hsu installation and operation manual · 2012. 6. 20. · the hss002 features a 24”x30”x8”...

HYPER SCADA SERVER INSTALLATION AND OPERATION MANUAL

Data Flow Systems, Inc . 605 N. John Rodes Blvd. , Melbourne , FL 32934

Phone 321-259-5009 • Fax 321-259-4006

NOTICE

Data Flow Systems, Inc. assumes no responsibility for any errors that may appear in this document, nor does it make any commitment to update the information contained herein. However, questions regarding the information contained in this document are welcomed.

Data Flow Systems also reserves the right to make changes to the specifications of the Hyper SCADA Server, Hyper Server Module, Network Interface Module, Fiber Interface Module, Network Fiber Module, Network Switch Module, and the HT3 SCADA software and to the information contained in this document at any time without notice.

DFS-00384-011-02

This document las t rev ised : June 20, 2012

i

TABLE OF CONTENTS

PREFACE ................................................................................................................1 Purpose of this Manual ................................................................................................... 1 Document Conventions................................................................................................... 1 Abbreviations Used in this Manual ............................................................................... 1

CHAPTER 1 : PRODUCT OVERVIEW ..................................................................3 Hyper SCADA Server..................................................................................................... 3

Description .................................................................................................................. 3 HSS001 ....................................................................................................................... 3 HSS002-X ................................................................................................................... 4 User Interface .............................................................................................................. 6 SCADA System Options............................................................................................. 7

Hyper Server Module ..................................................................................................... 8 Overview..................................................................................................................... 8 Features of the HSM ................................................................................................... 9 Specifications and Interface ...................................................................................... 10 Backup Battery Operation......................................................................................... 11 Power and Voltage Monitoring ................................................................................. 11

Network Modules .......................................................................................................... 12 Network Interface Modules....................................................................................... 13 Network Distribution Modules.................................................................................. 15 Network Module Applications .................................................................................. 16

CHAPTER 2 : BEFORE YOU BEGIN ..................................................................17 Safety Precautions......................................................................................................... 17

General Precautions .................................................................................................. 17 Working Inside the HSS............................................................................................ 17 Protecting Against Electrostatic Discharge............................................................... 18 Using the HSS ........................................................................................................... 18

Site Selection .................................................................................................................. 18 Receipt of Equipment ................................................................................................... 19 Installation Overview.................................................................................................... 19

CHAPTER 3 : MOUNTING AND AC WIRING INSTRUCTIONS .........................21 HSS001 ........................................................................................................................... 21

Unpacking the HSS001 ............................................................................................. 21 Mounting the HSS001............................................................................................... 21 Wiring the Unit for AC Power .................................................................................. 21

HSS002-X....................................................................................................................... 22 Unpacking the HSS002-X......................................................................................... 22 Mounting the HSS002-X........................................................................................... 22 Installing the HSS002-X’s Modules ......................................................................... 23 Wiring the HSS002-X for AC Power........................................................................ 25

CHAPTER 4 : DEVICE WIRING INSTRUCTIONS ..............................................27 Dial Out / Dial In ........................................................................................................... 27

HSS001 ..................................................................................................................... 27 HSS002-X ................................................................................................................. 29

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Alarm Notification Options...........................................................................................30 Audio Device .............................................................................................................30 Alarm Light, Alarm Horn, and Alarm Silence Button Options .................................32

CHAPTER 5 : NETWORK SETUP ...................................................................... 37 Overview .........................................................................................................................37 Functions of Network Modules in the HSS..................................................................38

Network Distribution and Isolation............................................................................38 Serial Tunneling.........................................................................................................38 Power Distribution .....................................................................................................38 Controlled by HSM....................................................................................................38 Reset Remotely ..........................................................................................................39

HSS001............................................................................................................................39 Description.................................................................................................................39 Network Distance Considerations..............................................................................39 What You’ll Need ......................................................................................................40 Installation and Configuration Procedure ..................................................................40

HSS002-1 Network Setup (Non-Redundant HSS002) ................................................43 Description.................................................................................................................43 Network Considerations/Vulnerabilities....................................................................43 What You’ll Need (Minimums).................................................................................44 Installation and Configuration Procedure ..................................................................45

HSS002-2 Network Setup (Redundant HSS002).........................................................47 Description.................................................................................................................47 Network Considerations.............................................................................................47 What You’ll Need ......................................................................................................48 Installation and Configuration Procedure ..................................................................49

CHAPTER 6 : TELEMETRY SYSTEM SETUP.................................................... 53 Network RTUs (HSS002-X only) ..................................................................................53

Overview....................................................................................................................53 Functions and Features ..............................................................................................54 Installation and Configuration Procedure ..................................................................56

Tunnel CTU....................................................................................................................61 Overview....................................................................................................................61 Functions and Features ..............................................................................................62 Installation and Configuration Procedure ..................................................................63

Serial Devices (HSS001).................................................................................................68 CHAPTER 7 : WORKSTATION CONFIGURATION............................................ 69

System Requirements ....................................................................................................69 Workstation Configuration...........................................................................................69

Editing the Hosts File.................................................................................................70 Change Browser Settings ...........................................................................................71 Install Plug-Ins and Java Policy File..........................................................................72 Start HT3....................................................................................................................72

CHAPTER 8 : CRITICAL DATA REDUNDANCY................................................ 73 Configuring Remote System Backup ...........................................................................73

Procedure for Configuring Backup Site.....................................................................73 Principles of Redundancy for an HSS002-2.................................................................75

Primary Server ...........................................................................................................75 Secondary Server .......................................................................................................75

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IP Sharing.................................................................................................................. 76 Safe IP Address ......................................................................................................... 76 Switch Over Process ................................................................................................. 76

HT3 Data Recovery....................................................................................................... 77 CHAPTER 9 : SYSTEM TESTING & TROUBLESHOOTING..............................79

Troubleshooting Toolbox.............................................................................................. 79 Access Network via Network Distribution Module.................................................... 79

Overview................................................................................................................... 79 Installation and Configuration Procedure.................................................................. 80

Potential Problems and Suggested Troubleshooting Steps........................................ 82 My Network RTU is offline!..................................................................................... 82 My Tunnel CTU is not Polling! ................................................................................ 82

Obtaining a Console to a FIM...................................................................................... 83 Replacing the HSM ....................................................................................................... 85

APPENDIX A: TECHNICAL SPECIFICATIONS .................................................87 Hyper SCADA Server................................................................................................... 87

HSS001 ..................................................................................................................... 87 HSS002 ..................................................................................................................... 87

Hyper Server Module ................................................................................................... 88 Network Interface Module ........................................................................................... 88 Fiber Interface Module................................................................................................. 89

FIM001...................................................................................................................... 89 Network Fiber Module.................................................................................................. 90

NFM001 .................................................................................................................... 90 Network Switch Module ............................................................................................... 90

APPENDIX B: PIN DEFINITIONS........................................................................91 Hyper Server Module Pin Definitions ......................................................................... 91 Network Interface Module Pin Definitions* ............................................................... 92

APPENDIX C: LED STATUS AND ERROR CODES ..........................................93 APPENDIX D: ADDRESSING MODULES ..........................................................95 APPENDIX E: SUPPORT, SERVICE, AND WARRANTY INFORMATION ........97

Support and Service ...................................................................................................... 97 Technical Product Assistance....................................................................................... 97 Return Authorization (RA) Procedure........................................................................ 97 Warranty........................................................................................................................ 99 Questions or Comments on This Manual.................................................................... 99

INDEX ..................................................................................................................101

1

PREFACE

PURPOSE OF THIS MANUAL

This manual is a reference guide for the Hyper SCADA Server (HSS). It describes procedures for installing, wiring, testing, and troubleshooting the HSS.

This manual contains:

Instructions for mounting and wiring the HSS Configuration option descriptions and setup instructions Instructions for implementing redundancy Information on how to test and troubleshoot the HSS Instructions for replacing the HSS’ Hyper Server Module (HSM) Technical data and specifications

See the HT3 User Guide for detailed instructions on configuring, monitoring, and controlling your telemetry system.

DOCUMENT CONVENTIONS

The following conventions are used throughout this manual:

Bulleted lists provide information, not procedural steps. Numbered lists provide sequential steps or hierarchal information. Italic type is used for emphasis.

ABBREVIATIONS USED IN THIS MANUAL

CIM – Computer Interface Module CTU – Central Terminal Unit FIM – Fiber Interface Module HSM – Hyper Server Module HSS – Hyper SCADA Server MBP – Modular Backplane NFM – Network Fiber Module NIM – Network Interface Module NSM – Network Switch Module PSM – Power Supply Module RIM – Radio Interface Module RTU – Remote Terminal Unit

HSS Installation and Operation Manual

2

Notes

3

Chapter 1: PRODUCT OVERVIEW

HYPER SCADA SERVER

Description

The Hyper SCADA Server (HSS) is a self-contained data collection and information server housed in a wall-mounted, lockable enclosure. The HSS is available in two models: HSS001 (baseline model; no redundancy) and the HSS002 (premium model with redundancy capabilities). The core of both units is the Hyper Server Module (HSM), which includes a CPU, two voice-grade modems for call-out (911) and call-in (411) functions, and the necessary network hardware.

HSS001

The HSS001 is housed in a small 13”x13”x7” NEMA 4X fiberglass enclosure. In addition to the HSM, the HSS001 features a Power Supply Module (PSM), a Network Switch Module (NSM), backup battery, and Network Interface Module (NIM). The NIM provides two driver-configurable 9-pin serial ports. Using a process called serial tunneling that is provided by the NIM, the HSM is able to communicate with two serial-type devices, including Modbus devices.

