boards while port 1 is a fixed serial port (RS-232).
This processor is targeted at the application space that is too complex for the PC-1 but does not required the additional features made available with a CP-30 based system. The CP-12 has extended functionality over the PC-1 such as redundant processor and communications modules support, and is compatible with Ethernet based boards.
The CP-12 uses the same configuration software as the PC-1 processor, and as such is programmable with ladder logic.
The CP-12 has 512 KB of flash memory for operating code and system parameter storage, and 512 KB of battery backed SRAM for all configuration and event storage data.
4.3.2 CP-12 Reset Procedures
The SRAM battery is enabled from the factory by default. The user can clear the SRAM by removing the SRAM link for five minutes.
This will clear the RTU configuration and Ladder Logic.
Behind the LED lens of the CP-12 there is a diagonally mounted jumper. This is a hardware feature unique to the CP-12 processor.
When the jumper pins are shorted while the module is being reset (or power cycled), the processor will enter Monitor Mode (the Kingfisher bootloader) and perform a read/write test of the SRAM. This will forcefully clear SRAM, having the same effect as removal of the SRAM link on the back of the CP-12 module.
Monitor Mode is a deterministic and efficient way of clearing a Processor as the module does not need to be removed from the Backplane, and as the SRAM is forcibly overwritten.
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Note: The RAM test is extremely fast. The CP-12 will clear the RAM nearly instantly. To exit monitor mode, remove the short and power cycle the unit again.
4.3.3 CP-12 Module LEDs
CP-12 LED Description
OK ON when Processor is functioning correctly
MON ON when Processor is in Monitor mode
WDT ON when Processor watchdog timer overflows, such as in the event of a software crash.
RST ON when in reset. Will be lit for 200 ms when cold starting.
TxD ON when transmitting data on corresponding Port
RxD ON when receiving data on corresponding Port
RTS ON when asserting Request To Send on corresponding Port
DCD ON when Data Carrier Detect affirmed on corresponding Port
10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port
100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port
LINK ON when Ethernet Link is established
COL ON when Ethernet Collision is detected
IOTX IORX
Intensity is proportional to load on backplane IO Bus (this bus is used to poll all IO modules)
CMTX CMRX
Intensity is proportional to load on load on backplane Communications Bus (this bus is used for communications modules data transmission)
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4.3.4 CP-12 Specifications PROCESSOR SPECIFICATIONS
Processor 40 MHz x86
Word Size 16 bit data bus
BIOS Yes
Flash Memory 512 KB
SRAM 512 KB
Bat tery Type Lithium Primary (not rechargeable)
Bat tery Life (module unpowered)
7 years @ 25°C
Real-t ime Clock Accuracy 1 minute per month (+/- 20 ppm)
Watchdog t imer Yes
Status Indicat ion Yes
Communicat ions Ports 1-3 (1 fixed, 2 option ports)
Port 1 (RS-232) 300 to 115200 Baud (factory default 9600 8-N-1)
Ports 2 and 3 (Opt ional) For supported port types, please see the Option Boards chapter
Configurat ion Software Toolbox 32
RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)
Communicat ions Protocol Kingfisher, Modbus + many more
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
Analogue Block Process ing Yes
PID Block Process ing Yes
Redundancy Yes. Two CP-12 modules can be installed in the one RTU. One processor module must be installed in an odd numbered slot and one in an even numbered slot.
Internal Power Consumpt ion (without Opt ion Boards)
150 mA from +5 VDC bus on backplane
I/O Bus Data Rate 250 kbps
CM Bus Data Rate 83 kbps
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Hot Swap Yes*
*) When 2 processors are present on the backplane, one processor can be swapped while the RTU is still running. However, a hot swap will cause a Warm Start of the remaining processor. All ports will be re-initialized and ready for communications within 6 seconds. New data received during the changeover may be lost. To preserve data and for more information please see the Redundancy appendix in the Toolbox 32 manual.
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4.3.5 CP-12 Ports The CP-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Communications Option Boards Chapter.
Port 1 Pins Direction RS232 signa l
1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD
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4.4 CP-30: High Performance Processor Module
4.4.1 Overview • Compliant with IEC-61131 programming languages • Up to 3 communications ports • Supports Communications and Processor Redundancy
The CP-30 is a high performance processor module that can provide exceptional speed, memory and functionality to your RTU.
Targeting large RTU systems, the CP-30 is equipped with a 166 MHz ARM9 CPU, capable of running all IEC-61131-3 certified languages, and utilises an Ethernet port as the default connection and configuration medium.
To configure the CP-30, a PC with an Ethernet port and the Toolbox PLUS+ software is required.
Toolbox PLUS+ features ISaGRAF™ software, which provides logic programming in the IEC-61131 standard languages: Structured Text, Ladder Diagram, Function Block Diagram, Instruction List, Sequential Function Chart and Flow Chart.
The processor module has up to three independent communications ports. Ports 2 and 3 can use plug-in option boards while port 1 is fixed as Ethernet (both 10 Mbps and 100 Mbps modes are supported).
RTUs can use a second CP-30 module to provide processor redundancy. One processor must be installed in an even-numbered backplane slot (the active processor on power up) and the other in an odd-numbered backplane slot (the passive processor on power up). The active processor continuously scans all backplane slots (among other tasks) so that it can detect, control and monitor all other RTU modules. The passive (standby) processor will switch to active mode when it detects that communications on the backplane stopped for longer than a predefined maximum time that may be caused (but not limited to) by:
• Failure, removal or reset of the active processor • Download of the configuration, logic or firmware to the active processor
The CP-30 flash memory is used for the storage of all operating code, RTU configuration and event logs. It also has 32 MB of SDRAM for program operation and general data storage and 128 KB (v1.x) / 512 KB (v2.x) of battery backed SRAM for non-volatile data such as retained variables and system log.
The module is powered from the +5 VDC rail on the backplane.
4.4.2 CP-30 Options and Ordering Info Unless explicitly noted, all hardware versions of CP-30 modules are described in this manual. The newer CP-30 version (v2.3) has some differences in the module features and specifications comparing with its predecessor (v1.6); in particular the amount of battery backed SRAM has increased from 128 KB to 512 KB, a quick reset to factory defaults has been added, the backup battery has been made user replaceable, and the operating temperature range has been extended to -40 °C to +85 °C.
CP-30 options, ordering info and main specification differences are summarised in the table below:
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Order Code I tem
H/W version
v1.61 V2.32
CP-30-x3y4
BB RAM size 128 KB 512 KB
Backup Battery Soldered User Replaceable
Factory Reset Module has to be removed from the slot (takes 5 min
waiting time minimum)
From the front of the module (quick)
Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C
Maximum current consumption from +5VDC rail on backplane 290 mA 200 mA
Notes: 1) And earlier versions (referred to as v1.x further in this Manual). 2) And later versions (referred to as v2.x further in this Manual). 3) ‘x’ designates a code of the communications option board installed on Port 2. 4) ‘y’ designates a code of the communications option board installed on Port 3.
Communications Option Boards codes:
Code Short Description Code Short Description
0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud
A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)
A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz
D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)
F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps
H HART Interface T21 Ethernet, Copper, 10/100 Mbps
I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps
Notes: 1) Discontinued products.
4.4.3 Backup Battery / Reset to Factory Defaults CP-30 modules include lithium coin backup battery for Real Time Clock operation and for preserving content of the battery backed SRAM when power is removed from the module.
Backup battery on v1.x is soldered to the PCB assembly of the CP-30 module. A battery retainer is used on v2.x, allowing the user to replace the battery without any special tools.
CAUTION: After removing and re-installing the SRAM link or after replacing the battery, ensure that the CP-30 is powered up for at least 1 s.
This will assure the backup battery functioning for the specified life span.
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Battery Backed RAM is connected to the backup battery via SRAM link located on the back of the CP-30 module as shown on the diagram below. The SRAM link is installed at shipping time by the factory.
The user can perform reset to factory defaults / clear the battery backed SRAM. Note. Reset to factory defaults clears RTU configuration and user logic but it will not clear the system log.
To perform reset to factory default using the SRAM link:
1. Remove CP-30 module from the backplane.
2. Remove the SRAM link for at least 5 min.
3. Install the SRAM link back on its header.
4. Install CP-30 on the backplane.
5. Switch backplane power ON (if it was OFF).
An alternative way of resetting the module to factory defaults has been added to the CP-30 v2.x hardware. It allows performing a quick reset to factory defaults:
1. Switch off power to the corresponding RTU rack.
2. Short together pins of the 2-pin header (located underneath LED display, on the front edge of the module) using a jumper link or another suitable conductive object (e.g. a metal screwdriver, ball-point pen, etc.).
3. Keeping the pins shorted, turn on the RTU power.
4. The short can be removed any time after that.
WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit board components.
CP-30 v2.x modules allow for a backup battery to be replaced by the user:
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1. Obtain (purchase or order from Semaphore) a new battery. WARNING. Only CR2450N batteries from Renata are specified for operating temperature range from -40°C to +85°C.
2. Disassemble the CP-30 module and pull the PCB out from enclosure as per ‘Installing
and Removing Option Boards’ (steps 1 to 5). WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit board components.
3. Remove old battery and safely dispose it of in accordance with your local regulations.
4. Insert the new battery all the way in into the battery holder observing correct polarity (negative terminal of the battery should face PCB surface). WARNING. Inserting battery in reverse polarity may permanently damage CP-30 module.
5. Reassemble the module as per ‘Installing and Removing Option Boards’ (steps 7 and 8).
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4.4.4 CP-30 Module LEDs
CP-30-xy (v1.x) CP-30-xy (v2.x)
LED Sta te Description
OK1,2
ON Normal operation.
0.5 s ON, 0.5 s OFF Firmware/configuration update in progress.
OFF Power off or module faulty.
F11,2
0.25 s ON, 0.25 s OFF
Port 2 configuration error.
OFF Normal operation.
F21,2
0.25 s ON, 0.25 s OFF Port 3 configuration error.
OFF Normal operation.
F31,2
ON Normal operation (active CP-30).
1 s ON, 1 s OFF
Normal operation (standby CP-30).
OFF
One of the following may be indicated:
• Module is booting up. • Initial synchronisation with standby processor in progress. • Module fault (ISaGRAF™ not started). • Logic cycle is longer than normal (blinks momentarily, on active
CP-30 only).
F4 – F73 n/a Reserved for future use.
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LED Sta te Description
P1 (Port 1) LEDs
10
ON Linked at 10 Mbps (no data activity).
Flashing Data activity (transmit or receive) at 10 Mbps.
OFF Port not connected or no link at 10 Mbps.
100
ON Linked at 100 Mbps (no data activity).
Flashing Data activity (transmit or receive) at 100 Mbps.
OFF Port not connected or no link at 100 Mbps.
LNK4 ON Linked at either 10 or 100 Mbps.
OFF Port not connected or no Ethernet link established.
COL4 ON Ethernet collision(s) detected.
OFF No collisions detected.
P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options
Tx4 TxD / 10ACT3
Flashing Port is transmitting serial data.
OFF Port is not transmitting.
Rx4 RxD / 100ACT3
Flashing Port is receiving serial data.
OFF Port is not receiving.
RTS4 RTS / LINK3
ON Request to Send output is asserted. It is usually asserted to signal readiness to transmit data to a serial device.
OFF Request to Send output is not asserted.
CD4 DCD / COL3
ON Carrier Detect input is asserted by a connected serial device.
OFF Carrier Detect input is not asserted.
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LED Sta te Description
P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options
Tx4 TxD / 10ACT3
Flashing Data activity (transmit or receive) at 10 Mbps.
OFF No data activity at 10 Mbps.
Rx4 RxD / 100ACT3
Flashing Data activity (transmit or receive) at 100 Mbps.
OFF No data activity at 100 Mbps.
RTS4 RTS / LINK3
ON Linked at either 10 or 100 Mbps.
OFF Port not connected or no Ethernet link established.
CD4 DCD / COL3
ON Ethernet collision(s) detected.
OFF No collisions detected.
Notes: 1) Progressively set ON during booting sequence. After a successful start-up: OK is ON; F1 and F2 are OFF; F3 is ON (for active processor) or flashing (for standby processor). 2) Flash rapidly to indicate firmware upgrade error. 3) CP-30 v2.x only. 4) CP-30 v1.x only.
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4.4.5 CP-30 Specifications
CP-30 Processor Module Specifica tions
Parameter v1.x v2.x
Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus
SRAM (Battery Backed) 128 KB 512 KB
Flash Memory 16 MB
SDRAM 32 MB
Real-time Clock Accuracy ±1 min / month (± 20 ppm) max
Backup Battery
Battery type CR2470 with tabs (solder type) CR2450 (coin, user replaceable)
Battery Life (module unpowered) 7 years @ 25 °C
Communications Ports
Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)
Optional 2 (for supported port types, please see the Option Boards chapter)
Input Power
Voltage 5 V ± 5%
Current1 290 mA 200 mA
Isolation
Port 1 Transient Voltage 1 kV
Environment
Operating Temperature -20 to +70 °C -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes: 1) No communications option cards installed on Ports 2 and 3.
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4.4.6 CP-30 Ports
Port 1 Pins Etherne t Signa l
1 Tx+
2 Tx-
3 Rx+
4 n/c
5 n/c
6 Rx-
7 n/c
8 n/c
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5. COMMUNICATIONS MODULES
5.1 Overview Communications modules can be utilized to add additional ports and multiple protocol capability to your RTU.
Each module is equipped with two expansion ports that can house a wide range of specialized option boards as follows:
Part Number Option Board Description
I Isolated Serial Interface, RS-232/RS-485/RS-422
F Fiber Optic Interface
D Dialup Modem (PSTN) V34 33.6 kbps
L Private Line or Analogue Radio Interface
H HART / Bell 202 interface*
A3 Ethernet MTRJ Fiber Optic Interface
T3 Ethernet RJ54 Copper – 10/100 Mbps
R2 900 MHz Spread Spectrum Radio for Australia
R3 2.4 GHz Spread Spectrum Radio for International
R4 900 MHz Spread Spectrum Radio for USA
* This option is not supported by MC-12 modules.
For more information regarding option boards and compatibility with superseded hardware, please refer to the chapter Option Boards.