Features of the HSS001

13”x13”x7” NEMA 4X Fiberglass Enclosure Hyper Server Module Network Switch Module Network Interface Module (Serial Interface) HT3 SCADA Software Program MySQL Software Program Integrated 411 Information Call In Function Integrated 911 Voice Alarm Call Out

Function RCA Audio Connector & Alarm Relay

Terminal Integrated Uninterruptible Power Supply

(UPS) Two Driver-Configurable 9-Pin Serial Ports 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols


4

NIM001HSM001

NETCARD

MODEM

PSM003

MODEM

10/100B-TX

2.6 AH BATTERY(INTEGRAL UPS)

100 WATTPOWERSUPPLY

NSM001

10/100BASE-TXNETWORKSWITCH

SERIALINTERFACE

�AUDIOOUT

ALARMTERMINALS

SO

UR

CE

LO

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SERIALPORT

COM 2 COM 1AC POWERINLET115 VAC60 HZ

BATTERY+ -

HSS001 MODULAR BACKPLANE

TE

LEP

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TE

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HO

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SERIALPORT

Figure 1-1, "HSS001 Block Diagram"

HSS002-X

The HSS002 features a 24”x30”x8” NEMA 4X steel enclosure. In addition to the HSM, the Hyper SCADA Server also features Network Switch Modules (NSM), Network Fiber Modules (NFM), Power Supply Modules (PSM), backup batteries, and surge suppressors. This combination of components provides a complete server with integral UPS function.

The HSS can be ordered with or without redundancy. A redundant unit contains a second backplane in which an additional HSM, NSM, and PSM are installed. The acting redundant HSM can take over the functions of the primary unit should the primary fail. When this transition occurs, there is no loss of function or data; it is transparent to the end user except for an alarm that is generated.

Features of the HSS002-1

24”x30”x8” NEMA 4X Steel Enclosure Accommodates Future “Hot Standby”

Redundancy Hyper Server Module Network Switch Module HT3 SCADA Software Program Browser-Based HMI Software MySQL Software Program Integrated 411 Information Call In

Function Integrated 911 Voice Alarm Call Out

Function Integrated Uninterruptible Power Supply

(UPS) 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols Optional Serial Interface Kit (Two 9-Pin

Serial Ports) Optional Network Fiber Interface (Serial

Tunneling) Optional RCA Audio & Alarm Relay

Terminal Kit

Product Overview

5

NFM001SPAREHSM001

NETCARD

MODEM

PSM003

MODEM

10/100B-TX

FIRST MBP001 BACKPLANE

NEW NEMA 2 ENCLOSURE

TO CLIENT NETWORK

TO CTU W/NIM

FUSESTFS TERMINALS

7.0 AH BATTERY

CALL IN/MAINTENANCE LINE

CALL OUT LINE

NSM001

TFS FUSES

This space reservedfor future upgradeto redundancy

SPARE

FIBER/10BASE-TOR10/100BASE-TXCONVERTER


100 WATTPOWERSUPPLY

CAT5NETWORKSURGEARRESTOR

2-LINESURGEPROTECTOR

Figure 1-2, "HSS002-1 Block Diagram"

Features of the HSS002-2

24”x30”x8” NEMA 4X Steel Enclosure Includes “Hot Standby” Redundancy Dual Hyper Server Modules Dual 100W Power Supply Modules Network Switch Module HT3 SCADA Software Program MySQL Software Program Integrated 411 Information Call In Function Integrated 911 Voice Alarm Call Out

Function Integrated Uninterruptible Power Supply

(UPS) 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols Optional Serial Interface Kit (Two 9-Pin

Serial Ports) Optional Network Fiber Interface (Serial

Tunneling) Optional RCA Audio & Alarm Relay

Terminal Kit


6

NFM001SPAREHSM001

NETCARD

MODEM

PSM003

MODEM

10/100B-TX

FIRST MBP001 BACKPLANE

NEW NEMA 2 ENCLOSURE

TO CLIENT NETWORK

TO CTU W/NIM

FUSES

HSM001

NETCARD

MODEM

PSM003

MODEM

10/100B-TX

SECOND MBP001 BACKPLANE

SPARESPARE SPARE

TFS TERMINALS

CALL OUT/MAINTENANCE LINE

CALL OUT LINE

NSM001

NSM001

TFS FUSES

SPARE

7.0 AH BATTERY 7.0 AH BATTERY

FIBER 10BASE-TOR 10/100BASE-TXCONVERTER

100 WATTPOWERSUPPLY


POWER SUPPLYAND BUSSCONNECTOR


100 WATTPOWERSUPPLY

2-LINESURGEPROTECTOR

�CAT5NETWORKSURGE

�ARRESTOR

Figure 1-3, "HSS002-2 Block Diagram"

User Interface

HT3, Data Flow Systems’ network-based SCADA software package, is installed on the HSM. HT3, which is compatible with most operating systems, allows for the monitor and control of remote, unmanned stations from a central location – the HSS.

Users access HT3 over a local area network from Windows-based workstations (Windows XP with SP2 or newer) using a Java-enabled Internet browser (Microsoft Internet Explorer 8.0 or newer).

The only software required on the workstations is Internet Explorer 8.0 or newer, Java 1.5, and a Java policy file. The Java policy file gives HT3’s Java applets permission to write to specific directories on your computer.

Connections to HT3 can be via either a local TCP/IP network or a PPP dial-up connection.

Other options for accessing HT3 are HT3 Mobile and HT3 Public.

HT3 Mobile is a streamlined version of HT3 optimized for today's smart phones. In HT3 Mobile, users will find all the essential tools needed for working in the field. The features provided in HT3 Mobile are alarms, screens, trends, and station status.

HT3 Public is an option for displaying custom screens on a utility’s website for public viewing. Public custom screens are view only; they don’t include controls.

Contact DFS for more information on adding HT3 Mobile and HT3 Public to your system.

http://hypertacii/documents/hypertacii/glossary.html#scada�

Product Overview

7

SCADA System Options

The HSS offers the flexibility of building your SCADA system around:

Network RTUs – Each Remote Terminal Unit, or station, features a Network Interface Module (NIM) or Fiber Interface Module (FIM) in place of a Radio Interface Module (RIM). All communication between the HSM and the station’s I/O modules are via the network.

Tunnel CTU – The system’s Central Terminal Unit features a FIM in addition to a RIM. The HSM communicates with remote, radio-based RTUs using a process called serial tunneling. Fiber provides isolation/protection from lightning strikes.

Combination of Tunnel CTU connected to a system of Network RTUs.

Network RTUs

Network RTUs are used for in-plant, close-proximity systems. Each RTU has a Fiber Interface Module (FIM) in place of a Radio Interface Module (RIM). This allows the HSM to communicate directly with each station via a network connection.

A network connection provides a more efficient means of transmitting and receiving data when compared to an RTU with a “rubber duck” antenna. For an overview of the FIM and its features, see “Network Modules,” p. 12.

Figure 1-4, "HSS - Network RTUs Configuration" (below) shows how an HSS002 and a system of Network RTUs could be configured.

NOTE: All modules in the HSS001 and HSS002 cabinets, except the NIM slot, communicate via CAT5 cable using the NSM as the hub. In an HSS, the backplane only supplies power to the modules; it is not a communications buss.

Hyper SCADA Server(HSS002-1)

Ethernet NetworkWorkstation

Workstation

Ne

twor

k R

TU

CAT 5

RACK MOUNT SWITCH

Net

wo

rk R

TU

Ne

twor

k R

TU

Ne

twor

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TU

Net

wo

rk R

TU

FIBER OPTIC CABLE

CAT 5

�H�S

M

VOID

VOID

NFM

NSM

PSM

DIN-RAIL MOUNTEDNETWORK SURGEARRESTOR

RACK MOUNTMEDIA CONVERTER

FIBER OPTIC CABLE

FIM

PSM

FIM

FIM

FIM

FIM

PSM

PSM

PSM

PSM

Figure 1-4, "HSS - Network RTUs Configuration"


8

Tunnel CTU

A Tunnel CTU is a Central Terminal Unit that contains both a Radio Interface Module (RIM) and a Fiber Interface Module (FIM). The FIM uses a process called “serial tunneling” to translate network data into a “language” (serial data) that the CTU’s RIM can understand. This serial data can then be sent out to the system’s radio-based RTUs.

Figure 1-5, "HSS with Tunnel CTU" (below) shows how an HSS002 – Tunnel CTU system could be configured.



WorkstationCentral Terminal Unit

HSM

VOID

VOID

NFM

NSM

PSM

CAT5 CABLE

DIN-RAIL MOUNTEDNETWORK SURGEARRESTOR

FIBEROPTICCABLE V

OID

VOID

VOID

FIM

RIM

PSM

REMOTETERMINALUNIT

REMOTETERMINALUNIT

REMOTETERMINALUNIT

Figure 1-5, "HSS with Tunnel CTU"

HYPER SERVER MODULE

Overview

The Hyper Server Module (HSM002) is a Linux-based computer that runs the HT3 SCADA software and MySQL database server engine. The HSM002 features a solid state hard drive and is housed on a plug-in module card that is manufactured by DFS. Compared to our previous model HSM (HSM001), this version of the module has increased processing speed and lower power consumption (which means it also runs cooler and doesn’t require a fan).

The HSM provides a communication interface with master transceiver radio(s) and network-based Remote Terminal Units (RTUs) via ancillary network modules (e.g., Network Fiber Modules and Network Switch Modules). The HSM can communicate with up to 250 Network RTUs per network (NIM) communication driver. It is capable of communicating with 100 fully-populated network-based RTUs with a total system poll rate

Product Overview

9

of less than five seconds. The HSM can also simultaneously poll multiple DFS (radio) and/or Modbus RTUs through the network using Fiber Interface Modules (FIMs).

A 10/100base-TX Ethernet network interface enables connectivity with workstation computers and VPN-secured Internet access. Users access the HT3 SCADA software over the network or the Internet from a standard web browser.

Two built-in, voice-grade modems, which double as data terminal modems, enable independent voice-based alarm dialing in addition to telemetry control and general status inquiries by telephone and dial-up computer.

Local voice alarm annunciation is available for use in a sound system (PA system, amplified speakers, or an amplifier plus speaker system). In addition, alarm horn and alarm light outputs are provided to accommodate large facilities where alarm announcements aren’t always within earshot of personnel.

Dual HSMs installed in a Hyper SCADA Server can be configured to provide automated Hot-Standby Redundancy. Data redundancy is managed by the system as it continually copies data from the primary HSM to the backup HSM (mirror imaging the primary). For non-redundant systems, daily data backups are directed to a defined primary workstation or designated server. A redundant HSS can also be configured to perform daily backups using this method in addition to its built-in redundancy process.