Lithium Battery
These products contain a lithium battery. There is a risk of explosion if battery is replaced by an incorrect
type. Dispose of used batteries in accordance with local regulations or return to the supplier.
Pile au Lithium
Ce produit contient une pile au lithium. Il y a un risque d’explosion si la pile est remplacée par un modèle incorrect. Jetez les piles
usagées conformément aux réglementations locales ou retournez-la au fournisseur.
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5.2 MC-10/11/30 Communications Modules
5.2.1 Overview • Up to three communications ports per module • Wide range of available option boards • Fixed Serial (RS-232) port on Port 1
Note: MC-10/11/30 is a SUPERSEDED product and is not being manufactured any more.
The MC-10/11/30 multi-communications module provides up to three additional communications ports. Ports 2 and 3 are optional and use plug-in option boards while Port 1 is fixed as a serial (RS-232) port.
This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. The MC-10/11/30 modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane. An RTU can have up to 16 ports.
5.2.2 MC-10/11/30 Module LEDs
MC-10 MC-11 MC-30
LED Description
OK ON when Module is functioning correctly
Tx ON when port is transmitting
Rx ON when port is receiving
RTS Request to send. Set ON when transmitting
CD Carrier Detect. ON while a communications signal is detected
L1, L2 Not used
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5.2.3 MC-10/11/30 Specifications MC-10/11/30 Communica tions Module Specifica tions
Processor Intel 80C386EX
Word Size 32 bit internal data bus 16 bit external data bus
Clock Speed 25 MHz
BIOS Yes
Flash Memory 1 MB
Stat ic CMOS RAM 1 MB
RTC (Real-Time Clock) Yes
WDT (Watchdog Timer) Yes
Status Indicat ion Yes
Communicat ions Ports 1-3 (1 fixed, 2 option ports)
Port 1 (RS-232) 300 to 115200 Baud
Ports 2 and 3 (Opt ional) For supported port types, please see the Communications Option Boards chapter
Communicat ions Protocol Kingfisher, DNP3, Modbus + many more
MC-10/11/30 modules per RTU Maximum of 16 ports per RTU For example, can use 5 MCs if each has 3 ports
Internal Power Consumpt ion (without Opt ion Boards)
310 mA from +5 VDC bus on backplane
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Hot Swap
Yes. Module can be swapped while RTU is running. However, Hot Swap will cause a Warm Start of the processor. All ports will be re-initialised and ready for communications within 6 seconds.
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5.2.4 MC-10/11/30 Block Diagram
5.2.5 MC-10/11/30 Ports The MC-10/11/30 module features up to three serial ports accessible by RJ45 connectors on the front of the module and covered by the snap on cable cover. Port 1 is at the top for RS232 connections only. Port 2 and 3 can be configured using plug-in option boards.
Port 1 Pins Direction RS232 signa l
1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD
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5.3 MC-12 Communications Module
5.3.1 Overview • Up to three communications ports per module • Supports Communications Redundancy • Wide range of available option boards • Fixed Serial (RS-232) port on Port 1
The MC-12 multi-communications module provides up to three additional communications ports. Ports two and three can house option boards while port 1 is fixed as a serial (RS-232) port.
An MC-12 supports a maximum baud rate of 83 kbps between itself and the RTU processor module. This bandwidth can be split across a maximum of 16 ports. Users should be mindful of this limitation when determining the number of ports used simultaneously in one installation.
The MC-12 is identical to the CP-12 with the exception of labelling, the lens cover, and firmware.
The MC-12 module is only for use with PC-1 or CP-10/11/12 based RTUs.
This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. One or more MC-12 modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
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5.3.2 MC-12 Module LEDs
MC-12 LED Description
OK ON when Module is functioning correctly
MON ON when Module is in Monitor mode
WDT ON when Module watchdog timer is overflows, such as in the event of a software crash.
RST ON when in reset. Will be lit for 200 ms when cold starting.
TxD ON when transmitting data on corresponding Port
RxD ON when receiving data on corresponding Port
RTS ON when Request To Send on corresponding Port is asserted
DCD ON when Data Carrier Detect affirmed on corresponding Port
10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port
100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port
LINK ON when Ethernet Link is established
COL ON when Ethernet Collision is detected
IOTX IORX
Brightness of each indicates load on backplane IO Bus (this bus is used to poll all IO modules)
CMTX CMRX
Brightness of each indicates load on backplane Communications Bus (this bus is used for communications modules data transmission)
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5.3.3 MC-12 Specifications MC-12 Communica tions Module Specifica tions
Processor 40 MHz x86
Word Size 16 bit data bus
BIOS Yes
Flash Memory 512 KB
Watchdog t imer Yes
Status Indicat ion Yes
Communicat ions Ports 1-3 (1 fixed, 2 option ports)
Port 1 (RS-232) 300 to 115200 Baud (factory default = 9600 bps)
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
Ports 2 and 3 (Opt ional) For supported port types, please see the Communications Option Boards chapter
Configurat ion Software Toolbox 32
RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)
Communicat ions Protocol Kingfisher, Modbus + many more
Analogue Block Process ing Yes
Internal Power Consumpt ion (without Opt ion Boards)
150 mA from +5 VDC bus on backplane
I/O Bus Data Rate 250 kbps
CM Bus Data Rate 83 kbps
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
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5.3.4 MC-12 Ports The MC-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Communications Option Boards chapter.
Port 1 Pins Direction RS232 signa l
1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD
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5.4 MC-31 Communications Module
5.4.1 Overview • Up to 3 communications ports • Fixed Ethernet (Twisted Pair) port on Port 1 • Supports Communications Redundancy • Wide range of available communications option boards
The MC-31 Communications Module provides three additional communications ports for an RTU. Port 1 is a fixed Ethernet port while Ports 2 and 3 are optional and can house variety of option boards.
The MC-31 hardware is identical to the CP-30 with the exception of labelling, the lens cover and firmware.
The MC-31 Communications modules can be used only with the CP-30 Processor modules.
They are powered from the +5 VDC rail on the backplane and can be swapped while RTU is running without causing RTU restart. One or more MC-31 modules can be used in the system.
5.4.2 MC-31 Options and Ordering Info MC-31 v1.5 and v1.6 modules have been supplied to the market for several years. At the time of publication of this Manual (3q2014), a new version of MC-31modules, hardware v2.3, has been released for production. This new version has some differences in the module features and specifications; in particular the operating temperature range has been extended to -40 °C to +85 °C.
MC-31 options, ordering info and main specification differences are summarised in the table below:
Order Code I tem
H/W version
v1.61 V2.32
MC-31-x3y4 Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C
Notes: 1) And earlier versions (referred to as v1.x further in this Manual). 2) And later versions (referred to as v2.x further in this Manual). 3) ‘x’ designates a code of the communications option board installed on Port 2. 4) ‘y’ designates a code of the communications option board installed on Port 3.
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Communications Option Boards codes:
Code Short Description Code Short Description
0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud
A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)
A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz
D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)
F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps
H HART Interface T21 Ethernet, Copper, 10/100 Mbps
I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps
Notes: 1) Discontinued products.
5.4.3 MC-31 Module LEDs
MC-31-xy (v1.x) MC-31-xy (v2.x)
LED Sta te Description
OK1,2
ON Normal operation.
0.5 s ON, 0.5 s OFF Firmware/configuration update in progress.
OFF Power off or module faulty.
F11,2
0.25 s ON, 0.25 s OFF
Port 2 configuration error.
OFF Normal operation.
F21,2
0.25 s ON, 0.25 s OFF Port 3 configuration error.
OFF Normal operation.
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LED Sta te Description
F31,2 OFF Normal operation.
F4 – F73 n/a Reserved for future use.
P1 (Port 1) LEDs
10
ON Linked at 10 Mbps (no data activity).
Flashing Data activity (transmit or receive) at 10 Mbps.
OFF Port not connected or no link at 10 Mbps.
100
ON Linked at 100 Mbps (no data activity).
Flashing Data activity (transmit or receive) at 100 Mbps.
OFF Port not connected or no link at 100 Mbps.
LNK4 ON Linked at either 10 or 100 Mbps.
OFF Port not connected or no Ethernet link established.
COL4 ON Ethernet collision(s) detected.
OFF No collisions detected.
P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options
Tx4 TxD / 10ACT3
Flashing Port is transmitting serial data.
OFF Port is not transmitting.
Rx4 RxD /
100ACT3
Flashing Port is receiving serial data.
OFF Port is not receiving.
RTS4 RTS / LINK3
ON Request to Send output is asserted. It is usually asserted to signal readiness to transmit data to a serial device.
OFF Request to Send output is not asserted.
CD4 DCD / COL3
ON Carrier Detect input is asserted by a connected serial device.
OFF Carrier Detect input is not asserted.
P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options
Tx4 TxD / 10ACT3
Flashing Data activity (transmit or receive) at 10 Mbps.
OFF No data activity at 10 Mbps.
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LED Sta te Description
Rx4 RxD /
100ACT3
Flashing Data activity (transmit or receive) at 100 Mbps.
OFF No data activity at 100 Mbps.
RTS4 RTS / LINK3
ON Linked at either 10 or 100 Mbps.
OFF Port not connected or no Ethernet link established.
CD4 DCD / COL3
ON Ethernet collision(s) detected.
OFF No collisions detected.
Notes: 1) Progressively set ON during booting sequence.
After a successful start-up: OK is ON; F1, F2 and F3 are OFF. 2) Flash rapidly to indicate firmware upgrade error. 3) MC-31 v2.x only. 4) MC-31 v1.x only.
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5.4.4 MC-31 Specifications
MC-31 Communica tions Module Specifica tions
Parameter v1.x v2.x
Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus
SRAM (Battery Backed) 128 KB 512 KB
Flash Memory 16 MB
SDRAM 32 MB
Communications Ports
Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)
Optional 2 (for supported port types, please see the Option Boards chapter)
Input Power
Voltage 5 V ± 5%
Current1 290 mA 200 mA
Isolation
Port 1 Transient Voltage 1 kV
Environment
Operating Temperature -20 to +70 °C -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes: 1) No communications option cards installed on Ports 2 and 3.
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5.4.5 MC-31 Ports
Port 1 Pins Etherne t Signa l
1 Tx+
2 Tx-
3 Rx+
4 n/c
5 n/c
6 Rx-
7 n/c
8 n/c
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6. COMMUNICATIONS OPTION BOARDS
6.1 Overview The following option boards are compatible with the CP-12/30 processor modules and the MC-12/31 communications modules (and the LP-3 stand-alone RTU). For PC-1 option boards please see the PC-1 Option Boards chapter.
These are the currently supported option boards:
Part Number Option Board Description I Isolated Serial
F Fiber Optic Interface
D Dialup Modem (PSTN) V34 33.6 kbps
L Private Line or Analogue Radio Interface
H HART / Bell 202 interface*
A3 Ethernet MTRJ Fiber Optic Interface
T3 Ethernet RJ45 Copper – 10/100 Mbps
R2 900 MHz Spread Spectrum Radio for Australia
R3 2.4 GHz Spread Spectrum Radio for International
R4 900 MHz Spread Spectrum Radio for USA
* This option is not supported by MC-12 modules.
For previous generation hardware, please refer to the section Compatibility.
6.2 Installing and removing Option Boards
Warning: Follow anti-static procedures
Electronic components can be damaged by even small amounts of static discharge. It is highly recommend that antistatic procedures be used. Avoid touching any components and metal parts. Do not store cards near strong electrostatic, electromagnetic, or radioactive fields.
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1. Insert a small screwdriver into the second hole at the bottom of the module case. Lever the side of the case outwards. Release the tab by firmly pulling the corner of the cover.
2. Insert the screwdriver into the second hole on the other side of the module. Lever the side of the case outwards. Release the tab by firmly pulling the corner of the cover.
3. Repeat steps 1 and 2 above for the top of the module.
4. Once all 4 tabs have been released, remove the front cover.
5. Remove the circuit board from the case by using a ‘toggling’ action
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6. Unplug the old option board (if applicable) and insert the new option board. Please ensure that all of the option board pins line up with the socket.
7. Slide the circuit board into the channel on the left side of the case. Hook the top of the cover into the case.
8. Press the bottom of the cover onto the case. At the same time, please ensure that the option boards line up with the cutouts. Ensure the cover is fully inserted and that the 4 tabs have all engaged.
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6.3 Option Board I: Isolated serial
6.3.1 Overview
The isolated serial option board provides an RS-232, RS-485 or an RS-422 interface. The port is software configurable for any of these modes. When RS-485 is configured for an isolated serial option board, the RTS and CD LEDs are set ON and when RS-422 is configured the RTS LED is set ON (there are no LEDs set on for RS-232). RS-485 requires a 120 Ω terminating resistor at each end of the transmission line and RS-422 requires a 100 Ω terminating resistor at the receiver end of the transmission line only (please see the wiring diagrams at the end of this section).
Option Board I Specifica tions
Baud rate 300 – 115200 bps
Internal Power Consumpt ion
70 mA from +5 VDC Bus on backplane
Output Power +4.3 V / 100 mA maximum
RS-422 Line drive 10 Receivers
RS-485 Line drive 32 Receivers
Communicat ions 8 data bits, no parity, 1 stop (8, N, 1)
Isolat ion Transient voltage: 2.5 kV
Operat ing Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
RTU Hardware Required
Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.3.2 Serial Option Board Connections RJ45 Pin Direction RS-232 RS-422 / RS-485
1 OUT DTR N/A
2 OUT 4.3 V N/A
3 OUT RTS TX+
4 IN DCD N/A
5 Common GND GND
6 IN CTS RX+
7 IN RxD RX-
8 OUT TxD TX-
RS-232 Wiring Diagram (Null Modem Cable)
Note: maximum recommended RS-232 cable length is 15 meters.
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RS-485 Wiring Diagram Each RTU can transmit/receive to any RTU, one at a time. Up to 32 RTUs (or other RS-485 devices) can be connected to the RS-485 bus. Maximum RS-485 wire length: 1200 m.
If the ground wire is not available, each GND terminal can be tied to EARTH locally via 100 Ω 0.5 W resistor.
For short cable runs (less than 5 m) a single 60 Ω terminating resistor can be used at one end of the RS-485 cable.
RS-422 Wiring Diagram The master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to the master RTU, one at a time. Note: outstation RTUs cannot communicate with each other. Up to 10 RTUs (or other RS-422 devices) can be connected to the RS-422 bus. Maximum RS-422 wire length: 1200 m.
If GND wire is not available, each GND terminal can be earthed locally via 100 Ω 0.5 W resistors.
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6.4 Option Board F: Fibre Optic Serial Board The fibre optic serial option board provides a serial interface via a fibre optic cable. A fibre optic port is treated the same way as a standard serial port except a fibre optic cable is used for the communications medium. A fibre optic link offers excellent electrical isolation and a high data rate. Two fibre optic cables are required for each fibre optic port.
Option Board F Specifica tions
Maximum Baud rate 115.2 kbps (equivalent to RS-232 port)
Communicat ions 8 data bits, no parity, 1 stop (8, N, 1)
Max imum Fiber Opt ic Cable Length
Approx. 4 km (depends on cable and other factors)
Supported Fiber Opt ic Cables
Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS
Opt ion Board Connectors (use male connectors on
cable)
Tx: ST female (light grey port) Rx: ST female (dark grey port)
Power Consumpt ion (Tx) 50 mA maximum from +5 VDC Bus on backplane
Line drive 1 Receiver (point to point)
Elec trical Isolat ion 15 kV
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
RTU Hardware Required
Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.5 Option Board D: 33.6 kbps Dial Option Board The dial option board provides a V34 PSTN interface to the Kingfisher RTU. The port speed is software configurable, and the dial board is designed to be compliant with telecommunications standards worldwide.
Dial Option Board Connections
RJ45 Pin PSTN Function
1 -
2 -
3 Reserved
4 Line -
5 Line +
6 Reserved
7 -
8 -
Telecommunication Line Cord
To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger telecommunications line cord.
Ligne de Télécommunication Cordon
Pour réduire les risques d’incendie, utilisez seulement du câble d’une section minimale de 0.13 mm² (26 AWG) pour les connections de
télécommunications.
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Dia l Option Board Specifica tions
PSTN Modem / Data Rate
V.34, 300 to 33600 bps, auto-negotiating
RTU DTE Port Speed 300 – 115200 bps
Line Impedance 600 Ω
Approval International
Transmit level -10 dBm
Receive level -43 dBm to -9 dBm
Diall ing Pulse or Tone
Internal Power Consumpt ion
165 mA from +5 VDC Bus on backplane
Isolat ion Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 5 kV
Recommended Init ial izat ion String
D Option: AT&FE0V0S0=2&W Original D Option: AT&FE0V0S0=2X0&W (ignores dial tone)
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Compat ibi l i ty
Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.6 Option Board L: Line/Analogue Radio Interface
The line option board provides a Private Line or analogue radio interface and is software configurable for either of these modes.
The board is optically isolated, operates at 1200 bps and provides FSK CCITT V.23 modulation.
6.6.1 Line Board Connections
RJ45 Pin Direction Line / Radio Function
1 OUT Tx -
2 IN Rx -
3 OUT RTS/PTT
4 IN CD
5 IN GND (0 V)
6 IN 12 V
7 IN Rx +
8 OUT Tx +
Telecommunication Line Cord
To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger telecommunications line cord.
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Ligne de Télécommunication Cordon
Pour réduire les risques d’incendie, utilisez seulement du câble d’une section minimale de 0.13 mm² (26 AWG) pour les connections de
télécommunications.
6.6.2 Connecting a Radio As the port is isolated it is necessary to use an external voltage source (normally from the RTU ‘radio’ connection +12 V) to power not only the radio but also the carrier detect circuit.
Some radios have a very low audio interface level (TX Audio), e.g. Maxon DM 0530, DM-2850, SD-125 and Tait T2010 / 2015. These radios will most likely require a resistor network external to the port to drop the TX Audio level.
Some radios (e.g. Maxon) have an internal pull up resistor to +5 V on the carrier detect line, if +12 V is used on the carrier detect optocoupler and then run to the carrier detect output on the radio, the optocoupler will always be driven. There are several ways to get around this:
1. Use a radio without an internal pull up to +5 V (Trio SR, possibly Tait).
2. Modify the radio by removing the internal pull up, as per manufacturer’s instructions.
3. Use +5 V to supply the carrier detect optoisolation circuit. (DO NOT USE +5 V FROM THE BACKPLANE CONNECTOR AS IT IS NOT ISOLATED).
Line / Radio Option Board Interface
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6.6.3 2-Wire Line, point-to-point Either RTU can transmit/receive one at a time.
Note: line termination is required.
6.6.4 2-Wire Line, multi-drop Any RTU can transmit/receive one at a time.
Note: line termination is required.
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6.6.5 4-Wire Line, point-to-point Either RTU can transmit/receive at any time.
6.6.6 4-Wire Line, multi-drop Master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to master RTU, one at a time.
Note that outstations cannot communicate to each other.
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Line /Radio Option Board Specifica tions
Baud rate 1200 Baud
Modulat ion FSK, CCITT V.23
Carrier detec t input Optical isolation Active low or high Min. input 2 mA (70 VDC maximum)
RTS/PTT output
Optical isolation Open collector output Active low 30 VDC maximum / 20 mA maximum Microwave networks typically use a negative supply rail for the carrier detect circuit. The more positive rail should be connected to pin #6 (RTS/PTT) and the difference between the rails must not exceed 30 VDC.
Output impedance 30 kΩ
Input impedance 30 kΩ
Line terminat ion 600 Ω
Line configurat ion
2 or 4 wire The port is not full duplex and cannot use the full duplex functionality of a 4-wire configuration. 4-wire configurations eliminate the ability to communicate peer to peer but allow an increased number of drops on one link.
Line drive in mult i-drop configurat ion
10 drops for 2 wire 20 drops for 4 wire
Transmit output level -6 dBm (LINE-2) -6 to -21 dBm software configurable (LINE-L)
Receive level -43 dBm to -9 dBm
Internal Power Consumpt ion
20 mA from +5 VDC Bus on backplane
Transmiss ion Dis tance
Allowing 3dB for background noise and a 10dB fade margin, up to 24dB of cable loss can be tolerated. Therefore, transmission distance = 24 / cable loss per Km (dB). Note: if there are more than 2 RTUs (or other devices) on the line, reduce the allowable cable loss (24) by 1dB per additional RTU or device.
Isolat ion Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 3.88 kV
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
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Compat ibi l i ty
Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.7 Option Board H: HART Interface
The HART option board provides a Bell 202 interface to devices supporting the HART protocol. Each HART option board can communicate with up to 15 Hart devices. Two HART option boards can be installed on the one RTU allowing up to 2 point-to-point circuits or 2 multi-drop circuits.
In a point-to-point installation, the loop current can be measured using an RTU analogue input channel. If using two separate point to point circuits and reading the loop current in each, the RTU analogue input channels must be isolated from each other.
In a multi-drop installation, the loop current is not used or measured.
For more information regarding HART configurations please refer to the “HART Implementation Guide” available on Semaphore Helpdesk.
6.7.1 HART Board Connections RJ45 Pin HART Function
1 Line +
2 to 7 n/c
8 Line -
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Point-to-point Wiring Configuration (Utilising Analogue Input)
Note: resistor value should be approximately 500 Ω.
Multi-drop Wiring Configuration
Note: the more HART devices connected, the closer the resistor value needs to be to 50 Ω
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Hybrid Wiring Configuration When using multiple HART networks on a single RTU, be sure to isolate the 24 V supplies.
HART Option Board Specifica tions
Baud-rate 1200 Baud, Half Duplex
Modulat ion Bell 202
Logical Frequenc ies 1 = 1200 Hz 0 = 2200 Hz
Internal Power Consumpt ion
20 mA from +5 VDC Bus on backplane
Max imum No. HART Devices
15 (multi-drop)
Data Available HART and loop current for point-to-point HART only for multi-drop
Isolat ion Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V)
Transient voltage: 3.88 kV Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Compat ibi l i ty
Can be installed in any of the following ports: CP-10/11/12/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
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6.8 Option Boards T3 & T2: 10/100 Ethernet Controller The Ethernet Option Boards provide full duplex Ethernet connectivity over UTP cables. The option boards feature automatic speed and MDI/MDI-X negotiation. Technical specifications of the T3 (currently in production) and T2 (superseded product) Ethernet Option Boards are described below.
Ethernet Option Board T3 Ethernet Option Board T2
Etherne t Option Board Specifica tions
Parameter T3 Option Board T2 Option Board
Connect ion Speed 10/100 Mbps (auto negotiated)
Connect ion Durabil i ty Approximately 750 cycles
Power Consumpt ion 300 mA (from +5 VDC Bus on backplane)
310 mA (from +5 VDC Bus on backplane)
Operat ing Temperature -40 to +85 °C -20 to +70 °C
Operat ing Humidity 5 to 95 % RH (non-condensing)
Storage Temperature -40 to +85 °C
Compat ibi l i ty
Can be installed in any of the following ports:
CP-11/12/30 Port 2 or Port 3 MC-11/12/31 Port 2 or Port 3 LP-2 Port 4 LP-3 Port 3 or Port 4
Can be installed in any of the following ports:
CP-30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
Port 1 Pins Etherne t Function
1 Tx+ 2 Tx- 3 Rx+ 4 n/c 5 n/c 6 Rx- 7 n/c 8 n/c
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6.9 Option Board A3: Fibre Optic Ethernet
The A3 option board provides Ethernet connectivity via fibre optic cable. The A3 is functionally equivalent to a T3 Ethernet board, but fibre optical cabling is used in place of copper cabling allowing for excellent electrical isolation.
A3 Etherne t Option Board Specifica tions
Connection Speed 10/100 Mbps
Optical Compliance Full ATM 100 Mbps physical layer Full 100 Mbps-FX (IEEE802.3u)
Fiber Optic Transceiver AFBR-5903Z
Supported Fiber Optic Cables Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS
Option Board Connectors (use male connectors on cable)
MTRJ connector. Available from Semaphore are the MTRJ-SC and MTRJ-ST adaptors.
Internal Power Consumption 600 mA from +5 VDC Bus on backplane
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Compatibility
Can be installed in any of the following ports: CP-11/12/30 Port 2 or Port 3 MC-11/12/31 Port 2 or Port 3 LP-2 Port 4 LP-3 Port 3 or Port 4
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6.10 Option Board R2: Australian Spread Spectrum Radio
The R2 Spread Spectrum radio option board uses the Digi 900 MHz RF module to provide a high speed data link in Australia. This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage.
Warning: RF Exposure
900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction with any other antenna or transmitter.
Avertissement: l'Exposition aux RF
Radio 900 MHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur.
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Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.
Modifications
L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit.
R2 Spread Spectrum Radio Board Specifica tions
Countries Supported Australia
Frequency 915-928 MHz
Transmit Power 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate — RTU to Radio 9600 bps
Data rate — Radio to Radio 115200 or 9600 bps
Power Consumption 3.7 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -110 dBm @ 9600 bps
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Compatibility
Can be installed in any of the following ports: CP-10/11/12/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
Please see http://www.digi.com for more information on XTend® 900MHz wireless module (P/N XTH9-MI-NA) specifications.
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6.11 Option Board R3: International Spread Spectrum Radio
The R3 Spread Spectrum radio option board uses the 2.4 GHz RF module to provide a high speed data link anywhere in the world (international). This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage.
Warning: RF Exposure
2.4 GHz Spread Spectrum Radio This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction with any other antenna or transmitter.
Avertissement: l'Exposition aux RF
Radio 2.4 GHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur.
Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.
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Modifications
L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit.
R3 Spread Spectrum Radio Board Specifica tions
Countries Supported International
Frequency 2.4000-2.4835 GHz
Transmit Power 50 mW
Range Indoors 180 m
Range Outdoors 5 km
Range with Yagi Up to 8 km
Data rate — RTU to Radio 19200 bps
Data rate — Radio to Radio 9600 bps
Power Consumption 0.75 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None#
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -105 dBm
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Compatibility
Can be installed in any of the following ports: CP-10/11/12/30 Port 3 only MC-10/11/12/30/31 Port 3 only LP-2 Port4 LP-3 Port 3 or Port 4
# Encryption by special request in the USA only.
Please see http://www.digi.com/ for more information on XStream® 2.4GHz wireless module (P/N X24-019NMI) specifications.
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6.12 Option Board R4: US/Canada Spread Spectrum Radio
The R4 Spread Spectrum radio option board uses the Digi 900 MHz RF module to provide a high speed data link in the US and Canada. This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage.
Warning: RF Exposure
900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction with any other antenna or transmitter.
Avertissement: l'Exposition aux RF
Radio 900 MHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur.
Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.
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Modifications
L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit.
R4 Spread Spectrum Radio Board Specifica tions
Countries Supported US & Canada
Frequency 902-928 MHz
Transmit Power 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate — RTU to Radio 9600 bps
Data rate — Radio to Radio 115200 or 9600 bps
Power Consumption 3.7 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None#
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -110 dBm @ 9600 bps
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Compatibility
Can be installed in any of the following ports: CP-10/11/12/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
# Encryption by special request in the USA only.
Please see http://www.digi.com for more information on XTend® 900MHz wireless module (P/N XT09-MI-NA) specifications.
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7. PC-1 OPTION BOARDS The PC-1 hybrid power supply and processor module has an accompanying range of communications option boards. These are not compatible with the CP series boards.
7.1 PC-1 Serial Option Board The serial option board provides a RS-232 or RS-485 interface. The port is software configurable for either of these modes. When RS-485 is used, a 120 Ω terminating resistor is required at each end of the transmission line.
PC-1 Serial Board Connections
RJ45 Pin Direction RS-232 RS-485
1 OUT DTR N/A
2 OUT +12 V
low power N/A
3 OUT RTS LINE - *
4 IN DCD N/A
5 COM GND (0 V) GND (0 V)
6 IN CTS N/A
7 IN RXD N/A
8 OUT TXD LINE + *
* Polarity is opposite to CP-xx
For RS-485 wiring diagram please refer to CP-xx/MC-xx serial board RS-485 Diagrams
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7.2 PC-1 Modem Board PL: Two Wire Line
The 2-wire (Private) line option board provides a 2-wire point-to-point connection to another RTU with a line option board.
The board is optically isolated, operates at 1200 bps and utilizes FSK CCITT V.23 modulation.