Other features of the HSM are a manual CPU shutdown button, status LEDs that indicate CPU activity and system status, and several configuration straps at the card edge that provide system-level configuration options.

Features of the HSM

Solid state hard drive

10/100base-TX Ethernet Network Interface

2 on-board voice modems

Voice alarm call-out

Dial out (911) / Dial in (411)

Communications Watchdog

DFS Backplane interface

Alarm horn driver with alarm silence input

Alarm light driver

Local voice alarm annunciation

Full system-backup capabilities

Button for manual CPU shutdown

LEDs indicate CPU activity and system status

Card-edge configuration straps for system level configurations

Reset and redundancy functions

Internet browser-based user interface

Linux operating system

HT3 SCADA software


10

Specifications and Interface

Model HSM002

Board Size 5.25” x 6.85”

Supply Voltage 11.8 to 13.4 VDC

Supply Current 0.8 Amps

Network Interface 10-100base-TX

LEDs CPU Power LED and 14 activity LEDs. For a description of the activity LEDs, see Appendix C: LED Status and Error Codes on page 93.

Figure 1-6, "HSM Interface"

Product Overview

11

Backup Battery Operation

Each model of the Hyper SCADA Server is equipped with a backup battery (two batteries are provided in the HSS002-2). The backup battery enables the Hyper Server Module to survive short term power outages and safely shut down before a complete loss of battery power.

Operating run times for a typical application running on battery power:

HSS001 (single 2.6 AH battery) - approximately 24 minutes.

HSS002-1 (single 7.0 AH battery) - approximately 60 minutes.

HSS002-2 (two 7.0 AH batteries) – approximately 26 minutes.

The HSM monitors the battery voltage and will begin a safe shutdown if voltage drops to 11.1 volts. See “Power and Voltage Monitoring,” below, for more information.

Power and Voltage Monitoring

The HSM’s onboard processor constantly monitors AC Power and DC Voltage. Parallel port bits on the HSM provide this data to HT3’s external points database. Because this information is stored in an accessible database, it can be monitored via custom screens and alarms.

If AC power is removed from the HSS (black/brown out), the backup battery begins providing power to the backplane. If it has been configured in HT3, an alarm for the external point HSS AC Power will be generated. If AC power is not restored and battery voltage drops to 11.1 volts, the onboard processor sends a shut down signal that prompts HT3 to begin a safe shutdown of the HSM’s operating system.

When shutdown of the OS is finished, the onboard processor shuts down the HSM’s microprocessor and hard drive. To be notified before shutdown that battery voltage is approaching a dangerous level, configure an alarm for the external point DC Voltage. The low level for the alarm must be set above the 11.1 volts threshold. If the low level is set at or below 11.1 volts, the HSM will shut down before the alarm can be generated.

The onboard processor continues to monitor voltage after shutdown is complete. When battery voltage reaches 12.3 volts (as a result of AC power being restored and the battery being recharged), the processor restarts the HSM’s microprocessor and hard drive.

IMPORTANT: There is an option to restart the system manually before battery voltage reaches 12.3 volts. However this course of action is only recommended for emergencies. If the decision is made to manually restart the system, battery voltage must be greater than 11.1 volts.


12

NETWORK MODULES

DFS’ network modules are designed as generic, network-interface and -distribution platforms for use with TAC II telemetry systems. Network modules are typically used in conjunction with a Hyper SCADA Server (HSS)-based TAC II SCADA system.

Four types of network modules are available, all of which are based on the same printed-circuit board. The network module type is determined by the auxiliary components that are mounted on the board – CPU, media converter, and network.

Network modules can be classified as either network interface modules or network distribution modules.

Network interface modules (Network Interface Module and Fiber Interface Module) feature a DOS-based network CPU and provide a function called "serial tunneling." Serial tunneling is a process that converts serial data into network data for transmission over an Ethernet network. A network interface module, such as the FIM, can also replace a Radio Interface Module (RIM) in an RTU to provide Ethernet-based communication with the central site (Hyper SCADA Server). The Fiber Interface Module's Ethernet media converter protects the unit from transient voltage damage.

Network distribution modules (Network Switch Module and Network Fiber Module) do not have processing capabilities (they do not come with the DOS-based network CPU). They are used strictly as a point of network distribution, or as a media converter (CAT5 to fiber optic) to protect network devices, such as the Hyper SCADA Server, from transient voltage damage.

The network modules provide the means for rapid data retrieval by enabling the telemetry system’s Remote Terminal Units (RTUs) to communicate over a network. In addition to an increased communication speed, the network modules’ higher sample rate also produces more accurate, near-real-time data retrieval.

A card retainer interlock is included on all of the network modules. The interlock is a magnetic power up switch that prevents the network module (and all other modules powered by it) from being removed while powered up and drawing current. This interlock is only used if the network module is installed in the RIM slot of an RTU or CTU. If the network module is in an I/O module slot, the bypass is made by placing a jumper across pins 3 and 5.

Product Overview

13

Network Interface Modules

Network Interface Module (NIM)

The Network Interface Module (NIM) is a DOS-based module designed as a generic, network-interface platform for use with TAC II telemetry systems. The NIM functions as an interface between a 10base-T Ethernet network and up to fifteen function modules of any combination. By communicating via a network instead of through traditional radios, the NIM is able to pass data quickly and reliably. DFS’ HT3 server can complete a system-polling loop in less than 5 seconds while communicating – simultaneously – with up to 100 NIM-based RTUs. The NIM plugs into the Radio Interface Module (RIM) slot of a Remote Terminal Unit (RTU) and provides the normal RIM functions of power supply, monitor, and control. The NIM can also be used with a RIM, a Computer Interface Module (CIM), or other NIMs. The NIM is capable of using serial tunneling – a process by which serial communications over a network is achieved – to communicate with RS232 devices, including Modbus devices.

Features of the NIM

DOS-based network CPU

250 addresses per communications link

Uses standard TCP/IP for communication

May be polled by multiple HT3 servers

System polling time of 2-5 seconds

Plug-and-play network configuration

Serial tunneling to RS-232 devices

LEDs on power, transmit data, network link, CPU failure, and test

Two (2) configurable RS-232 ports

RS-232 Service Port for system debugging

Test mode switch for system debugging

Battery back up during power failure

Flash memory for field upgrades

Program updates available from HT3 server

No on-board adjustments, switches or straps (self configuring)

Card retainer interlock that is bypassable and shareable

Typical Application for the NIM

Serial Tunneling Device – The NIM uses serial tunneling, a process by which serial communications over a network is achieved, to communicate with RS-232 devices, including Modbus devices.


14

Fiber Interface Module (FIM)

The FIM is a network-interface platform for use with TAC II telemetry systems. It functions as an interface between a 10 or 10/100 Base T Ethernet network and up to fifteen (15) function modules of any combination. The FIM’s Ethernet media converter, which protects the unit from transient voltage damage, is available in 10 Mbps and 10/100 Mbps speeds and can be ordered with support for either multi-mode or single mode fiber.

Features of the FIM

DOS-based network CPU

10 Mbps or 10/100 Mbps Ethernet media converter

250 addresses per communications link

Uses standard TCP/IP protocol for communication

May be polled by multiple HT3 servers

System polling rate of 2-5 seconds

Plug-and-play network configuration

Serial tunneling to RS-232 devices

2 configurable RS-232 communication ports

RS-232 service port and test mode switch for system debugging


Flash memory for field upgrades

Program updates available from HT3 server

LEDs for power, receive data, transmit data, network link, network traffic, COMM2, microprocessor fault, and test mode

No on-board adjustments, switches, or straps (self-configuring)


Typical Applications for the FIM

Serial Tunneling Device in CTU – When used in a CTU, the FIM uses “serial tunneling” to convert the RIM’s serial TTL (radio) data into network data for transmission over fiber optic cable to the Hyper SCADA Server.

Network Communication in RTU – When used in a 200 Series RTU, the FIM replaces the RIM; communications with the central site is accomplished via Ethernet. The FIM will interface with up to 15 I/O modules of any combination.

Product Overview

15

Available FIM Models

The FIM is available in four models:

FIM001-10: 10 Mbps; multi-mode fiber applications up to 2 km

FIM001-10/100: 10/100 Mbps; multi-mode fiber applications up to 2 km

FIM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km

FIM001-SM-10/100: 10/100 Mbps; single-mode fiber applications from 2-15 km

Network Distribution Modules

Network Fiber Module (NFM)

The Network Fiber Module (NFM) is designed as a generic, network media converter for use with TAC II telemetry systems. The NFM interfaces between the Hyper Server Module (HSM) - a component of the Hyper Server Unit (HSU) - and one of the following two components: the client network or the telemetry network (RTUs or CTU). Each HSU features at least two NFMs. The NFM’s main function is to provide the HSU’s components with protection from transient voltage damage. The NFM can be ordered to interface with either a 10 Mbps or 100 Mbps network. Additionally, the Ethernet and Fast Ethernet converters can each be ordered to support either multi-mode or single mode fiber applications.

Features of the NFM

10Mbps or 100Mbps Ethernet Media Converter


Monitors RTU power and DC bias




Typical Application for the NFM

Hyper SCADA Server (HSS) Media Converter – Plugs in module slot and provides transient voltage protection to the HSS’s Hyper Server Module (HSM). One NFM interfaces between the HSM and the client network. A second NFM interfaces between the HSM and the telemetry system (RTUs or CTU).

Available NFM Models

NFM001: 10 Mbps; multi-mode fiber applications up to 2 km

NFM001-F: 10/100 Mbps; multi-mode fiber applications up to 2 km

NFM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km

FIM001-FSM: 10/100 Mbps; single-mode fiber applications from 2-15 km


16

Network Switch Module (NSM)

The Network Switch Module (NSM) is designed as a generic 5-port network switch for use with TAC II telemetry systems. The NSM features a 5-port 10/100 Fast Ethernet UTP switch that can be used to connect the telemetry network and the client network in an in-plant monitor and control configuration.

Features of the NSM

5-port 10/100 Fast Ethernet UTP switch


Monitors RTU power and DC bias




Typical Application for the NSM

HSS (Hyper SCADA Server) Network Connectivity – The Network Switch Module can be inserted in one of the HSS' module slots to provide a connection from the Hyper Server Module (HSM) to the client network and the telemetry system’s RTUs and/or CTU. Temporary Network Connection: The NSM can also be placed in an RTU to provide a temporary network connection, for example, when programming a PLC.

Network Module Applications

Internally, the HSS uses the Network Switch Module (NSM) and the Network Fiber Module (NFM) to enable communications with telemetry hardware and users (client workstations), and to protect the unit from transient voltage damage and isolate it from signal noise.

The Network Switch Module is a central distribution point for all of the HSS’ components, allowing the HSM to communicate with the local area network and the telemetry system.

The Network Fiber Module provides a media conversion point (fiber optic to CAT5) within the HSS. Fiber optic cable (multi-mode or single mode depending on the distance to be covered) is used to protect the HSS’ components from transient voltage damage when connecting the HSS to the “outside world.”

Fiber Interface Modules (FIM) can be used in both Network (FIM-based) RTUs and radio-based Tunnel CTUs. When the FIM is installed in the Radio Interface Module (RIM) slot of a Remote Terminal Unit (RTU), it provides the normal RIM functions of power supply, monitor, and control. In a Network RTU, the FIM functions as an interface between an Ethernet network and up to fifteen function modules of any combination. Using a FIM in a radio-based CTU (Tunnel CTU) allows data to be sent between a radio network and an Ethernet network.

17

Chapter 2: BEFORE YOU BEGIN

SAFETY PRECAUTIONS

Review the following statements before installing, servicing, or replacing any of the Hyper SCADA Server’s (HSS) components.

General Precautions

Only trained and qualified personnel should install, service, or replace this equipment.

Carefully read the installation and wiring instructions before connecting any of the HSS’ components to their power source.

Do not work on the HSS, or connect or disconnect any of its cables during periods of lightning activity.

To prevent overheating the HSS, do not operate it in an area that exceeds the maximum recommended temperature of 86°F (30°C).

The recommended operating environment for the network interface and distribution modules is 0°-40° C (32°-104° F) with a relative humidity of 5%-95% (noncondensing).

Ensure that the unit is connected to earth ground during normal use.

Working Inside the HSS

Before working in the HSS where the removal of components is necessary, perform the following steps in the sequence indicated:

1. Power down all HSMs using the CPU Power▼(Down) button. 2. Turn off the main circuit breaker on the HSS. 3. Turn off the Power Supply Module’s (PSM) circuit breaker. 4. IMPORTANT: Ensure that any other power sources coming into the enclosure are

turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. For example, there could be a relay on the DIN-rail that is connected to power from another source.

5. Ensure that any fiber-optic cables connected to the HSS will not become entangled in or caught on anything in the surrounding area.

6. Put on an electrostatic discharge wrist strap that is attached to ground before touching anything inside the enclosure.

In addition, take note of these safety guidelines when appropriate:

When disconnecting a cable, pull on its connector or on its strain-relief loop, not on the cable itself. Some cables have a connector with locking tabs; when disconnecting this type of cable, press in on the locking tabs before disconnecting the cable. When pulling connectors apart, keep them evenly aligned to avoid bending any connector pins. Also, before connecting a cable, make sure both connectors are correctly oriented and aligned.

Handle components and boards with care. Don't touch the components or contacts on a board. Hold a board by its edges or by its metal mounting bracket.


18

Extra care must be taken when handling any of the modules. Rough handling can damage them. Place modules on a clean and grounded surface after removal. When installing modules, use gentle pressure to slide them in the module slots. Insert them slowly; never use force.

Protecting Against Electrostatic Discharge

Static electricity can harm delicate components inside the HSS. To prevent static damage, put on an electrostatic discharge wrist strap before touching any of the HSS’ electronic components.

In addition to the preceding precautions, the following steps can be taken to prevent damage from electrostatic discharge (ESD):

When unpacking a static-sensitive component from its shipping carton, do not remove the component's antistatic packing material until ready to install the component in the HSS. Be sure to put on an electrostatic discharge wrist strap before unwrapping the antistatic packaging.

When transporting a sensitive component, first place it in an antistatic container or packaging.

Handle all sensitive components in a static-safe area. Place the equipment on a grounded surface. If possible, use antistatic floor pads and workbench pads.

NOTE: Contact DFS if electrostatic discharge packaging is needed for return shipments. See “Return Authorization (RA) Procedure,” p. 97 for more information on returning equipment.

Using the HSS

When using the HSS, observe the following safety guidelines:

To help prevent electric shock, wire the HSS and peripheral power cables into properly grounded power sources.

Be sure nothing rests on the HSS’ cables and that the cables are not located where they can be stepped on or tripped over.

Do not spill food or liquids on the HSS. If the HSS gets wet, see “Appendix E: Support, Service, and Warranty Information,” p. 97.

Keep the HSS away from radiators and heat sources.

SITE SELECTION

When selecting a site for the HSS, keep the following in mind:

The HSS must be located in an air-conditioned [5-30ºC (41-86ºF)], moisture-free [10-80% relative humidity (noncondensing)], office-type environment.

The HSS’ main interface is through a network; there is no console interface. For this reason, the HSS must be connected to the existing local area network, either directly or via a network hub. Alternatively, a master workstation (single computer with necessary hardware and software) can be connected directly to the HSS.

The HSS requires a 120V AC power supply.

Before You Begin

19

To utilize the call-in and call-out features, the HSS must have access to at least one telephone line.

The HSS enclosure is a 23” x 23.50” box with a continuous-hinged door. Allow enough space around the enclosure to ensure that the door has complete freedom of movement.

RECEIPT OF EQUIPMENT

When equipment is received, examine the outside of the carton for any damage incurred during shipment. Remove the packing list and the equipment from the shipping carton. Carefully inspect the equipment for damage. Resolve any damage with the local carrier. Report damages to Data Flow Systems (321-259-5009). Include the serial number of the unit and the extent of damage in your report.

INSTALLATION OVERVIEW

The table below outlines the steps required to get your HSS SDADA system up and running. Each step is followed by the chapter where detailed instructions can be found.

Procedure Chapter

Mount the unit Chapter 3: Mounting and AC Wiring Instructions

Install modules (HSS002-X only) Chapter 3: Mounting and AC Wiring Instructions

Wire AC power Chapter 3: Mounting and AC Wiring Instructions

Wire call out/call in Chapter 4: Device Wiring Instructions

Wire alarm notification devices (optional)

Chapter 4: Device Wiring Instructions

Configure HSS for networking Chapter 5: Network Setup

Configure telemetry devices (RTUs, CTUs, Modbus) and connect to HSS

Chapter 6: Telemetry System Setup

Configure workstations Chapter 7: Workstation Configuration

Configure critical data redundancy Chapter 8: Critical Data Redundancy


20

Notes

21

Chapter 3: MOUNTING AND AC WIRING INSTRUCTIONS

HSS001

Unpacking the HSS001

1. Carefully open the box in which the HSS001 was shipped and remove the unit. 2. Your HSS001 is shipped with the modules preinstalled in their appropriate slots with

packing material placed between the modules to help prevent shipping damage. Before mounting the HSS001, open the enclosure's door and remove the packing material.

3. Visually inspect the enclosure and the modules. If any equipment appears damaged, read the information in the Return Authorization (RA) Procedure (p. 97) for instructions on having the equipment replaced or repaired.

Mounting the HSS001

IMPORTANT: The HSS001 must be mounted to the wall in a vertical position to ensure proper airflow through the vents in the enclosure. These vents are used to help keep the unit and its components from overheating. Do not install the unit in a horizontal position or lay the unit down on its front, top, back, or sides.

The HSS001 is designed to operate in an air conditioned, moisture-free, office-type environment [41-860F (5-300C)]. When selecting an installation site, make sure that it provides an acceptable environment.

There are four mounting bosses on the back of the unit for attaching the brackets to the enclosure. Attach the four mounting brackets to the back of the HSS001’s enclosure using the supplied screws. Use all four brackets to ensure that the unit will be securely mounted. The mounting brackets may be aligned vertically or horizontally. After attaching the brackets to the enclosure, securely fasten the HSS001 to the wall in the desired location.

Wiring the Unit for AC Power

W A R N I N G

The HSS001 should only be installed and serviced by DFS personnel or other qualified technicians.

The HSS001 must be installed in accordance with all national and local wiring rules.

The rated voltage and current for the HSS001 are 120 VAC and 2 Amperes

The HSS001 uses a 100-watt power supply module (PSM003) to provide 12V DC operating power to all the modules on its backplane and continuous charging to its backup battery. There is no wiring required for these functions; all connections are built into the backplane.


22

The HSS includes a power cord that can be plugged into any standard grounding-type outlet. An optional power supply kit can be obtained for situations that require that you run your own conduit.

IMPORTANT: When using the power cord included with the HSS, the power cord must be plugged into a grounded socket-outlet. The socket outlet must be installed near the HSS and be easily accessible.

Use the optional power supply kit (part no. 016-0181) when running your own conduit. This kit includes an IEC 320/C13 AC power plug assembly that features screw terminals. The power plug assembly is rated at 10 Amps/250 Volts. The rated voltage and current for the HSS001 are 120 VAC and 2 Amperes.

HSS002-X

Unpacking the HSS002-X

IMPORTANT: When handling the HSS002-X's components, follow the instructions in "Protecting Against Electrostatic Discharge" (page 18).

The HSS002-X enclosure and modules are shipped separately in two or more boxes.

1. Carefully open all boxes and locate the box that contains the enclosure. Remove the enclosure and visually inspect it. *

2. From the box that contains the modules, carefully remove each module from its packing and visually inspect it for shipping damage. *

* If any equipment appears damaged, read the information in the Return Authorization (RA) Procedure (p. 97) for instructions on having the equipment replaced or repaired.