PC-1 Modem Board Connections
RJ45 Pin Direction Radio Function
1 OUT DTR
2 OUT +12 V low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXA
8 OUT TXA
PC-1 2 Wire Line Wiring Diagram (point-to-point)
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7.3 PC-1 Modem Board: Analogue Radio Interface
The analogue radio option board provides an FSK interface to external analogue radios (typically Trio or Maxon).
Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait radios. Please indicate which Radio you are using when ordering a radio option card.
PC-1 Analogue Radio Board Connections
RJ12 Pin Direction Radio Function
1 OUT DTR
2 OUT +12 V low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXA
8 OUT TXA
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8. COMPATIBILITY Not all option boards are universally compatible with all processors and communications modules. The following tables are a selection guide for assuring the hardware you have selected will function as expected.
Communications Option Boards
CPU/Comms Module A A3 D E F H I L R2 R3 R4 T T2 T3
CP-30 firmware v2676 or later MC-31 firmware v2676 or later MC-30 firmware v276 or later CP-11 firmware v1.45b or later CP-10/11 firmware v1.45a or earlier
CP-12
CP-21 MC-10/11 firmware v159 or earlier MC-11 firmware v160 or later
MC-12
PC-1 with MC-10/11
PC-1 with MC-12 Note: The above table was correct at the time of writing. Please refer to Semaphore Helpdesk for any recent changes.
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9. ANALOGUE INPUT MODULES Analogue input modules provide analogue inputs to the Kingfisher RTU.
Each module is equipped with a fully isolated 24 VDC power supply for energizing field equipment such as sensor loops.
9.1 AI-1: 8 Channel Analogue Current Input Module
9.1.1 Overview • 12 Bit resolution • 1.5 kV Field to Logic Isolation • 2 ms scan rate • 24 VDC isolated DC output • 0 – 20 mA or 4 – 20 mA current inputs • 0 – 5 VDC or 1 – 5 VDC Voltage Inputs (requires factory modification)
The analogue input module provides eight input channels, each capable of converting an analogue input signal to a digital variable for use as required by your application. A link on the rear of the module selects 4-20 mA or 0-20 mA for all 8 channels. The default range is 4 to 20 mA.
The module can also be factory modified to handle voltage inputs of 0-5 VDC or 1-5 VDC.
Conversion speed for each of the eight channels is 20 µs and this provides a total update rate of two milliseconds for the module. Resolution of the converted signal is 12 bits binary (1 part in 4096) over the range. The placement of the 12 bits from the A/D converter in the #AI data word is as follows:
LSB MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
If the current source is reversed into the input, or is less than the low end of the current range, then the module will output a data word corresponding to the low end of the current range (0000H in #AI). If an input that is out of range is entered (i.e. greater than 20 mA), the A/D converter will output up to full scale (corresponding to 7FF8H in #AI).
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Scaling of the input is shown below:
Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to GND. The GND connection provides access to the backplane (frame ground).
This module can be installed in any I/O slot of a 4, 6 or 12-slot backplane.
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Block-diagram of the AI-1 module is shown on the figure below.
AI-1 Block Diagram
9.1.2 AI-1 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
A1-A8 OFF Channel Input level < 1%
ON Channel Input level > 1%
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9.1.3 AI-1 Specifications AI-1 Analogue Input Module Specifications
Input Current Ranges 4-20 mA and 0-20 mA
Input Voltage Ranges 1-5 V and 0-5 V *
Inputs per Module 8
Update Rate 2 ms (all eight channels)
Accuracy + 0.25% @ 25 °C
Resolution 12 bit (no sign bit)
Common Mode Voltage 1500 V
Linearity < 1 Least Significant Bit
Isolation 1.5 kV between field and logic
Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection > 80 dB from DC to 1 kHz
Input Impedance 250 Ω standard 11 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Fi l ter Cutoff Frequency
2 kHz @ -3 dB
Output Power 24 VDC / 160 mA, Isolated
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R9 to R16 (channels 1 to 8 correspondingly).
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9.1.4 AI-1 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
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9.2 AI-10: 8 Channel High Impedance Analogue Input Module
9.2.1 Overview • 16 Bit resolution • 3 kV field to logic isolation • Bipolar differential channels • 24 VDC isolated DC output • AI-10: Current / Low Impedance Inputs • AI-10-V: High Impedance Voltage Inputs • 10 ms (1 ms*) scan rate • Mains noise rejection* * AI-10 hardware version 2.x only.
Unless explicitly noted, all hardware versions of AI-10 modules are described in this section. The newer AI-10 v2.x modules can be recognised by the label on the side which indicates the hardware version. If the version number is not printed on the label then the module is v1.6 or older.
The AI-10-V modules (v1.x only) are identical to the AI-10 modules but have the 250 Ω current sensing resistors disconnected. This increases the input impedance for each channel to more than 1 MΩ which is suitably high for voltage transducers. Each channel has its own current sensing resistor, so any combination of channels can be converted.
In order to modify AI-10 v1.x the current sensing resistors have to be physically disconnected (either by lifting one pin or by complete removal of the resistor). The circuit board resistors to change are: R64 to R71 (channels 1 to 8 correspondingly). It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients.
The AI-10 v2.x has internal jumpers (shorting links) that allow the input to be configured for either current or voltage measurement. If a jumper is installed (default) then the related input is configured to measure current. If a jumper is removed then the related input is configured to measure voltage. Note that the factory fitted jumpers are yellow in colour and of a higher grade than commonly found. Use of other jumpers may result in degradation of measurement accuracy and so should be avoided. Appropriate handling precautions have to be observed to avoid ESD and other damage when removing or installing shorting links.
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All AI-10 modules provide: • 8 analogue inputs with high electrical isolation between the field terminals and the RTU
logic. • A 24 V isolated output that can be used to power field sensors / transducers • 16 bit input resolution • Full compatibility with the AI-1 and AI-4 analogue input modules but with enhanced
resolution.
The AI-10 supports various current input ranges as follows: • 0-20 mA • 4-20 mA • ±10 mA1 • ±20 mA1
1 For AI-10 v2.x only unipolar current ranges are recommended for use. Bipolar ranges are not calibrated for current measurement.
The AI-10-V supports various voltage input ranges as follows: • 0-5 V1 • 1-5 V1 • ±2.5 V • ±5 V • ±10 V
1 For AI-10 v2.x only bipolar voltage ranges are recommended for use. Unipolar ranges are not calibrated for voltage measurement.
To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to ground.
This module consumes power from the +5 VDC and +12 VDC RTU rails. A built-in 24V DC-DC converter is used to provide isolated power to the analogue front-end and can also be utilised to power the field devices if required.
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Block-diagrams of the AI-10 modules are shown on the figures below.
AI-10 v1.x Block Diagram
AI-10 v2.x Block Diagram
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9.2.2 AI-10 Module LEDs
AI-10 LEDs State Description
OK1
OFF Module Fault (no power)
ON Module OK
1 s ON, 1 s OFF Module Fault
LED B (unlabelled)
1 s ON, 1 s OFF
Processor module has not communicated with the module for more than 15 seconds (e.g. no processor module is present in rack)
0.1 s ON, 1.9 s OFF1
Module Fault (Module running on internal clock source as the external crystal is faulty – module needs repair)
OFF Normal operation
LED C (unlabelled)
ON1 Module Fault (firmware not loaded – module needs repair)
OFF Normal operation
DC OK OFF AI-10 loop power OFF
ON AI-10 loop power ON
1-8 (left side)
OFF Channel Input level < 1%
ON Channel Input level > 1%
1-8 (right side)
OFF Channel Normal
ON Channel Fault (under/over range, data invalid) 1) On AI-10 v2.x only
Note: On power up some LEDs may come ON for a short time.
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9.2.3 AI-10 Specifications AI-10 / AI-10-V Analogue Input Module Specifications
Parameter Hardw are v1.x Hardw are v2.x
Input Current ranges1,2 4-20, 0-20, ±20, ±10 mA (software selectable)
Input Voltage ranges3,4,5 1-5, 0-5, ±2.5, ±5, ±10 VDC (software selectable)
Inputs per Module 8
Sub System Isolation The analogue subsystem of the AI-10 is fully isolated from the RTU’s digital system.
Isolation 3 kV Transient
Input impedance AI-10 : 250 Ω standard, > 1 MΩ optional5 AI-10-V : > 1 MΩ
Input Fi l ter Cutoff Frequency 1.5 kHz @ -3 dB 9 Hz @ -3 dB
Common Mode Rejection 80 dB minimum 66 dB minimum
Mains Rejection None 42dB minimum @ 50Hz 45dB minimum @ 60Hz
Maximum Input Voltage ±12 V to GND ±12 V differential
±12 V to GND ±24 V differential
Accuracy ± 0.1% @ +25 °C ± 0.25% @ -20 to +70 °C
± 0.1% @ 0 to +50 °C2,3 ± 0.2% @ -40 to +85 °C2,3
Resolution 16 bit (15 data bits and 1 sign bit)
Output Power Isolated 24 VDC, 160 mA maximum
Operating Temperature -30 to +80 °C -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
Compatibility
One range setting for all channels when used with a PC-1 or CP-11/12/21 processor. Individual range setting for each channel when used with a CP-30 processor.
1) AI-10 only. 2) For AI-10 V2.x only unipolar current ranges are recommended for use. Bipolar ranges are not
calibrated for current measurement and their accuracy can reach 1.4% of full scale when used to measure current.
3) For AI-10 V2.x only bipolar voltage ranges are recommended for use. Unipolar ranges are not calibrated for voltage measurement and their accuracy can reach 1.4% of full scale when used to measure voltage.
4) Analogue Input channels can be modified from low impedance to high impedance by disconnecting the 250 Ω channel resistor.
5) The ±10 V input range can only be used on an AI-10 input channel if the current sensing resistor has been disconnected. Resistors have already been disconnected in an AI-10-V.
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9.2.4 AI-10 / AI-10-V Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
Loop
* When using the +24 V output to power a transducer, the negative input terminal of the analogue input channel (2, 4, 6, 8, 12, 14, 16 or 18) must be wired to the OV terminal (10 or 20). This will complete the current loop due to electrical isolation between the input channel and the module +24 V Output. Note: Any channels sharing the same power source (e.g. +24 V from module or a field power supply) are no longer isolated from one other.
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10. ANALOGUE OUTPUT MODULE The AO-3 analogue output module provides four 12-bit current loop outputs allowing a Kingfisher RTU to drive analogue loads.
10.1 AO-3: Analogue Output Module
10.1.1 Overview • 12 bit resolution • 3 kV field to logic isolation • Open loop detection • 0 – 20 or 4 – 20 mA outputs • 3 kV channel group to channel group isolation
The AO-3 provides four current output channels that use 12-bit digital to analogue converters (DAC). The AO-3 also provides open loop detection.
The sign bit is not used in the digital to analogue conversion process. The placement of the 12 bits within the data word is as follows:
LSB MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
This module provides two output ranges. The default range is 4 to 20 mA with user data scaled so that a count of 0 corresponds to 4 mA and a count of 32760 corresponds to 20 mA. A range link (on the rear of the module) selects either 4-20 mA or 0-20 mA for all four channels. The default condition is 4-20 mA with the link on. The module provides 12 bits of resolution in either range.
Scaling of the output is shown below.
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Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups that are isolated from each other and from the backplane logic. Each group is powered by a separate DC-DC converter module that produces an isolated voltage of +24 V to drive the current loop outputs and analogue front-end.
The current loop drivers on the module are source type drivers. To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields should be connected to E (Shield) on the user terminal connector block. The E connection provides path to the backplane (frame Earth / Ground) resulting in attenuation of noise caused by the shield drain currents. To further improve noise immunity, direct connection of the analogue cable shields to the Earth / Ground rails with metal clamps or similar method is recommended, especially in environments with high electromagnetic noise levels.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane in a system. Up to 10 Analogue output modules can be installed on a single 12-slot backplane.
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Block-diagram of the AO-3 module is shown on the figure below.
AO-3 Block Diagram
10.1.2 AO-3 Module LEDs
AO-3 LEDs State Description
OK OFF Module fault / no power
ON Normal
RST OFF Module running
ON Module in Reset (power-on or watchdog)
ANALOGUE OUT 1-4 OFF Channel output set to 0%
ON Channel output greater than 0%
OPEN LOOP 1-4 OFF Closed Loop (load detected)
ON Open Loop (no load)
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10.1.3 AO-3 Specifications AO-3 Analogue Output Module Specifications
Output Current Range 4 to 20 mA [default] or 0 to 20 mA (loop current is supplied by module)
Outputs per Module 4
Output Power Isolated 24 VDC / 40 mA for outputs 1 & 2 Isolated 24 VDC / 40 mA for outputs 3 & 4
Supply Voltage (nominal) +5 VDC and +12 VDC from backplane
Update Rate 250 ms (all channels) Determined by I/O scan time and is application dependent
Resolution 12 bit (no sign bit)
Accuracy ± 0.2% @ 25 °C ± 0.5% @ -20 to +70 °C
Load Resistance 0 to 850 Ω
Load Capacitance 2000 pF maximum
Load Inductance 1 H maximum
Isolation
Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups. Each group is isolated from the other group and from the backplane logic. There is no isolation between outputs 1 & 2 and no isolation between outputs 3 & 4. Transient voltage (Group to Group and Group to Logic): 5 kV. Maximum working voltage in respect to system earth/ground must not exceed SELV limits (42.4 VPEAK / 60 VDC).
Operating Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 90 % RH (non-condensing)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
Open Loop Detection
Yes. Monitors output circuit for failure (e.g. cable breakage) or if the load is disconnected. Note: when using the 0-20 mA range, Open Loop Detection cannot be guaranteed on an output when set below 160 / 0.1 mA / 0.5%.
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10.1.4 AO-3 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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0 – 20 / 4 – 20 mA Current Loop Receiver
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11. DIGITAL INPUT MODULES
11.1 Overview The Digital Input Modules allow various level digital signals to be interpreted by your RTU.
All modules provide a minimum of 1 kV field isolation, 16 input channels and can be configured to use counters and input buffers to count incoming pulses.