Mounting the HSS002-X

IMPORTANT: The HSS002-X is designed to be mounted to the wall in a vertical position. This ensures proper airflow throughout the enclosure and provides easy access to the internal devices. Do not install the unit in a horizontal position or lay the unit down on its front, top, back, or sides.

The HSS002-X is designed to operate in an air conditioned, moisture-free, office-type environment [41-860F (5-300C)]. When selecting an installation site, make sure that it provides an acceptable environment.

There are four mounting bosses on the back of the unit for attaching the brackets to the enclosure. Attach the four mounting brackets to the back of the HSS002-X’s enclosure using the supplied screws. Use all four brackets to ensure that the unit will be securely mounted. The mounting brackets may be aligned vertically or horizontally. After attaching the brackets to the enclosure, securely fasten the HSS002-X to the wall in the desired location.

Mounting and AC Wiring Instructions

23

Installing the HSS002-X’s Modules

Refer to the diagrams on the next page for correct placement of modules. Modules can be identified by their affixed labels.

When inserting modules, line up the module's card edge connector with the slot and apply gentle pressure. Never force a module into a slot. If the module does not snap into place easily, realign the connector to the slot, and try inserting it again.

HSS002-1


24

HSS002-2

Mounting and AC Wiring Instructions

25

Wiring the HSS002-X for AC Power

W A R N I N G

The HSS should only be installed and serviced by DFS personnel or other qualified technicians.

The HSS must be installed in accordance with all national and local wiring rules.

Before starting this installation, verify that no power is coming into the HSS or to any device(s) wired to it.

The HSS002-1 uses a 100-watt power supply module (PSM003) to provide 12V DC operating power to all the modules on its backplane and continuous charging to its backup battery. There is no wiring required for these functions; all connections are built into the backplane. An additional PSM003 is installed on the second backplane of the HSS002-2. Each PSM is primarily responsible for powering the modules on its own backplane, but is also wired to provide redundant power to the auxiliary backplane if it loses power.

Each PSM must be wired directly to a 120V AC commercial power source using #16 AWG wire. A heavier gauge of wire or the installation of an interposing 10-amp breaker in the utility's control panel may be required in order to comply with local electrical codes.

The procedure for wiring power is the same for both the HSS002-1 and the HSS002-2. Connections from the backplate to all of the DIN-rail mounted components, including the 10-amp breaker and the neutral terminal block used in this procedure, are prewired at the factory. Refer to the diagram below when wiring AC power. Note that the diagram shows only the right portion of the DIN rail.

1. Locate the “hot” (black) wire. Strip back approximately 1/4“ of the wire’s insulation and remove the excess. Connect this wire to the line side of the 10-amp breaker using the breaker’s screw-type connection.

2. Locate the “neutral” (white) wire. Strip back approximately 1/4” of the wire’s insulation and remove the excess. Connect this wire to pin 1 on the neutral terminal block using the block’s Wago compression-type connector.

3. Locate the “ground” (green and yellow) wire. Strip back approximately ¼ inch of the wire’s insulation, remove the excess, and terminate it with a #10 ring terminal. Connect the grounding wire to the HSS’ ground lug.

10

LINENH

LOADPin 1

Ground Lug

Figure 3-1, "HSS002-X AC Wiring"


26

Notes

27

Chapter 4: DEVICE WIRING INSTRUCTIONS

This chapter provides information on wiring the HSS to a call-out (911) and/or call-in (411) telephone line, and a sound system (PA system, amplified speaker, or combination amplifier and speaker).

DIAL OUT / DIAL IN

Each HSM features two voice modems, which enable dial in (411), dial out (911), and PPP dial-up, and allow alarm annunciation via a sound system (PA system, an amplified speaker, or an amplifier-plus-speaker system).

The wiring method depends on the number of telephone lines available. (Is one line used for both call in and call out? Or, is one line dedicated to call in and a second line dedicated to call out?)

When connecting the HSS to the telephone lines, basic precautions should be followed to reduce the risk of fire, electric shock, and personal injury.

Safety Precautions

Avoid working during an electrical storm. Do not install a telephone jack in a wet location unless the jack is specifically

designed for wet locations. Never touch telephone wires or terminals that are not insulated unless the telephone

line has been disconnected at the network interface. Use caution when installing or modifying telephone wiring.

HSS001

NOTE: By default, HT3 SCADA software is configured for two phone lines. If only one phone line is used for both the call in and call out functions, HT3’s configuration must be changed. See “Call In and Call Out: Configuring 911 & 411” in the HT3 User Guide for more information.

One Telephone Line Setup (HSS001)

Please note that if you are using only one line for both functions, call out (911) takes precedence. If you are calling in and an alarm occurs (one with call out enabled), the system will disconnect your call in order to place the 911 call.

This setup requires a configuration change in HT3. See “Call In and Call Out: Configuring 911 & 411” in the HT3 User Guide for instructions.


28

Follow these instructions when using one line for both the Call Out and Call In functions.

1. From your telephone room or

telephone wall jack, locate the telephone line's tip and ring wires and terminate them using an RJ11 modular plug.

2. Insert the plug into the LINE 2 jack. LINE 2 is prewired to the Line 2 termination points on the HSM’s card edge.

1 2

COM2 COM1

TO WALL JACK /TELEPHONE ROOM

SO

UR

CE

LOA

D

+ -

Battery

CALL OUT (911) / CALL IN (411) LINE

BATTERYTERMINALS

ACPOWER

SERIALPORTS

ALARMTERMINALS

AUDIOOUT

TELEPHONELINES

PSM003

NSM001

NIM001

HSM001

Two Telephone Line Setup (HSS001)

Follow these instructions when using two separate telephone lines for the Call Out and Call In functions.

1. From your telephone room or

telephone wall jack, locate line 1's and line 2's tip and ring wires. Terminate each line's tip and ring wires using an RJ11 modular telephone connector.

2. Plug the line that will handle call out (911 calls) in the LINE 1 jack. LINE 1 is prewired to the Line 1 termination points on the HSM’s card edge.

3. Plug the line that will handle call in (411 calls) in the LINE 2 jack. LINE 2 is prewired to the Line 2 termination points on the HSM’s card edge.

1 2

COM2 COM1

SO

UR

CE

LOA

D

+ -

HSM001

NIM001

NSM001

PSM003

TELEPHONELINES

AUDIOOUT

ALARMTERMINALS

SERIALPORTS

BATTERYTERMINALS

ACPOWER

BATTERY

CALL IN (411) LINE

CALL OUT (911) LINETO WALL JACK /TELEPHONE ROOM

Device Wiring Instructions

29

HSS002-X

NOTE: By default, HT3 SCADA software is configured for two phone lines. If only one phone line is used for both the call in and call out functions, HT3‘s configuration must be changed. See “Call In and Call Out: Configuring 911 & 411” in the HT3 User Guide for more information.

One Telephone Line Setup (HSS002-X)

Follow these instructions when using one telephone line for both the Call Out and Call In functions. Refer to Figure 4-1, "Wiring HSS002-X for Call Out / Call In".

Please note that if you are only using one line for both functions, call out (911) takes precedence. If you are calling in and an alarm occurs (one with call out enabled), the system will disconnect your call in order to place the 911 call.

1. From your telephone room or telephone wall jack, locate the telephone line’s tip and ring wires and terminate them using an RJ11 or RJ12 modular plug.

2. Insert the plug into the LINE IN jack located on the HSS’ DIN rail. LINE IN is prewired to the Line 2 termination points on the HSM’s card edge (pin7, Line 2 Tip and pin 5, Line 2 Ring).

Two Telephone Line Setup (HSS002-X)

Follow these instructions when using two separate telephone lines for the Call Out and Call In functions. Refer to Figure 4-1, "Wiring HSS002-X for Call Out / Call In".

1. From your telephone room or telephone wall jack, locate line 1’s and line 2’s tip and ring wires. Terminate each line’s tip and ring wires using an RJ11 or RJ12 modular telephone connector.

2. Plug the line that will handle call in (411 calls) in the LINE IN jack that is located on the HSS’ DIN rail. LINE IN is prewired to the Line 2 termination points on the HSM’s card edge (pin7, Line 2 Tip and pin 5, Line 2 Ring).

3. Plug the line that will handle call out (911 calls) in the LINE OUT jack that is located on the HSS’ DIN rail. LINE OUT is prewired to the Line 1 termination points on the HSM’s card edge (pin 11, Line 1 Tip, pin 9, Line 1 Ring).

TO HSM(PREWIRED)

LINEOUT

LINEIN

DINRAIL

DINRAIL

TO HSM(PREWIRED)

Figure 4-1, "Wiring HSS002-X for Call Out / Call In"


30

ALARM NOTIFICATION OPTIONS

The HSS offers several alarm notification options.

Alarms are always displayed at client computers that are running the HT3 SCADA software.

An Alarm LED is located on the Hyper Server Module (HSM). Alarms can be announced through an audio device. An external light can illuminate when an alarm occurs. A horn can sound when an alarm occurs.

Audio Device

Alarms can be announced at a client workstation that is running the HT3 SCADA software. For this to function, the client workstation must be capable of playing sound files, either through internal or external speakers.

It is possible to have alarms announced at a remote site away from the workstation computer as well as locally. Alarms can be announced from an audio device, such as a PA system, an amplifier-plus-speaker system, or amplified speaker, in addition to being announced at a workstation.

W A R N I N G

Before starting this installation, verify that no power is coming into the HSS or to any device(s) wired to it.

Before connecting the HSS to an audio device:

Ensure that the sound system has its own power source. Do not use the HSS to power the sound system.

Before connecting the sound system to the HSS, turn off the sound system’s power. This helps prevent damage to speakers as well as to any connected equipment.

Connecting the HSS001 to an audio device

The HSS001's RCA mono jack (Audio Out) may be used to connect an audio device, such as a PA system, an amplifier-plus-speaker system, or amplified speaker, to the HSS001. With this type of set up, alarm announcements can be heard remotely in addition to being heard locally at the workstations.

Connecting the HSS002-X to an audio device

Be sure to match the audio device’s polarity (+ / –) to those of the HSS002-X’s Hyper Server Module (Audio Output + and Audio Output -). If the polarities don’t match, the sound may be distorted.