Summary:
Module Maximum input Voltage
Channel group 1 maximum capture speed
Channel group 2 maximum capture speed
DI-5-1 28 VDC Channels 1 and 2 10 kHz
Channels 3 and 4 255 Hz
DI-5-1-48 60 VDC Channels 1 and 2
10 kHz Channels 3 and 4
255 Hz
DI-10-1 DI-10-1-48
+130 VDC 125 VAC
Channels 1 to 4 10 kHz
Channels 5 to 16 1 kHz
DI-10(-GPS) DI-10-48(GPS)
+130 VDC 250 VAC
Channels 1 to 16 10 kHz
11.2 DI-5: DC Input 16 Channel Digital Input Module
11.2.1 Overview • Pulse counting on channels 1 to 4 (up to 10 kHz) • Positive or Negative Polarity Inputs • Isolated DC Outputs for powering inputs
The DI-5 provides 16 input channels with one common. As a wide input voltage is accepted a wide range of input devices can be used such as buttons, reed switches, line switches, PIR sensors, and proximity sensors. Any combination of inputs powered externally or by the modules own isolated DC supply (+12 V) can be used.
Applying a high input voltage results in logic 1 in the modules status register. Low (or not present) input voltages result in logic 0.
The DI-5 counter can also count pulses in the first 4 digital inputs. It is able to count up to 10 kHz on inputs 1 and 2 and can count up to 255 Hz on inputs 3 and 4. The pulse total and the frequency for each of the first 4 digital inputs are stored.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane system.
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Block-diagram of the DI-5 module is shown on the figure below.
DI-5 Block Diagram
11.2.2 DI-5 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
1 - 16 OFF Digital Input OFF
ON Digital Input ON
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11.2.3 DI-5 Specifications DI-5 Input Module Specifications
Rated Voltage + 12 to 24 VDC nominal (supports reverse polarity) Note: The DI-5-1-48 High Input Voltage module in the Custom Products chapter supports higher DC input voltages (48 VDC nominal)
Inputs per Module 16
Input Characteristics
Impedance 2.7 kΩ
ON-state Voltage Channels 1 and 2 : 10 to 28 VDC maximum Channels 3 to 16 : 7.5 to 28 VDC maximum
OFF-state Voltage Channels 1 and 2 : 0 to 3.5 VDC Channels 3 to 16 : 0 to 3.0 VDC
ON-state Current 4.3 mA minimum
OFF-state Current 1 mA maximum
ON Response Time Channels 1 and 2 : 50 µs maximum Channels 3 and 4 : 500 µs maximum Channels 5 to 16 : 10 ms maximum
OFF Response Time Channels 1 and 2 : 50 µs maximum Channels 3 and 4 : 500 µs maximum Channels 5 to 16 : 17 ms maximum
Isolation 5 kV Transient
Output Power 12 VDC / 250 mA (3 W) isolated, supplied by module
Operating Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Pulse Totalisation Channels 1 to 4 : 0-65535 Pulses
Pulse Rates / Frequency
Channels 1 and 2 : 10 kHz maximum Channels 3 and 4 : 255 Hz maximum
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
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11.2.4 DI-5 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Powered by Module:
External positive supply:
External negative supply:
Combined positive and negative power supplies:
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11.3 DI-10: AC or DC Input, 16 Channel
11.3.1 Overview • Frequency/Pulse/Quadrature counters on up to 7 inputs/pairs • Isolated DC Field Power Output • Software Debounce • AC or DC Inputs • Sequence of events recording (with optional GPS time synchronisation) • Hot Swappable
The DI-10 provides 16 AC or DC input channels allowing it to interface a wide range of input devices to your RTU. Inputs can be powered by the module’s own +12 VDC Field Output Power or from external AC or DC power sources.
Applying a high positive or AC input voltage results in a logical ‘1’ in the status register, no or low input voltage results in a logical ‘0’. Negative DC input voltages cannot be used with DI-10 modules.
The DI-10 features software configurable pre-conditioning of inputs such as debounce filters, channel inversion and sequence-of-event recording selectable on any channel(s).
The DI-10 can also perform frequency, pulse or quadrature counting for up to 7 input channels (or pairs of input channels for quadrature counters).
DI-10 modules can be swapped while RTU is running without causing RTU restart. Inputs are cleared in RTU memory while module is removed.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
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Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
11.3.2 DI-10 Options and Ordering Info Unless explicitly noted, all hardware versions of DI-10 modules are described in this manual. Comparing with its predecessor (v3.2), the newer DI-10 version (v4.3) has some differences in the module features and specifications and also has a new optional GPS time synchronisation of the sequence of event recording.
The DI-10 modules without “-48” suffix in their Order Code have Digital Inputs compatible with 12 V and 24 V control systems. The modules with the “-48” suffix in the Order Code have elevated change-over thresholds of Digital Inputs designed for use in 48 V and higher control systems.
Any DI-10 v4.3 module can be a GPS Slave, having its events timing synchronised to an accurate timing signal generated by a DI-10-[48]GPS v4.3 module (GPS Master) that has an additional interface for connection to an external 3rd party GPS device. Any number of GPS Slaves and GPS Masters can be installed in the RTU. With more than one GPS Master installed in the system, each of them will generate time synchronisation signal for the GPS Slaves in parallel, providing system redundancy if it is required.
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DI-10 options, ordering info, the main features and / or main specification differences are summarised in the table below:
Order Code
H/W version
Target System Voltage IEC 61131
types I & III compliant
High-speed inputs4
GPS
v3.21 v4.32 12 V & 24 V3 ≥48 V Slave Master
DI-10-1 4
DI-10-1-48 5 4
DI-10 16
DI-10-48 5 16
DI-10-GPS 6 16
DI-10-48GPS 5,6 16
Notes: 1) And earlier versions (here and further in this Manual). 2) And later versions (here and further in this Manual). 3) Will also work with higher input voltages within the specified input range. 4) Up to 7 counters in total is currently supported by firmware. 5) DI-10-48 refers also to DI-10-1-48 and to DI-10-48GPS models further in this
document. 6) DI-10-GPS refers also to DI-10-48GPS model further in this document.
11.3.3 Theory of operation Block-diagram of DI-10 v3.2 module is shown on the figure below.
DI-10 v3.2 Block Diagram
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Digital Inputs are connected to the input optocouplers via series diodes, resistors and 3.6 mA current limiters. Optocouplers with integrated Schmitt triggers are installed on first four (high-speed) channels. When input voltage and, consequently, input current of an optocoupler exceeds its threshold, microcontroller (MCU) reads this input as ‘1’, otherwise it is ‘0’.
Block-diagram of DI-10 v4.3 module is shown on the picture below.
DI-10 v4.3 Block Diagram
Digital Inputs are connected to a digital serialiser via series diodes and over-voltage protection circuits. The digital serialiser has its threshold input current set (and limited) to 2.51 mA. External signal sources should be able to supply 2.51 mA current to the DI-10 v4.3 module. When the input voltage exceeds its threshold, the microcontroller (MCU) reads this input as ‘1’, otherwise it is ‘0’.
11.3.4 Configurable Functions The first 4 channels of the DI-10 v3.2 and all channels of the DI-10 v4.3 are high speed and capable of counting up to 10kHz, while channels 5 to 16 of the DI-10 v3.2 can count up to 1 kHz.
Seven user-configurable counters are available which appear as 16-bit unsigned integer values in the analogue input register. Each of these counters can be configured either to measure frequency, to count pulses or to decode quadrature signals. Any channel from 1 to 16 can be assigned as an input to any frequency or pulse counter. Any pair of eight channel pairs (1-2, 3-4, etc.) can be assigned as inputs to any quadrature counter.
Channel inversion can be configured on any input channel. Normally a high voltage level results in a logical HIGH state (1) to be set in the digital input register with the corresponding LED illuminating on the front panel. By enabling channel inversion, a low voltage level applied to an input will result in a logical HIGH (1).
Software debounce can be activated on any input channel. The time constant can be configured from 1 ms to 250 ms. When AC inputs are used, the input channel must be configured with the debounce filter set to ‘AC Filter’ as shown below.
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A 1 ms debouncing is automatically enforced when ‘AC Filter’ is chosen.
11.3.5 Sequence of Events Recording Sequence-of-Event (SoE) recording can be configured for any input channel. When enabled, any change of state (event) on the input is logged to 1 millisecond resolution.
These events are automatically included in the Event Log of the RTU. The DI-10 module has an internal timer that is synchronised with the Real Time Clock of the processor.
Timestamps of the DI-10 v4.3 are guaranteed to be within ±2 ms of UTC time when optional GPS synchronisation feature is used in the RTU system.
The DI-10 module has a buffer capable of storing 1000 events. This means bursts of up to one thousand events can be recorded at a time. Events are uploaded to the processor module at a maximum rate of 100 events per second.
Please note that SoE recording is not supported when using a PC-1 processor.
11.3.6 GPS T ime Synchronisation (Optional) When a GPS device is attached to the DI-10-GPS module, it will synchronise the time on the CP-30 processor and all other DI-10 modules (GPS Slaves) in the RTU via signalling on the backplane. SoE timestamps on all DI-10 v4.3 modules will then be synchronised to the GPS time within 2 ms.
This feature does NOT work with other Kingfisher Plus+ processor modules (such as CP-12, CP-11, CP-21 and PC-1) nor with DI-10 v3.2 modules.
The GPS time synchronisation feature requires at least one DI-10-GPS module (GPS Master) per RTU. More than one GPS Master can be used to provide redundancy.
One of the unused backplane connections (24V power rail) is used to carry the time synchronisation signal between DI-10 modules.
WARNING. Installing DI-10 v4.3 modules on 24V backplanes (that are used in some old Kingfisher installations) will damage DI-10 modules and void their warranty.
To support time synchronisation of the DI-10 modules across multiple backplanes, the time synchronisation signal must be connected between them. This signal is available on backplane power connector J14:
Backplane Power Header J14
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Only two rails (24V and 0V) are required to be connected for time synchronisation between backplanes to work.
The following cables can be ordered from Semaphore to provide required connections:
• BPC-01 or BPC-02 Backplane Power Cables. WARNING. All power rails of the connected backplanes will be connected as well.
• BPC-02-GPS time synchronisation cable. • BPC-SPLIT splitter cable if more than two backplanes need to be connected.
The DI-10-GPS has an RJ-45 jack for direct connection of a Garmin GPS16x-HVS device. It is located directly underneath the LED display of the DI-10-GPS module.
The Garmin GPS16x-HVS can be ordered from Semaphore directly or via many commercial outlets.
RJ45 Jack for GPS device
RJ-45 pin-out and wire colours of the Garmin GPS16x-HVS are shown on the DI-10 v4.3 block-diagram. If a different model of GPS device is to be used, an adapter should be constructed using signal information in the table below.
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RJ45 Pin
DI-10-GPS Signal
Direction (DI-10-GPS)
Direction (GPS Device) Signal Level Note
1 +12V OUT IN +12 V Power for GPS (100 mA max)
2 GND - - - Power & Signal Ground
3 PWR_ONn OUT IN Open Drain to GND
Pulled to GND: GPS ON Floating: GPS OFF
4 Din OUT IN RS-232 Serial Data to GPS
5 Dout IN OUT RS-232 Serial Data from GPS
6 PPS IN OUT 5 V TTL Pulse Per Second
7 nc Not connected
8 nc Not connected
11.3.7 DI-10 Module LEDs
DI-10-1 [-48] (v3.2) DI-10 [-48] (v4.3) DI-10-[48]GPS (v4.3)
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LED State Description
OK
ON Module operating normally
0.5 s ON, 0.5 s OFF Internal Fault: (module needs repair)1
OFF Power off
ERR1
1 s ON, 1 s OFF
Backplane communications time-out (15 s) expired (no polling received from the RTU processor module)
0.1 s ON, 1.9 s OFF
Module faulty and needs repair.
OFF Normal
GPS1,2
ON GPS serial port data detected and GPS is synchronised to the GPS network.
1 s ON, 1 s OFF
GPS serial port data detected but the GPS is not synchronised to the GPS network.
1.8 s ON, 0.2 s OFF
Time Synchronized to another DI-10-[48]GPS (master). This implies that no GPS is connected to this module so it acts as a DI-10 (slave).
0.2 s ON, 0.2 s OFF
Timing error in GPS slave synchronisation signal. This stays active until the next properly timed synchronisation signal, which could be a few minutes. This implies that no GPS is connected to this module so it acts as a DI-10 (slave).
OFF No GPS detected.
SYNC1
1.8 s ON, 0.2 s OFF
Time Synchronised to a DI-10-[48]GPS (master).
0.2 s ON, 0.2 s OFF
Timing error in GPS slave synchronisation signal. This stays active until the next properly timed synchronisation signal, which could be a few minutes.
OFF No time synchronisation signal detected.
PCON ON +12V DC-DC converter on
OFF +12V DC-DC converter off. No digital input sampling occurs.
1-16 ON Digital Input ON
(channel input level is above low-to-high threshold)
OFF Digital Input OFF (channel input level is below high-to-low threshold)
Notes: 1) Only hardware v4.3 or later. 2) Only on DI-10-GPS modules (GPS Master).
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11.3.8 DI-10 Specifications
DI-10 Digital Input Module Specifications
Parameter v3.2 v4.3
Digital Inputs per Module 16
Maximum Input Voltage 130 VDC / 125 VAC 130 VDC / 250 VAC
Maximum Current per Input1 3.7 mA 2.6 mA
Digital Input Levels
ON-state Voltage @ Input Current
Standard modules
≥7.5 VDC @ 1.0 mA (Ch. 1-4) ≥7.5 VDC @ 0.5 mA (Ch. 5-16) ≥20.0 VAC @ 1.0 mA (Ch. 1-4)
≥20.0 VDC @ 0.5 mA (Ch. 5-16)
≥7.5 VDC @ 2.5 mA
≥20.0 VAC @ 1.2 mA
-48 modules
≥35.0 VDC @ 1.0 mA (Ch. 1-4) ≥35.0 VDC @ 0.5 mA (Ch. 5-16) ≥27.0 VAC @ 1.0 mA (Ch. 1-4)
≥27.0 VDC @ 0.5 mA (Ch. 5-16)
≥35.0 VDC @ 2.5 mA
≥27.0 VAC @ 1.2 mA
OFF-state Voltage
Standard modules ≤3.0 VDC ≤3.0 VAC
≤3.0 VDC ≤3.0 VAC
-48 modules ≤24.0 VDC ≤15.0 VAC
≤24.0 VDC ≤15.0 VAC
Digital Input Thresholds2
Low-to-High Transition
Standard modules 5.4 VDC / 3.8 VAC (Ch. 1-4) 5.3 VDC / 4.0 VAC (Ch. 5-16) 7.2 VDC / 5.1 VAC
-48 modules 36.2 VDC / 27.6 VAC (Ch. 1-4)
34.7 VDC / 24.9 VAC (Ch. 5-16) 26.4 VDC / 19.1 VAC
High-to-Low Transition
Standard modules 5.1 VDC / 3.7 VAC (Ch. 1-4) 5.1 VDC / 3.7 VAC (Ch. 5-16) 6.3 VDC / 4.4 VAC
-48 modules 36.0 VDC / 25.5 VAC (Ch. 1-4)
34.5 VDC / 24.3 VAC (Ch. 5-16) 25.5 VDC / 18.4 VAC
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DI-10 Digital Input Module Specifications
Parameter v3.2 v4.3
Digital Input Timing
ON Response Time (max) 50 µs (DC, Ch. 1-4)
500 µs (DC, Ch. 5-16) 30 ms (AC)
50 µs (DC)
30 ms (AC)
OFF Response Time (max) 50 µs (DC, Ch. 1-4)
500 µs (DC, Ch. 5-16) 30 ms (AC)
50 µs (DC)
30 ms (AC)
Filtering None,1, 3, 10, 30, 100, 250 ms or AC Filter
Frequency, Pulse and Quadrature Counters
Total number of Counters 7 maximum
Maximum Frequency 10 kHz (Ch. 1-4) 1 kHz (Ch. 5-16)
10 kHz
Frequency Counting 1 Hz resolution on any input(s)
Pulse Counting 0-65535 Pulses on any input(s)
Quadrature Counting 0-65535 Pulses on any of the inputs pair(s) 1-2, 3-4, etc.
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DI-10 Digital Input Module Specifications
Parameter v3.2 v4.3
Sequence of Events
Time Stamp Resolution 1 ms
Events Time Stamp Accuracy
with GPS synchronisation3 n/a ±2 ms to UTC time
Events Buffer Size 1000 events
Events Transfer Rate (via backplane to a Processor Module)
100 events/s maximum
Output Power
To Field Devices Isolated 12 V 80 mA maximum
To GPS Device4 n/a Isolated 12 V 100 mA
maximum
Isolation
Maximum Working Voltage (in respect to system
earth / ground) 130 VDC / 125 VAC 130 VDC / 264 VAC
Transient Voltage 3 kV
Environment
Operating Temperature -20 to +70 °C -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes: 1) Limited by internal circuitry of a DI-10 module. 2) Approximate values for information only (not factory tested) 3) For systems without GPS, the time-stamping accuracy depends on the accuracy of the Real
Time Clock in the RTU Processor module, the SCADA / Network time management protocol used, the Backplane time synchronisation latency (that is influenced by the type of the Processor module used and by its loading with the RTU logic and communications), by the number of installed DI-10 modules and by other system-dependent parameters.
4) Only on DI-10-GPS modules (GPS Master)
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11.3.9 DI-10 Wiring Diagram An edge-pluggable terminal block Fujicon F5021 is used for wiring of Digital Inputs and power outputs to the DI-10 module PCB. It can be un-coupled from the DI-10 board for wiring convenience if required.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
Note 1. Pins 9 and 19 (+12Vout) are connected together internally.
Note 2. Pins 10 and 20 (0V) are connected together internally.
Powered by Module
External DC Power Supply
Note: DC voltage applied to any input channel must be positive in respect to 0V.
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External AC Power Supply
Note: AC filter must be enabled in the DI-10 configuration for this channel.
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12. DIGITAL OUTPUT MODULES
12.1 Overview The digital output modules provide relay and transistor outputs to the Kingfisher series of RTUs.
The DO-1 and DO-2 offer relay outputs, eight and sixteen respectively, while the DO-6 is transistor based.
The DO-6 is compatible with the TEL-REL-00x series of relay output boards to allow for higher current and voltage switching.
12.2 Switching Inductive Loads When switching inductive loads, users should be mindful of possible reduced relay service life due to back-EMF. To mitigate this negative effect, suppression circuits should be used when switching inductive loads.
Switching DC Supplied inductive loads (high switching relay output)
Switching DC Supplied inductive loads (ground switching relay output)
Switching AC supplied inductive loads (*MOV = Metal Oxide Varistor)
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12.3 DO-1: 8 Channel Isolated Relay Output Module
12.3.1 Overview • 8 SPDT isolated relay outputs • 500 V channel pair isolation • One common per channel pair • Can switch AC or DC voltages • 3 kV coil to contact isolation
The DO-1 provides 8 normally open or normally closed relay circuits for controlling output loads. All output channels are isolated from each other and arranged into pairs. Each channel pair shares a separate common terminal (please see the “DO-1 Wiring Diagram” section for more details).
The relay outputs can control a wide range of user supplied load devices such as motors, starters, solenoids, and indicators. The user is required to supply the AC or DC power to operate the field devices connected to this module. Internal fuses offer protection to the relay contacts should their maximum load be exceeded.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
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Block-diagram of the DO-1 module is shown on the figure below.
DO-1 Block Diagram
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
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Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
12.3.2 DO-1 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
A1, A2 B3, B4 C5, C6 D7, D8
OFF Digital output OFF (open)
ON Digital output ON (closed)
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12.3.3 DO-1 Specifications DO-1 Isolated Relay Output Module Specifications
Outputs per Module 8
Commons 4 (each common supplies 2 outputs)
Relay Type SPDT (Single Pole, Double Throw)
Rated Load (per common) 5 A at 250 VAC Resistive 5 A at 30 VDC Resistive (20 A maximum per DO-1 module)
Maximum Operating Voltage 380 VAC, 125 VDC
Maximum Switching Power - Resistive 1250 VA, 150 W
Maximum Switching Power - Inductive 375 VA, 80 W
Minimum Load 10 mA at 5 VDC
Relay Operations 100,000 minimum at 1800 operations per hour at rated load
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Isolation 3 kV coil to contacts 500 V between channel groups
Relay Part Number Omron G6B-2114P-US (G6B datasheet is available from http://components.omron.eu/)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
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12.3.4 DO-1 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Wiring Example
Note: Polarity can be reversed.
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12.4 DO-2: 16 Channel Relay Output Module
12.4.1 Overview • 16 SPST relay outputs • One common per 8 channels • 3 kV coil to contact isolation • Can switch AC or DC voltages
The DO-2 provides 16 normally-open relay circuits for controlling output loads provided by the user. The output points are arranged in two groups of eight. Each group shares a common terminal. The relay outputs can be used to control a wide range of devices such as motor starters, solenoids, and indicators.
Internal fuses protect the DO-2 relay contacts should ratings be exceeded.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Block-diagram of the DO-2 module is shown on the figure below.
DO-2 Block Diagram
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Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
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12.4.2 DO-2 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
1-16 OFF Digital output OFF (open)
ON Digital output ON (closed)
12.4.3 DO-2 Specifications DO-2 16 Channel Digital Output Module Specifications
Outputs per Module 16
Commons 2 (each common supplies 8 outputs)
Relay Type SPST (Single Pole Single Throw, Normally Open)
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per common
Minimum Load 10 mA @ 5 VDC (wetting current)
Contact Resistance 100 mΩ maximum
Operating Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Isolation Maximum working voltage in respect to system earth/ground must not exceed 250 VAC / 130 VDC Transient voltage: 3 kV
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Fuse Monitor LED Enabled when the common is wired to pins 10 and 20. CAUTION! When wired, a maximum voltage of 30 V AC or DC can be used to power the common.
Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
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12.4.4 DO-2 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Note: Optional Link for DC Supply Only. Enables the use of fail LED FU.
Caution: A maximum of 30 V (AC or DC) can be used to power the common if the link is installed.
Wiring Example
Note: Polarity can be reversed.
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12.5 DO-6: 16 Channel Open Drain Output Module
12.5.1 Overview • 16 Open-drain outputs • Designed to operate TELREL 00x relay board • DC Field Output (non-isolated)
The DO-6 provides 16 open drain NFET outputs for controlling various loads including the TELREL series of relay boards. Power for external loads can be provided from the modules +12 VDC which is sourced from the backplane rail.
The DO-6 output channels are current limited and are protected from high levels of EMI (electro-magnetic interference) that may trigger false outputs.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Block-diagram of the DO-6 module is shown on the figure below.
DO-6 Block Diagram
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12.5.2 DO-6 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
A1-A16 OFF Digital output OFF (open)
ON Digital output ON (closed)
12.5.3 DO-6 Specifications DO-6 Channel Open Drain Output Module Specifications
Outputs per Module 16
Commons 1
Rated Voltage 30 VDC maximum.
Output Type N-FET, Open Drain
Rated Load 70 mA per channel
Current Limit 90 mA per channel
Output Power 12 VDC non-regulated, non-isolated (supplied by module directly from backplane), 1.6 A maximum
ON Response Time 15 ms maximum
OFF Response Time 15 ms maximum
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
Compatibility The DO-6 is functionally equivalent and pin compatible with the superseded DO-5.
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12.5.4 DO-6 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Note: The +12 V Output is sourced from the backplane power rail and is not isolated. Users should exercise caution to avoid shorting or overloading this output.
External DC power supply:
Load powered by module:
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13. RELAY EXPANSION BOARDS
13.1 Overview The Kingfisher Relay Expansion Boards are designed to be used in conjunction to the DO-6 module. The relay boards allow much more flexible use of the DO-6 module due to the wide range of relay types available.
Each relay board has unique internal wiring. Users should be mindful that they are not completely pin-compatible. Please refer to individual wiring diagrams for details.
TEL REL 002
• 16 Channel Isolated Relay SPDT for DO-6-x complete with 1.5m cable • Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel) • Max Current 16 A @ 250 VAC resistive, 16 A @ 30 VDC resistive, 0.45 A @
125 VDC Inductive. • 5 kV isolation (Coil to Contact) • Omron G2R-1-E 12 VDC Relay
TEL REL 003
• Relay Board - 16 Channel Isolated Relay SPST for DO-6-x complete with 1.5m cable
• Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel) • Max Current 8 A @ 250 VAC resistive, 8 A @ 30 VDC resistive, 1 A @ 125 VDC
Inductive • 5 kV isolation (Coil to Contact) • Omron G2RG-2A4 12 VDC Relay
TEL REL 004
• Relay Board - 16 Channel Isolated Relay DPDT for DO-6-x complete with 1.5m cable
• Max Voltage 380 VAC, 125 VDC, 32 commons (2 common per channel) • Max Current 5 A @ 250 VAC resistive, 5 A @ 30 VDC resistive • 5 kV isolation (Coil to Contact) • Omron G2R-2 12 VDC Relay
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Kingfisher Plus+ Hardware Manual
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Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
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13.2 TEL REL 002: SPDT Relay Board
13.2.1 Overview • 16 SPDT Relay Outputs • Common for each channel • 5 kV coil to contact isolation • Can switch AC or DC voltages
The TEL REL 002 is designed to accompany the DO-6 to provide 16 SPDT voltage free output contacts.
Each relay consumes 43 mA @ +12 VDC from the backplane power supply. An external supply can be connected to a screw terminal on the PCV is available (this is not the case if the standard cable supplied with the DO-6 modules is utilized).
LED indicators are provided for each relay on the relay board. LED ON = relay active.
13.2.2 TEL REL 002 Specifications TEL REL 002 SPDT Relay Boards Specifications
Outputs per Terminal Board 16
Commons 16 (1 common per channel)
Relay Type (per channel) SPDT (Single Pole, Double Throw)
Rated Load (per contact) 16 A @ 250 VAC Resistive 16 A @ 30 VDC Resistive
Maximum Operating Voltage 380 VAC, 125 VDC
Maximum Switching Power - Resistive
16 A @ 30 VDC 5 A @ 48 VDC 0.6 A @ 125 VDC
Maximum Switching Power - Inductive
16 A @ 12 VDC 8 A @ 30 VDC 0.7 A @ 48 VDC 0.45 A @ 125 VDC
Minimum Load 100 mA at 5 VDC
Contact Resistance 100 mΩ maximum
Relay Operations 100,000 minimum at 1800 operations per hour at rated load
Operating Temperature -20 to +70 °C (no icing)
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 43 mA
Coil Resistance 275 Ω @ 12 VDC
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Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1500 mm (for connection to the DO-6 module)
Connection Terminals Phoenix double height PCB terminal unit arranged in a dual three way terminal (please see wiring diagram). These terminals can take wire sizes up to 4 mm2.
Relay Part Number Omron G2R-1-E 12 VDC (datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
13.2.3 TEL REL 002 Wiring Diagram
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DO-6 to TEL REL 00x Interface Cable
Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 VD C Blue/Red 19
20 + 12 VD C Green/Red 20
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13.3 TEL REL 003: SPST Relay Board
13.3.1 Overview • 16 SPST Relay Outputs • Common for each channel • 5 kV coil to contact isolation • Can switch AC or DC voltages • Higher inductive rating than other TEL REL 002
(1 A @ 125 V as opposed to 0.4 A @ 125 V)
The TEL REL 003 board is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides superior inductive load rating than the TEL REL 002.
LED indicators are provided for each relay on the relay board. LED ON = relay active.
13.3.2 TEL REL 003 Specifications TEL REL 003 SPST Relay Board Specifications
Outputs per Terminal Board 16
Commons 16 (1 common per channel)
Relay Type (per channel) SPST (Single Pole, Single Throw)
Rated Load (per contact) 8 A at 250 VAC Resistive 8 A at 30 VDC Resistive 1 A at 125 VDC Inductive
Maximum Operating Voltage 380 VAC, 125 VDC
Maximum Switching Power - Resistive
2000 VA, 240 W
Contact Resistance 100 mΩ maximum
Relay Operations 100,000 minimum at 1800 operations per hour at rated resistive load 50,000 minimum at 360 operations per hour at rated inductive load
Operating Temperature -20 to +70 °C (no icing)
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 66 mA
Coil Resistance 180 Ω @ 12 VDC
Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1.5 m (for connection to the DO-6 module)
Connection Terminals Weidmuller single height PCB 3-way terminal unit (please see wiring diagram). These terminals can take wire sizes up to 4 mm2.