Ensure that the audio device has its own power source and ground. Do not use the HSS002-X to power or ground the audio device.

Refer to the figures on the next page for wiring illustrations.


31

PIN 3, AUDIO OUTPUT +

PIN 1, AUDIO OUTPUT -

HYPER SERVER MODULE

AUDIO +

AUDIO -AUDIO CABLEPA SYSTEM /

AMPLIFIED SPEAKERS /AMPLIFIER + SPEAKERS

Figure 4-2, "Audio Device Connected to HSS002-1"

1

1

HYPER SERVER MODULE (1)






AUDIO +

AUDIO -

AUDIOCABLE

PA SYSTEM /AMPLIFIED SPEAKERS /AMPLIFIER + SPEAKERS

1K OHM 1/4 WATT RESISTOR1

Figure 4-3, "Single-channel Audio Device Connected to HSS002-2"







AUDIO +

AUDIO -

PA SYSTEM /AMPLIFIED SPEAKERS /AMPLIFIER + SPEAKERS

AUDIO +

AUDIO -

RIGHTCHANNEL

LEFTCHANNEL

Figure 4-4, "Multi-channel Audio Device Connected to HSS002-2"


32

Alarm Light, Alarm Horn, and Alarm Silence Button Options

The HSM features an Alarm LED that illuminates when an alarm condition occurs. It is also possible to add an external light in a location that is visible from all points in the plant.

In addition to an external alarm light, an alarm horn that sounds when an alarm condition occurs can be connected. The alarm horn features an optional alarm silence button (HSS002-X only).

W A R N I N G

Before wiring any of the HSS’ alarm options, verify that no power is coming into the HSS or to any device(s) wired to it.

HSS001 Alarm Options

The HSS001 includes alarm terminals (source and load) that can be used to connect an external light or horn. The alarm terminals are rated for 125 VAC/60 VDC max./.5 mA max.

An alarm silence button is not included. You can wire an external relay to function as an alarm silence button if this feature is necessary.

HSS002-X Alarm Light

Before wiring an alarm light, ensure that:

Each set of contacts on the relay is rated for the voltage and current it is switching. The coil is rated for the +12VDC with which the HSS is driving it. The alarm light has its own power source and ground. Do not use the HSS to power

or ground the external light.

Refer to the diagram below when wiring an alarm light to the HSS002-1. A wiring diagram for the HSS002-2 is provided on the next page.

NO

HYPER SERVER MODULE

PIN 42, SYSTEM DC +

PIN 16, ALARM LIGHT OUT

+ SIDE OF COIL

- SIDE OF COIL

+12 VDCPOWERDISTRIBUTIONBLOCK

EXTERNAL LIGHTPOWER SOURCE

COMMON

NEUTRALRETURN

Figure 4-5, "HSS002-1 Alarm Light Wiring"


33

NO

HYPER SERVER MODULE

PIN 42, SYSTEM DC +


HYPER SERVER MODULE

PIN 42, SYSTEM DC +


+ SIDE OF COIL

- SIDE OF COIL

+12 VDCPOWERDISTRIBUTIONBLOCK (1)

+12 VDCPOWERDISTRIBUTIONBLOCK (1)

+ SIDE OF COIL

- SIDE OF COIL

COMMON

COMMON

NONEUTRALRETURN

ALARM LIGHTPOWER SOURCE

Figure 4-6, "HSS002-2 Alarm Light Wiring"

HSS002-X Alarm Horn

Before wiring an alarm horn, ensure that:

Each set of contacts on the relay is rated for the voltage and current it is switching. The coil is rated for the +12VDC with which the HSS is driving it. The alarm light has its own power source and ground. Do not use the HSS to power

or ground the external light.

Refer to the diagram below when wiring an alarm horn to the HSS002-1. A wiring diagram for the HSS002-2 is provided on the next page.


34

NO

HYPER SERVER MODULE

PIN 42, SYSTEM DC +

PIN 14, ALARM HORN OUT

+ SIDE OF COIL

- SIDE OF COIL

+12VDCPOWERDISTRIBUTIONBLOCK

COMMONALARM HORNPOWER SOURCE

NEUTRALRETURN

Figure 4-7, "HSS002-1 Alarm Horn Wiring"

HYPER SERVER MODULE

PIN 42, SYSTEM DC +


HYPER SERVER MODULE

PIN 42, SYSTEM DC +


+ SIDE OF COIL

- SIDE OF COIL

+12VDCPOWERDISTRIBUTIONBLOCK (1)

+ SIDE OF COIL

- SIDE OF COIL

+12VDCPOWERDISTRIBUTIONBLOCK (2)

COMMON

COMMON

ALARM HORNPOWER SOURCE

NEUTRALRETURN

NO

NO

Figure 4-8, "HSS002-2 Alarm Horn Wiring"


35

HSS002-X Alarm Silence Button

This feature is available on the HSS002 only. Before wiring an alarm silence button, ensure that:

Contacts on the relay are rated for the voltage and current it is switching. The coil is rated for 43.6 mA at 12VDC, and the contact is rated for 8 amps at

250VAC / 8 amps at 30VDC. The alarm silence button has its own power source and ground. Do not use the HSS

to power or ground the alarm silence.

Refer to Figure 4-9, "HSS002-1 Alarm Silence Button Wiring" and Figure 4-10, "HSS002-2 Alarm Silence Button Wiring", below.

HYPER SERVER MODULE

PIN 40, SYSTEM DC GROUND

PIN 18, ALARM SILENCE INPUTNO NC

COMMON

POWERSUPPLY +

POWERSUPPLY -

Figure 4-9, "HSS002-1 Alarm Silence Button Wiring"

POWERSUPPLY +

POWERSUPPLY -

COMMON

NCNO

DC GROUNDDISTRIBUTIONBLOCK


PIN 40, SYSTEM DC GROUND

PIN 18, ALARM SILENCE INPUT


PIN 18, ALARM SILENCE INPUT

Figure 4-10, "HSS002-2 Alarm Silence Button Wiring"


36

Notes

37

Chapter 5: NETWORK SETUP

OVERVIEW

The Hyper Server Module (HSM) itself has no console interface, although a keyboard and monitor can be connected for troubleshooting. In order for workstations to access the HSM and the HT3 SCADA software, the HSS must be connected to an Ethernet network via a network switch, hub, or directly to a stand-alone master workstation. All client computers must be able to access the same network the HSM uses.

The term “master workstation” is used to describe a computer that is connected directly to the HSS’ NSM instead of a LAN switch/hub. This dedicated workstation is necessary when the HSS is not a part of an existing client local area network.

When the HSS is connected via a component of an Ethernet network, users access it from client computers.

The diagram below illustrates one way in which a redundant HSS can be used in a SCADA system using both a CTU and a system of network-based RTUs.

VO

ID

PS

M

RIM

VO

ID

FIM

PS

M

FIM

PS

M

FIM

CTU

RTU100

RTU200

HSS FIBER CABLE

FIBER CABLES

VO

ID

CAT5 CABLETO NETWORK /PCs

PS

M

NS

M

NF

M

UN

SU

SE

D

UN

SU

SE

D

HS

M

PS

M

NS

M

NF

M

NF

M

UN

SU

SE

D

HS

M

SERVICEPORT

NETWORKSURGEARRESTOR

Figure 5-1, "Typical HSS002-2 Configuration with Redundancy"


38

FUNCTIONS OF NETWORK MODULES IN THE HSS

Network Distribution and Isolation

A Network Switch Module (NSM) is installed in the RIM or NSM slot of the HSS’ backplane (HSS001 and HSS002-1). In a redundant unit (HSS002-2), two NSMs are installed: one in each backplane. The NSMs provide a central network distribution point for the Hyper Server Modules installed in the HSS.

The HSS002-X features a NFM that fiber-optically isolates the HSM(s) from the telemetry system’s CTU or network-based RTUs. All of the network distribution modules communicate via Ethernet to the Hyper Server Module. The HSS buss supplies power to each module.

Serial Tunneling

The Network Interface Module (NIM) or the Fiber Interface Module (FIM) in the HSS001 can act as an interface between the serial devices connected to the HSS and the network. The HSS001’s two serial ports (COM1 and COM2) are connected to the NIM. This allows the serial devices to pass their data to network devices through a process called serial tunneling.

In serial tunneling, the HSM bundles serial data into network packets and forwards it to the NIM. When the NIM sees an incoming packet, it switches to serial tunnel mode, extracts the serial data, and sends the data out the appropriate COM port. When a serial device sends data to one of the NIM’s COM ports, the NIM bundles the data into network packets and forwards them to the HSM.

NOTE: COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Both COM1 and COM2 are used only as a stand-alone serial tunnel; there is no buss communication.

COM1: Pin 2=RXD, Pin 4=TXD, Pin 6=GND, Pin 11=RTS, Pin 13=CTS


Power Distribution

The “skeleton board” for each module, which is used as the base of all network modules (NIM, FIM, NSM, and NFM), provides power to the attached network hardware (switches or converters). The network distribution modules, because they are wired to the HSS’ backplane(s), obtain power from the backplane and benefit from the HSS’ battery backup function.

Controlled by HSM

The Network Switch Module (NSM) monitors the HSM’s Power Supply Module (PSM) and reports status to the HSM. It also initiates a PSM shutdown when requested by the HSM. The HSM instructs the network distribution module to cycle power to its network hardware if communication problems are experienced.

Network Setup

39

Reset Remotely

The microprocessors on both types of network distribution modules are programmed to monitor the TX data line of the HSS bus. If communication problems are experienced, the modules can be remotely reset via software on the HSM. It is possible to “toggle” the TX data line to either reset the network hardware on the network distribution modules, or shut down the power supply in order to perform a battery test. HT3’s System Control Panel provides the ability to perform these functions from any configured Windows workstation. See “Using System Troubleshooting and Maintenance Tools” in the HT3 User Guide for more information.