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Relay Part Number Omron G2RG-2A4 12 VDC (datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
13.3.3 TEL REL 003 Wiring Diagram
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DO-6 to TEL REL 00x Interface Cable
Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 VD C Blue/Red 19
20 + 12 VD C Green/Red 20
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13.4 TEL REL 004: DPDT Relay Board
13.4.1 Overview • 16 DPDT relay outputs • 2 commons per channel • 5 kV coil to contact isolation • Can switch AC or DC voltages
The TEL REL 004 is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides Double Pole Double Throw (DPDT) relays. This allows the user to utilize both normally open and normally closed relay operation.
LED indicators are provided for each relay on the relay board. LED ON = relay active.
13.4.2 TEL REL 004 Specifications TEL REL 004 DPDT Relay Board Specifications
Outputs per Terminal Board 16
Commons 32 (2 commons per channel)
Relay Type (per channel) DPDT (Double Pole, Double Throw)
Rated Load (per contact) 5 A at 250 VAC Resistive 5 A at 30 VDC Resistive
Maximum Current 5 A
Maximum Operating Voltage 380 VAC, 125 VDC (2 A maximum)
Maximum Switching Power 750 VA, 90 W Resistive
Minimum Load 10 mA at 5 VDC
Contact Resistance 50 mΩ maximum
Relay Operations >10,000,000
Operating Temperature -20 to +70 °C (no icing)
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 44 mA per coil
Coil Resistance 275 Ω @ 12 VDC
Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1.5 m (for connection to the DO-5/6 module)
Relay Part Number Omron G2R-2 12 VDC (datasheet is available from http://components.omron.eu/ )
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
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13.4.3 TEL REL 004 Wiring Diagram
DO-6 to TEL REL 00x Interface Cable
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Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 VD C Blue/Red 19
20 + 12 VD C Green/Red 20
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14. COMBINATION IO MODULES Combinational IO modules provide digital and analogue IO in a single module. They can be installed in any 4, 6, or 12 slot backplane.
14.1 IO-2: Combinational Digital IO Module
14.1.1 Overview • 8 SPST relay outputs • Digital inputs
This module can be installed in any slot of a 4, 6 or 12 slot backplane.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
Digital Inputs The digital inputs are designed to be powered using an external power supply. A wide range of digital input devices can be used such as push buttons, limit switches and electronic proximity switches. Current through an input (in either direction) results in a logic 1 in the status register. Power to operate the field devices must also be supplied by the user.
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Digital Outputs The output points are arranged in one group of eight points with one common. The output switching capacity of each output is 2 amps. The relay outputs can control a wide range of load devices such as motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate the field devices. An internal fuse protects the relay contacts should ratings be exceeded.
Block-diagram of the IO-2 module is shown on the figure below.
IO-2 Block Diagram
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14.1.2 IO-2 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
A1-A8 OFF Digital input OFF
ON Digital input ON
B1-B8 OFF Digital output OFF (open)
ON Digital output ON (closed)
14.1.3 IO-2 Specifications IO-2 Combina tiona l IO Module Specifica tions
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
Input Characteris t ics
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage
Isolat ion 3 kV between field and logic
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DIGITAL OUTPUTS
Outputs per Module 8
Commons 1 (common supplies all 8 outputs)
Relay Type SPST (Single Pole Single Throw)
Max imum Switched Voltage 30 VDC, 250 VAC
Max imum Switched Current 5 A per common
Isolat ion 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Res is tance 100 mΩ maximum
Relay Operat ions 70,000 minimum at 1800 operations per hour at rated load
Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
14.1.4 IO-2 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Digital Input Example: (Note polarity can be
reversed on power supply)
Digital Output Example:
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED ‘FU’ on module. CAUTION: when the link is installed a maximum of 30 V AC or DC can be used to power the common.
Note: DC powered inputs and low voltage AC inputs can both be used on the same module.
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14.2 IO-3: Combinational Analogue/Digital IO Module
14.2.1 Overview • 4 SPST relay outputs • 4 analogue inputs • 4 digital inputs • 1 analogue output
This module can be installed in any slot of a 4, 6 or 12 slot backplane.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
Analogue IO The IO-3 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. All channels are updated four times per second (250 ms refresh time). The placement of the bits within the data word is shown below.
LSB MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
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Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
Digital IO Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.
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Block-diagram of the IO-3 module is shown on the figure below.
IO-3 Block Diagram
14.2.2 IO-3 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
A1-A4 - Not used
B1 - Not used
C1-C4 OFF Digital input OFF
ON Digital input ON
D1-D4 OFF Digital output OFF (open)
ON Digital output ON (closed)
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14.2.3 IO-3 Specifications IO-3 Analogue/Digital Combinational IO Module Specifications
Supply Voltage (nominal) +5 VDC and +12 VDC from backplane
Isolat ion 5 kV Transient
Output Power 24 VDC / 100 mA max, Isolated
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
ANALOGUE INPUTS
Input Current Ranges 4 to 20 mA or 0 to 20 mA
Input Voltage Ranges * 1 to 5 V and 0 to 5 V *
Inputs per Module 4
Update Rate 2 ms (all four channels)
Accuracy + 0.25% @ 25 °C
Resolut ion 12 bit (no sign bit)
Linearity < 1 Least Significant Bit
Isolat ion Transient voltage: 1 kV
Common Mode Rejec t ion > 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejec t ion > 80 dB from DC to 1 kHz
Input Impedance 250 Ω standard 15 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Fi l ter Cutoff Frequency 325 Hz @ -3 dB
ANALOGUE OUTPUT
Output Current Range 4 to 20 mA or 0 to 20 mA
Outputs per Module 1
Update Rate 250 ms (all channels) Determined by I/O scan time and is application dependent
Accuracy + 0.25% @ 25 °C
Resolut ion 12 bit (no sign bit)
User Load 0 to 850 Ω
Output Load Capac itance 2000 pF
Output Load Inductance 1 H
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DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 4
Input Characteris t ics
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage
DIGITAL OUTPUTS
Outputs per Module 4
Commons 1 (common supplies all 4 outputs)
Relay Type SPNO (Single Pole, Normally Open)
Max imum Switched Voltage 30 VDC, 250 VAC
Max imum Switched Current
4 A per channel 5 A per common
Minimum Load 10 mA @ 5 VDC (wetting current)
Contact Res is tance 100 mΩ maximum
Relay Operat ions 70,000 minimum at 1800 operations per hour at rated load
Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R39, R41, R43 and R45 (channels 1 to 4 correspondingly).
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14.2.4 IO-3 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED ‘FU’ on module. CAUTION: when the link is installed a maximum of 30 V AC or DC can be used to power the common.
Note: DC powered inputs are low voltage AC inputs can both be used on the same module.
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Analogue Input Examples
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
Analogue Output Example
Analogue load
Digital Input Example
Sensing the output form a field contact
Digital Output Examples
Driving external load from digital output
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14.3 IO-4: Combinational Analogue / Digital IO Module
14.3.1 Overview • 2 SPST relay outputs • 2 analogue inputs • 8 digital inputs
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment.
Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this product, including field wiring.
Failure to do so may cause fire and may result in a serious personnel injury or even death.
Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.
Analogue IO The IO-4 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Channel 1 can be utilized for a strain gauge input of range approximately 50 mV. 5 V excitation voltage is supplied from this module (please refer to the wiring diagram for further information).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.
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LSB MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
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Digital IO Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.
Block-diagram of the IO-4 module is shown on the figure below.
IO-4 Block Diagram
14.3.2 IO-4 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
FU OFF Fuse OK
ON Fuse fail
A1-A8 OFF Digital input OFF
ON Digital input ON
B1-B2 OFF Digital output OFF (open)
ON Digital output ON (closed)
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14.3.3 IO-4 Specifications IO-4 Analogue / Digital Combinational Module Specifications
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Output Power 24 VDC / 100 mA max, Isolated
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
ANALOGUE INPUTS
Input Current Ranges 4-20 mA and 0-20 mA
Input Voltage Ranges * 1-5 V and 0-5 V *
Inputs per Module 2
Update Rate 2 ms (all four channels)
Accuracy + 0.25% @ 25 °C
Resolution 12 bit (no sign bit)
Common Mode Voltage 1500 V
Linearity <1 Least Significant Bit
Isolation 1000 VRMS between field and logic
Common Mode Rejection >70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection >80 dB from DC to 1 kHz
Input Impedance 250 Ω standard 15 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Fi l ter Cutoff Frequency 325 Hz @ -3 dB
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DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
Input Characteristics
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage
Isolation 1000 VRMS between field and logic
DIGITAL OUTPUTS
Outputs per Module 2
Commons 1 (common supplies both outputs)
Relay Type SPST (Single Pole Single Throw)
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per common
Isolation 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Resistance 100 mΩ maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the “Switching Inductive Loads” section for more details). Contacts should also be protected with external fusing.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R85 and R41 (channels 1 and 2 correspondingly).
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14.3.4 IO-4 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED ‘FU’ on module. CAUTION! When link is installed, a maximum voltage of 30 V AC or DC can be used to power the common.
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Strain gauge input (4 wire Wheatstone bridge)
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (externally powered)
3 wire transmitter (externally powered)
4 wire transmitter (externally powered)
Field contact input (externally powered)
Driving digital load (externally powered)
Passive field contact (powered by module)
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14.4 IO-5: Combinational Analogue / Digital IO Module
14.4.1 Overview • 4 analogue inputs • 1 analogue output with open line detection • 4 digital inputs • 4 sinking solid state outputs
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Analogue IO Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.
LSB MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
For analogue outputs, an Open Line Detection circuit will indicate whether current loop is open or closed. Please note that open line detection circuit performance cannot be guaranteed when AO value is set to less than 1% (328 decimal) of full scale in the 0-20 mA range.
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The IO-5 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Digital Inputs For high speed isolated digital inputs are provided on the module. All four digital inputs share on one common rail.
All channels can be configured as pulse counters that appear 16 bit unsigned integer values in the analogue input registers of the RTU processor module. Because of processor module limitations, only channels 1 and 2 can be configured as pulse counters when used with the CP-11/12/21 and PC-1 processors (Toolbox 32). All four channels can be used as pulse counters when used with CP-30 processor module (Toolbox PLUS+).
Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches, Hall sensors, proximity switches, etc.
Digital Outputs The IO-5 provides 4 open-drain (sinking) outputs for controlling various loads. Power for the loads can be provided from the on-board isolated +24 VDC power supply or from an external power source.
The IO-5 output channels provide continuous protection from overloads.
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Block-diagram of the IO-5 module is shown on the figure below.
IO-5 Block Diagram
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14.4.2 IO-5 Module LEDs
LED State Description
OK OFF Module fault (no power)
ON Normal
RST OFF Normal
ON Module Reset in progress
24Va OFF Field Power disabled
ON Field Power enabled
AI 1-4 OFF Analogue input is less or equal to 1% of range
ON Analogue input is greater than 1% of range
AO1 OFF Analogue output is set to less or equal to 1% of range
ON Analogue output is set to greater than 1% of range
OL OFF Analogue output line is closed (loaded)
ON Analogue output line is open / loop current equal to zero
DI 1-4 OFF Digital input OFF
ON Digital input ON
DO 1-4 OFF Digital output OFF (Output switch does not conduct)
ON Digital output ON (Output switch conducts)
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14.4.3 IO-5 Specifications IO-5 Ana logue / Digita l Combina tiona l Module Specifica tions
Operat ing Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Output Power 24 VDC / 100 mA max, Isolated
Max imum Work ing Voltage on any contac t of
the field connector 42.4 VPEAK / 60 VDC relative to system (backplane) ground
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start.
ANALOGUE INPUTS
Input Current Ranges 4 - 20 mA or 0 - 20 mA
Input Voltage Ranges * 1 - 5 V or 0 - 5 V *
Inputs per Module 4
Resolut ion Unsigned 12 bit
Accuracy (inc ludes Gain, Linearity
and Offset errors)
± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C
Update Rate 120 ms
Cross-Channel Rejec t ion > 115 dB from DC to 1 kHz
Input Impedance 250 Ω standard 1 MΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Fi l ter Cutoff Frequency 7 Hz @ -3 dB
AC noise at tenuat ion 16 dB @ 50 Hz 18 dB @ 60 Hz
Output Field Power 24 VDC / 80 mA Isolated
Isolat ion 5 kV Transient
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ANALOGUE OUTPUT
Output Current Range 4 - 20 mA or 0 - 20 mA
Outputs per Module 1
Output Type Isolated, Sourcing
Resolut ion Unsigned 12 bit
Update Rate 250 ms Determined by I/O scan time and is application dependent
Accuracy (inc ludes Gain, Linearity and Offset errors)
± 0.25% @ 25°C ± 0.50% @ -20 to +70 °C
User Load 0 to 850 Ω
Isolat ion 5 kV Transient
DIGITAL INPUTS
Inputs per Module 4 with one common
Input Type Optically isolated, Sinking
Max imum Input Voltage 30 VDC
Guaranteed ON-state Voltage 10 VDC minimum
Guaranteed OFF-s tate Voltage 4.0 VDC maximum
Counters Type Pulse, Unsigned 16-bit (all channels)
Max imum Counters Speed 10 kHz
Input Current Approx. (VIN / 4.7) mA:
2 mA @ 9.4 VIN; 6.4 mA @ 30 VIN
Isolat ion 5 kV Transient
DIGITAL OUTPUTS
Outputs per Module 4 with one common
Output Type Optically isolated, Solid State, Sinking
Max imum Switched Voltage 30 VDC
Max imum Switched Current 2 A per channel
Isolat ion 3 kV Transient
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are:
• Ch.1: R81 (or R85+R86); • Ch.2: R82 (or R87+R88); • Ch.3: R83 (or R89+R90); • Ch.4: R84 (or R91+R92).
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14.4.4 IO-5 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.
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Analogue Input Examples
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
Analogue Output Example
Analogue load
Digital Input Example
Sensing the output form a field contact
Digital Output Example
Driving external load from digital output
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15. ADAPTORS AND CABLES
15.1 Overview A range of adaptor and cable accessories are available for the Kingfisher range to allow for communications interfacing. The adaptor plugs universally adapt to RJ45 to allow standard CAT5/6 cabling to be used between RTUs, PLCs and communications devices.
Connectivity Example
Reference:
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Summary of available adaptors and cables
Part Number Description
ADP-04 Maxon and Tait radios (DB9F to RJ45 Adaptor) for 'R' option
ADP-05 PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options
ADP-N DB9 port saver. Used with ADP-05 for concealed PC serial ports (e.g. Current HP Notebooks)
ADP-05-N PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver.
ADP-07 PSTN modem external 25 pin (DB25M to RJ45 Adaptor) for 'S' options, confirm PSTN pin-outs
ADP-08 RJ45 to DB9 Female Converter (Straight Connect)
ADP-08 M RJ45 to DB9 Male Converter (Straight Connect) for Serial Port to MaxStream External Spread Spectrum Radio
ADP-16 Trio "D" and "E" Series Radio (DB9M to RJ45 Adapter) for 'S' options
ADP-25 Uni-Op Display Model - MD02R-04-00A5 (DB15M to RJ45 Adapter) for 'S' options
ADP-28 Trio "H" series Spread Spectrum Radio (DB9M to RJ45 Adapter) for 'S' options
ADP-29 Trio "M" series Radio (Modem fitted) (DB9M to RJ45 Adapter) for 'S' options
ADP-31 Trio "M" series Radio (DB9M to RJ45 Adapter) for PC-1 'R' option
RJC-05 Cable RJ45 Plug both ends "1:1" - 0.5 meters
RJC-10 Cable RJ45 Plug both ends "1:1" - 1.0 meter
RJC-20 Cable RJ45 Plug both ends "1:1" - 2.0 meters
RJC-30 Cable RJ45 Plug both ends "1:1" - 3.0 meters
RJC-50 Cable RJ45 Plug both ends "1:1" - 5.0 meters
RJC-100 Cable RJ45 Plug both ends "1:1" - 10.0 meters
RJC-ADP-22B Wavecom GSM Cable (RJ45 to HD15) for 'S' options, to suit Fastrack Xtend FXT009, and superseded 1205-1306, Supreme 10
RJC-ADP-26 Maxon MM-6280IND 3G Cable (RJ45 to DB15) for 'S' options
RJC-ADP-27 Motorola Satellite Series 9522 L-Band Cable (RJ45 to DB25) for 'S' options
RJC-ADP-30 Trio "M" series radio Cable (RJ45 to DB15) for 'L' option
RJC-45/12 RJ45 to RJ12 Phone Lead - 2.0meters
RJC-X-OVE R Serial RJ45 to RJ45 cross over cable - 1.5 meters
RJC-ETHER-X-OVER Ethernet RJ45 to RJ45 cross over cable - 2.0 meters
CAB-OPTION-J Image Capture Option cable - SMB to BNC female - 2.5m
CAB-IO-1 External I/O cable - 1m
CAB-IO-2 External I/O cable - 2m
CAB-IO-5 External I/O cable - 5m
CAB-FO-PATCH-1 Patch Cable for A3 Ethernet Option Board (MTRJ to ST)
CAB-FO-PATCH-2 Patch Cable for A3 Ethernet Option Board (MTRJ to SC)
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15.2 RTU Test Cables RJC-X-OVER: Kingfisher Plus+ RJ45 to RJ45 RS-232 Null Modem Cable (serial crossover)
RJ45 to Kingfisher RTU Serial Port RJ45 to Kingfisher RTU Serial Port
RJC-ETHER-X-OVER: Kingfisher Plus+ RJ45 to RJ45 Ethernet Crossover Cable
RJ45 to Kingfisher RTU Ethernet Port RJ45 to Kingfisher RTU Ethernet Port
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15.3 Device Cables and Adaptors ADP-04: PC-1/MC-1 Radio Port to Tait T2010 or Maxon RDM-01 Radio (SD125)
RJ45 to Kingfisher RTU Radio Port To Tait 2010 or Maxon RDM-01 radio
ADP-05: RTU Serial Port to PC Serial Port (Creates a null modem cable)
To Kingfisher Serial Port To PC Serial Port
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ADP-07: RTU Serial Port to External PSTN Modem
To Kingfisher Serial Port To PSTN Modem
ADP-08: RJ45 to DB9 Female Converter (Straight Connect)
(Note: when coupled with an ADP-05 forms a null modem cable DB9 female to DB9 female)
To Kingfisher Serial Port To External Device
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ADP-08-M : Serial Port to Digi External Spread Spectrum Radio
For Digi XTend-PKG or XStream-PKG, and other 3rd party radios.
To Kingfisher Serial Port To External Radio
ADP-09: Serial Port to HITECH or Nematron Display Panel
To Kingfisher Serial Port To Operators Panel
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ADP-16: Serial Port to Trio D-Series Radio or Trio E/K/M Series Radio
Hardware flow control supported.
To Kingfisher Serial Port To Trio Radio
RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio
For TC-450SR, TC-900SR or RTU Serial Port to Trio S-Series Radio with 24/48SR modem.
To Kingfisher Serial Port To Trio Radio
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RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125)
To Kingfisher Serial Port To Maxon Radio
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RJC-ADP-20: CP-xx Line Option Board to Trio S Series Analogue Radio
For use with TC-450SR or TC-900SR.
To Kingfisher Serial Port To Maxon Radio
RJC-ADP-21: CP-xx Line Option Board to Tait T2010 Analogue Radio
To Kingfisher Serial Port To Tait Radio
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RJC-ADP-22B: Serial Port to Wavecom GSM
For use with the WM02-G900, Fastrack, Fastrack Supreme, or Fastrack Xtend.
Note: Adds a RTS/DTR link to the previous RJC-ADP-22 cable. Link required for Fastrack Supreme. Link will also work with the older WM02-G900 and Fastrack modems.
To Kingfisher Serial Port To GSM or GPRS Modem
RJC-ADP-23: PC-1/MC-1 Radio Port/Serial Port to Trio S- Series (SB) Repeater
To Kingfisher Serial Port To GSM or GPRS Modem
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RJC-ADP-26: Serial Port to Maxon MM-6280IND 3G Data Modem (previously used for the Maxon MM-5100 CDMA Modem)
To Kingfisher Serial Port To 3G Data Modem
RJC-ADP-27: RTU Serial Port to Motorola 9522 Satellite Transceiver
To Kingfisher Serial Port To Satellite Transceiver
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ADP-28: RTU Serial Port to Trio H–Series Spread Spectrum Radio
To Kingfisher Serial Port To Trio Radio
ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR450
For hardware flow control see the ADP-16.
To Kingfisher Serial Port To Trio Radio
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RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio (no modem fitted) E.g. MR450
To Kingfisher Serial Port To Trio Radio
ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g. MR450
To Kingfisher Serial Port To Trio Radio
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CAB-FO-PATCH-1: A3 Ethernet MTRJ Fibre Optic to 2 × ST adaptor cable
To Kingfisher A3 Option Board To external Device
CAB-FO-PATCH-2: A3 Ethernet MTRJ Fibre Optic to 2 × SC adaptor cable
To Kingfisher A3 Option Board To external Device
Maxon Intermax: Serial Modem to Kingfisher Serial Port
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16. ACCESSORIES Accessories are available that can ease the installation of your RTU. These include rack mounting hardware and battery carrier mounts.
16.1 MBR-3: 19” Rack Mounting for BA-12
A 12 slot backplane (BA-12) is mounted in a 19 inch rack using two MBR-3 mounting brackets. The MBR-3 brackets replace the surface mount brackets supplied with BA-12 backplanes. Each pair of MBR-3 brackets is supplied with four M4 x 6 mm pan head screws.
Installation Note: The holes in the MBR-3 brackets that are used to attach the brackets to the back of the backplane are drilled oversize to accommodate slight variances in racking equipment. By loosening these screws, pushing the brackets toward the centre of the backplane and then re-tightening the screws, the unit will fit freely into any correctly sized 19-inch rack.
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16.2 TEL-RAK-002: 19” Rack Mounting for BA-4/6/40 A four slot backplane (BA-4 or BA-40) or a six slot backplane (BA-6) is mounted in a 19 inch rack using a TEL-RAK-002 mounting bracket. One BA-6 or two BA-4/BA-40 backplanes can be attached to the TEL-RAK-002 using the surface mount brackets supplied with each backplane. The TEL-RAK-002 is supplied with eight M3 x 5 mm screws for attaching the backplane(s).
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16.3 Battery Bracket: 7 Ah Battery Mounting Bracket When using a 7 Ah backup battery, a standard battery holder is available for mounting on an enclosure gear plate. The bracket supports the battery and allows a General Power Outlet (GPO) to be mounted on the front using M3 x 10 mm pan head screws. The battery holder also allows an ISB50LN lightning arrester to be mounted underneath.
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17. GLOSSARY
AI, AO, DI, DO Analogue Input, Analogue Output, Digital Input and Digital Output respectively
Byte A group of 8 bits. Each bit can be a 0 (off) or a 1 (on) allowing up to 256 combinations.
Comms Communications
Current Sinking Current is supplied into the RTU’s IO terminal.
IO Input / Output
Port A physical connection or socket on an RTU used for communications
Processor Module Processor module containing a CPU (Central Processing Unit)
Protocol
Refers to the format of messages that may be passed to, from and through an RTU in communication with local and remote devices. Communications may use one or more RTU ports. Examples of protocols used within telemetry include Kingfisher, Modbus and DNP3.
RTU Acronym for Remote Terminal Unit. Describes a group of processor, communications and IO modules that comprise a device for monitoring and control of equipment in remote locations.
TCP/IP Transfer Control Protocol / Internet Protocol. Commonly used for Ethernet communications.
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18. APPENDIX A: SYSTEM INSTALLATION Superseded items are not present in this hardware manual.
For information regarding any modules not present in this document please refer to the Superseded Products Manual available on Semaphore Helpdesk.
To avoid fire hazards and exposure to electrical shock and other safety hazards, all instructions listed below must be followed.
Enclosure Requirements All components of a Kingfisher RTU shall be installed inside of an enclosure providing safety and environmental protection as required. The enclosure shall be made from metal or other material with a flammability rating of V-0 or better in accordance with the requirements of the IEC 60950-1 standard for a fire enclosure. An enclosure not required to prevent a fire hazard if the RTU is installed above concrete or another non-combustible surface.
An RTU shall be mounted with all modules in a vertical position as illustrated below. The enclosure must provide sufficient clearances for conventional air cooling, with a minimum clearance of 100 mm between the RTU modules and the top and bottom of the enclosure:
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RTU Installation Example
1. Vent must be installed if enclosure has a battery. Install a second vent in lower right corner if battery capacity exceeds 26 Ah or if environmental conditions require greater airflow.
2. Install Backplane low enough to allow for airflow through modules. 3. Radio or Modem.
Note: Radio or Modem can be mounted on rear of door by using DIN rail. Ensure that the radio is mounted on the top left corner of the door to allow radio to clear the RTU modules when the door is closed.
4. Gear plate. 5. PSU-x AC Power Supply Unit. 6. Slotted duct (20 × 60 mm). 7. IO wiring terminal. 8. Double GPO.
One outlet for the RTU and a spare for a laptop. When 7 Ah battery is used, DGPO is mounted on side of battery bracket (available from your supplier).
9. Lightning arrester. Install high enough to allow easy access for antenna lead connection. 10. Battery bracket. Can rest on front lip of enclosure. 11. Earthing stud. Ensure GPO, Backplane and lightning arrester are connected to this point
using appropriate earthing methods. 12. Leave at least 30 mm clearance to allow room for glands and cables. 13. Cable glands mounted through gland plate. 14. Enclosure must not contain openings in this area to avoid fire risk to external
environment.
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Mains Power Connection Only appropriately qualified and trained personnel can install and service this equipment. Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide appropriate short-circuit backup protection, with its breaking capacity of at least 1500 A.
Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit breaker, depending on installation) before performing any operation on this product. Failure to do so may cause fire and may result in a serious personnel injury or even death.
Disconnect power cord from the Power Supply Module and wait for its LEDs on the front panel to go OFF before wiring, removing or servicing.
Earth / Ground Conductors Earth / Ground conductors should be connected in a tree fashion with branches routed to a central earth ground point. This ensures that no ground conductor carries current from any other branch. This method is shown in the following figure.
PROGRAMMING DEVICE
RTU CABINET MOTOR DRIVES AND OTHER ELECTRICAL
CONTROL EQUIPMENT
MACHINERY
CENTRAL GROUND POINT EARTH GROUND
NOTE: SIGNAL AND POWER CONNECTIONS NOT SHOWN
BACKPLANE BACKPLANE
Recommended System Grounding
Earth / Ground conductors should be as short and as large in size as possible. Braided straps or ground cables (typically green insulation with a yellow tracer - AWG #12/5 mm2 or larger) can be used to minimise resistance. Conductors must always be large enough to carry the maximum short circuit current of the path being considered.
Safety Earth / Ground Although safety of the Power Supply Module and other modules with the potentially hazardous voltage levels have been assessed and found to be in compliance with the appropriate requirements, an additional level of protection from a potential electrical shock can be provided by connecting the RTU backplane to the safety earth / ground.
The Earth / Ground rail of the backplane PCB can be grounded by mounting screws to the metal back-plate of the backplane when properly installed. Additional grounding wire straps should be used in case reliable screw connections cannot be assured. Earth / Ground connections should be made from one of the PCB mounting tabs to a system earth / ground terminal (usually a threaded stud) using a minimum AWG#12 wire and ring terminals. Use of a nut and star washer for each wire on the ground connection lug is recommended to ensure adequate grounding. Ensure the paint coating is removed under the lug to make good electrical contact.
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All backplanes grouped together in a RTU system must have a common ground connection. This is especially important for backplanes that are not mounted in the same enclosure.
The best way to provide proper ground connections is to ensure that the RTU backplane metal frame is directly connected to the mounting panel (or rear plate) by connecting a ground strap from one of the ground lugs on either side of the backplane to the mounting panel or cabinet in accordance with local safety requirements.
Functional Earth / Ground Yellow / Green wire in the mains power cord provides only functional (NOT Safety) Earth / Ground connection and cannot be relied upon for safety purposes.
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