HSS001

Description

The HSS001 contains a single backplane with the following modules installed: Hyper Server Module, Network Switch Module, and Power Supply Module. It also includes one of the following: Network Interface Module, Network Fiber Module, or Fiber Interface Module. The HSS001 also includes two 9-pin serial ports for connecting serial-type devices (including Modbus devices), a 2.6 AH backup battery, two telephone line input jacks, one RCA mono jack, and alarm terminals (for connecting an alarm light/horn). Critical data is backed up nightly to a Windows workstation. For more information on Critical Data Redundancy, see the HT3 User Guide.

Network Distance Considerations

When planning an installation, consider the following when selecting the type of fiber-optic cable (multi-mode or single-mode) and the type of media converters:

Will the HSS be connected to an existing local area network (LAN) or directly to a master workstation?

If the HSS is to be connected to an existing LAN, what is the speed of the network?

If the HSS is to be connected to a master workstation, what is the speed of the media converters used in the HSS?

What is the distance between the HSS and the telemetry system connection point (the CTU or the media converter) to which the system’s Network RTUs are connected?

What is the distance between the HSS and the LAN/master workstation?

Is the master workstation/LAN situated in a different location than the HSS (for example, in a different building)

Cable Selection

Multi-mode fiber-optic cable covers distances up to 2 km (~1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~9.3 miles).


40

Converter Selection

The converter used on the Fiber Interface Module (FIM) and the Network Fiber Module (NFM) is a 10Mbps Ethernet Media Converter. This converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU or Network RTUs. The type of media converter used is solely based on application.

Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be a 10/100Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length).

What You’ll Need

Two (2) Free/unused IP addresses - one for the HSM and one for the NIM/FIM

CAT5 cables terminated with RJ-45 connectors

Telephone cable terminated with RJ-11 connectors

Computer with Windows operating system installed

Keyboard and monitor (for connecting to the HSM when configuring its IP address)

Installation and Configuration Procedure

Step 1: Configure the NIM’s IP Address

The HSS001's NIM acts as an interface between the serial devices connected to the HSS001 and the network. The NIM is referred to as a "tunneling device," because its function is to pass - or tunnel - serial data through a network. The NIM requires a valid IP address.

IMPORTANT: (1) The NIM cannot be addressed greater than 250. (2) The ground (G) switch must remain in the ON position. (3) The BRAIN switch, when set to the OFF position, allows for an IP address to be configured when using a NIM/FIM. Set the BRAIN switch to ON when using a network distribution module (i.e., NFM).

Network Setup

41

The NIM features automatic IP addressing. It obtains the first three octets of its network address from an HSM broadcast (a network service called NIM Broadcast). The last octet comes from the NIM Tunneling IP Address block (located in the HSS001 to the left of the NIM).

The last octet is configured by placing each of the DIP switches on the address block in either the ON or OFF position. The address is calculated by adding up the bits that are OFF.

The example at right shows the NIM addressed at 208. The 128, 64, and 16 switches have been placed in the OFF position (128 + 64 +16 = 208). See “Appendix D: Addressing Modules” for more information on module addressing.

G

BRAIN

128

64

32

16

8

4

2

1

NIM TUNNELINGIP ADDRESS

ON

OFF

When the NIM boots up, it receives a broadcast from the HSM that says, "This is your subnet." The NIM reads its subnet, mates it with the tunnel address, and begins to talk at that IP address.

Step 2: Make Network Connection

This section provides information on making connections inside the HSS001. See “Chapter 6: Telemetry System Setup” for information on connecting the HSS001 to the telemetry system’s serial devices.

If the HSS001 is to be connected to an existing network (via a hub, switch, router), follow the instructions given for Option 1: Client Network. If there is no network available and the HSS001 is being connected directly to a workstation, follow the directions in Option 2: Dedicated Workstation.

The diagrams on the next page show connections for two versions of the HSS001 – one with a NIM installed in the second slot; one with a FIM installed. For both versions, connection to the workstation/network is identical. The only difference is in how the NSM is connected to the NIM/FIM.

The HSS includes a NIM when using the unit’s COM ports to connect to serial-type devices [see “Serial Devices (HSS001),” page 68]. The HSS requires a NFM/FIM when the unit is connected to a Tunnel CTU (see “Tunnel CTU,” page 61).

Option 1: Client Network – When connecting the HSS to a client network via a device such as a hub, switch, or router, connect port 1 (one) on the NSM to a port on the other device.

Option 2: Dedicated Workstation – When connecting the HSS to a dedicated workstation (stand-alone PC), connect port 1 (one) on the NSM to a port on the computer's network card.


42

HSS001 with FIM

HSS001 with NIM

Step 3: Configure the HSM’s Static IP Address

1. Connect a PS-2 keyboard and monitor to the HSM. Ports for connecting a keyboard and monitor are easily accessible and clearly marked.

2. Restore power to the unit. A. Turn on the PSM. B. Connect the battery. The HSS is now activated.

3. It is not necessary to power up the HSM; it will automatically power up when it senses power has been applied. LED sequence during power up is as follows: C. The ACT LED is constant. The SDN LED blinks slowly and then more quickly.

+CPU and +5V LEDS are constant and remain constant during and after power up. D. The SDN LED goes off and the ACT LED is constant.

Network Setup

43

E. The ACT LED begins to blink indicating that the HSM is fully powered. 4. When the HSM is fully powered and booted up, a login prompt appears on the monitor.

Enter mgr for the login and htiimgr for the password. 5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx

represents the IP address of the HSM). Follow the on-screen prompts.

HSS002-1 NETWORK SETUP (NON-REDUNDANT HSS002)

Description

A non-redundant HSS002 contains a single backplane with the following modules installed: Hyper Server Module, two Network Fiber Modules, Network Switch Module, and Power Supply Module. It also includes one 7.0 AH backup battery and DIN-rail mounted surge protection devices for connecting phone and audio lines. Critical data is backed up nightly to a networked drive or a Windows workstation. For more information on Critical Data Redundancy, see the HT3 User Guide.

Network Considerations/Vulnerabilities

When planning an installation, consider the type of fiber-optic cable (multi-mode or single-mode) and the type of media converters needed (see technical specifications beginning on page 88). Consider the following when evaluating network vulnerabilities:

Will the HSS be connected to an existing local area network (LAN) or directly to a dedicated/master workstation?

If the HSS is to be connected to an existing LAN, what is the subnet mask and speed of the network?

If the HSS is to be connected to a master workstation, determine if that workstation has access to the internet. If so, determine vulnerabilities (possibility of hacker attacks) on the HSS’ Apache web server. Also determine the speed of the media converters used in the HSS.

What is the distance between the HSS and the telemetry system connection point, such as the CTU of the media converter for each of the system’s Network RTUs?

What is the distance between the HSS and the LAN distribution device (switch, router) or the master workstation?

Is the master workstation/LAN situated in a separate area from the HSS (for example, in a different building)

Additional NFMs Required in HSS

If the distance between the HSS and the LAN/master workstation is greater than the maximum Ethernet distance (100 meters or 328 feet), or if the LAN/master workstation is in a different location than the HSS (for example, a different building), additional NFMs may be required in the HSS. Fiber optic cable is used to isolate components from lightning strikes. Therefore a media converter (available on the NFM/FIM) may be required for network RTUs or additional CTUs.


44

Cable Selection

Multi-mode fiber-optic cable covers distances up to 2 km (~1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~9.3 miles).

Converter Selection


Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be 10/100 Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length).

What You’ll Need (Minimums)

Two free, or unused, static IP addresses. One for the HSM. The other for the CTU. These IP addresses must be on the same network.

HSS with Hyper Server Module (HSM), Power Supply Module (PSM), Network Switch Module (NSM), and Network Fiber Module (NFM) installed. (Refer to the specifications for the Network Fiber Module provided on page 90 in “Appendix A: Technical Specifications” when selecting an NFM.)

NIM/FIM for Tunnel CTU or Network RTUs (NOTE: Network RTUs require desktop-style or rack mount fiber-optic media converters between them and the HSS).

Local area network or master workstation. (NOTE: Each may require appropriate fiber-optic media converters between them and the HSS)

Configuration jumpers (black #16 stranded wire can be used for making jumpers). Three CAT 5 patch cables terminated with RJ-45 connectors. One CAT5 cable of sufficient length to cover the distance from the HSS to the

local area network or master workstation. One fiber-optic cable of sufficient length to cover the distance between the HSS

and the telemetry system connection point (the Tunnel CTU or the media converter to which the system’s Network RTUs are connected). In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters.

PS-2 keyboard and monitor. This will be connected to the HSM after all components are installed in the HSS and will be used to configure the HSM’s IP address.

Electrostatic discharge wrist strap (this must be worn while working inside the unit).

Network Setup

45


This section provides information on making connections inside the HSS002-X. See “Chapter 6: Telemetry System Setup” for information on connecting the HSS002-X to the telemetry system (Tunnel CTU or Network RTUs).

See Figure 5-4, "HSS Jumper and Address Settings" (p. 52) to view a diagram of the HSS’ address and jumper settings. Refer to “HSS002-1 Internal Wiring” (below) when wiring the HSS002-1.

Figure 5-2, "HSS002-1 Internal Wiring"

Please follow normal Ethernet wiring practices when installing the HSS.

Step 1: Prepare the Unit

1. Safely power down the HSS. A. Press the power down button on the HSM, the shutdown LED (SDN) begins to

flash indicating that the shut down process has begun. B. SDN then goes constant indicating that services to the HSM have been turned off. C. After a few moments, the CPU power LED (+CPU) goes out indicating that it is

now safe to remove power. D. Disconnect the battery. E. Ensure that any other power sources coming into the enclosure are turned off. Even

if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure.

2. Ensure that all module address blocks, except the RIM slot’s address block, have been removed.

3. For the network module installed in the RIM/NSM slot (usually a network switch


46

module), ensure that all of the address block’s DIP switches are in the ON, or closed, position.

4. Ensure that each of the HSS’ remaining network distribution modules is addressed at 256. This is accomplished by placing a jumper across pins 43 and 25 (with no J(X) switch installed).

Step 2: Make Ethernet Connections

1. Connect the HSM to port 4 on the NSM using a CAT 5 patch cable that has been terminated with RJ-45 connectors. Connect the NFM to port 3 of the NSM.

2. Connect the DIN-rail mounted network surge arrestor to port 1 (one) of the NSM. 3. From the surge arrestor, make a connection to the local area network or to the master

workstation using CAT5 cable. [IMPORTANT: To minimize signal interference, avoid installing CAT5 cable near florescent lighting or other AC conduit.]

4. Connect the NFM to the telemetry system connection point. Connection is through a fiber-optic cable that is attached to the NFM’s media converter (TX and RX connectors).

Step 3: Configure the HSM’s IP Address

1. Connect a PS-2 keyboard and a VGA monitor to the HSM. Ports for connecting a keyboard and monitor are easily accessible and clearly marked.

2. Restore power to the unit. A. Turn on the PSM. B. Connect the battery. The HSS is now activated.

3. It is not necessary to use the HSM’s CPU Power ▲ (Up) button. The HSM will automatically power up when it senses power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly.

+CPU and +5V LEDS are constant and remain constant during and after power up. B. The SDN LED goes off and the ACT LED is constant. C. The ACT LED begins to blink indicating that the HSM is fully powered.

4. When the HSM is fully powered and booted up, a login prompt appears on the monitor. Enter mgr for the login and htiimgr for the password.

5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the IP address of the HSM). Enter Y or N to confirm IP change.

Step 4: Reboot the HSM.

1. Press the power down button on the HSM and watch the HSM's LEDs. When the +CPU LED goes off, the HSM is fully powered down. After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed.

2. After 10 seconds have passed, press the power up button on the HSM and watch the HSM's LEDs. When the ACT LED begins to blink, the HSM is fully powered up.

We recommend that you keep the keyboard and monitor attached to the HSM until you verify that you can communicate with the HSM from a Windows workstation.

Network Setup

47

HSS002-2 NETWORK SETUP (REDUNDANT HSS002)

Description

A redundant HSS features two backplanes and two 7.0 AH backup batteries. The top backplane is fully populated: it contains a HSM, a Network Fiber Module, a Network Switch Module, and a Power Supply Module. The bottom backplane features an additional HSM, NSM, and PSM.

The HSS also contains DIN-rail mounted devices for connecting network, telephone, and audio lines. The telephone and audio lines are used for call out (911) and call in (411), and voice alarm notification.

Connection between the two HSMs, the external telemetry system and local area network, is via the HSS’ two Network Switch Modules. Refer to Figure 5-3, "HSS002-2 Internal Wiring", page 49, to see a diagram of these connections.

Either HSM can act as the primary server. The primary HSM is responsible for controlling the telemetry system and collecting data. Critical data is continually copied to the redundant HSM that monitors the Primary HSM’s functions. If the primary HSM were to fail, the redundant HSM would automatically take over the primary server role with no loss of data or function.

Network Considerations


Will the HSS be connected to an existing local area network (LAN) or directly to a master workstation?

If the HSS is to be connected to an existing LAN, what is the speed of the network?

What is the distance between the HSS and the telemetry system connection point (the CTU or the media converter to which the system’s Network RTUs are connected)?

What is the distance between the HSS and the entry point to the LAN?

Is the LAN/master workstation situated in a different location than the HSS (for example, in a different building)

Additional NFM Required in HSS

If the distance between the HSS and the LAN/master workstation is greater than 100 meters (328 feet), or if the LAN/master workstation is in a location away from the HSS (for example, a different building), an additional NFM must be installed in the HSS. Fiber optic cable must be used to connect this NFM, via a media converter, to the LAN/master workstation.

Cable Selection

Also see “Converter Selection.”

Multi-mode fiber-optic cable covers distances up to 2 km (~ 1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~ 9.3 miles).


48

Converter Selection


Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be 10/100Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length).

What You’ll Need

A minimum of four free, or unused, static IP addresses. One for each of the HSMs, one to act as the Shared IP, and one for the CTU Tunnel. These IP addresses must be on the same network. See “Principles of Redundancy for an HSS002-2” in “Chapter 8: Critical Data Redundancy” for more information on the Shared IP.

A Safe IP address. This IP address is always "up" and is on the same network as the HSS. See “Principles of Redundancy for an HSS002-2” in Chapter 8: Critical Data Redundancy for more information on the Safe IP.

HSS with two Hyper Server Modules (HSM), two Power Supply Modules (PSM), two Network Switch Modules (NSM), and one Network Fiber Module (NFM) installed. (Refer to the specifications for the Network Fiber Module provided on page 90 in “Appendix A: Technical Specifications” when selecting an NFM.)

Tunnel CTU or Network RTUs (Network RTUs require desktop-style or rack-mount fiber-optic media converter between them and the HSS and a separate static IP address for each).

Local area network or master workstation. Each requires appropriate fiber-optic media converter between it and the HSS.

Configuration jumpers (black #16 stranded wire can be used for making jumpers). Five CAT 5 patch cables terminate with RJ-45 connectors. One CAT5 cable of sufficient length to cover the distance from the HSS to the

local area network or master workstation. One fiber-optic cable of sufficient length to cover the distance between the HSS

and the telemetry system connection point (the Tunnel CTU or the media converter to which the system’s Network RTUs are connected). In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters.

Electrostatic discharge wrist strap (this must be worn while working inside the unit).

Network Setup

49


This section provides information on making connections inside the HSS. See “Chapter 6: Telemetry System Setup” for information on connecting the HSS to the telemetry system (CTU or Network RTUs).

See Figure 5-4, "HSS Jumper and Address Settings" (p. 52) to view a diagram of the HSS' address and jumper settings.

NOTE: The instructions below refer to the two Hyper Server Modules as HSM1 and HSM2; the two Network Switch Modules are referred to as NSM1 and NSM2. HSM1 and NSM1 are installed in the top backplane; HSM2 and NSM2 are installed on the lower backplane. The two Network Fiber Modules that are installed on the top backplane are referred to as NFM1 and NFM2. Refer to Figure 5-3, "HSS002-2 Internal Wiring" (below) when wiring the HSS002-2.

Figure 5-3, "HSS002-2 Internal Wiring"


50

Please follow normal Ethernet wiring practices when installing the HSS.

Step 1: Prepare the Unit

1. Safely power down the HSS.

A. Press the power down button on the HSM, the shutdown LED (SDN) begins to flash indicating that the shut down process has begun.

B. SDN then goes constant indicating that services to the HSM have been turned off. C. After a few moments, the CPU power LED (+CPU) goes out indicating that it is

now safe to remove power. D. Disconnect the battery. E. Ensure that any other power sources coming into the enclosure are turned off. Even

if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure.

2. Ensure that all module address blocks, except the two RIM slot address blocks, have been removed.

3. Ensure that a jumper has been placed across pins 3 and 5 on each NSM and. Placing a jumper across these pins allows the modules to bypass the startup plate.

4. For the network modules installed in the top and bottom RIM slots (usually network switch modules), ensure that all of the address block’s DIP switches are in the ON, or closed, position.

5. Ensure that each of the HSS’ remaining network distribution modules is addressed at 256. This is accomplished by placing a jumper across pins 43 and 25.

See “Appendix D: Addressing Modules” for more information on module addressing

Step 2: Make Ethernet Connections

See note at end of this section.

1. Use a CAT 5 patch cable to connect each HSM to port 4 of its corresponding NSM (HSM1 NSM1; HSM2 NSM2). This connection provides each HSM with a link to the local area (client) network and the telemetry system.

2. Connect the NFM to port 3 of NSM1 using a CAT 5 patch cable terminated with RJ-45 connectors.

3. Connect port 1 (one) on NSM2 to port 2 (two) of NSM1. This connection provides the communications link between the two HSMs, which allows them to pass data back and forth and switch primary and redundant roles.

4. Connection port 1 (one) on NSM1 to the DIN-rail mounted network surge arrestor. 5. From the surge arrestor, make a connection to the local area network or to the master

workstation using CAT5 cable. [IMPORTANT: To minimize signal interference, avoid installing CAT5 cable near florescent lighting or other AC conduit.]

6. Connect the NFM to the telemetry system connection point. Connection is through a fiber-optic cable that is attached to the NFM’s media converter (TX and RX connectors).

Network Setup

51

Step 3: Configure the HSMs’ IP Addresses

NOTE: A Class C IP subnet mask (255.255.255.0) is used by default. If a different subnet mask is required, contact the DFS Service department for specific instructions.

1. Connect the keyboard and monitor to the upper HSM (HSM installed on the top backplane). Ports for connecting a keyboard and monitor are easily accessible and clearly marked.

2. Restore power to the HSS. A. Turn on both PSMs. B. Connect both batteries. The HSS is now activated.

3. It is not necessary to power up the HSM; it will automatically power up when it senses power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly.


4. When the HSM is fully powered and booted up, a login prompt appears on the monitor. Enter mgr for the login and htiimgr for the password.

5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the IP address of the HSM).

6. Disconnect the keyboard and monitor from the upper HSM and connect them to the lower HSM. The login prompt should be displayed on the monitor. (NOTE: If the login prompt is not displayed, press the space bar to refresh the video display.)

7. Repeat steps 4 and 5 to configure the lower HSM’s IP address.

Step 4: Reboot the HSMs

Reboot the HSMs one at a time. The order in which the HSMs are rebooted is not important.

1. Press the power down button on the HSM and watch the HSM's LEDs. When the +CPU LED goes off, the HSM is fully powered down. After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed.

2. After 10 seconds have passed, press the power up button on the HSM and watch the HSM's LEDs. When the ACT LED begins to blink, the HSM is fully powered up.

We recommend that you keep the keyboard and monitor attached to one of the HSMs until you verify that you can communicate with the HSS from a Windows workstation. Specific instructions for configuring a redundant servicer can be found in separate documents. Contact Data Flow Systems’ Service department for more information.


52

Figure 5-4, "HSS Jumper and Address Settings"

53

Chapter 6: TELEMETRY SYSTEM SETUP

There are many options for configuring an HSS-based telemetry system. These options depend on the type of system the HSS will be communicating with – a system of Network RTUs or a Tunnel CTU?

The following sections describe a few of these different system configurations and provide basic instructions on how to connect them to the HSS. Your configuration may differ based on your system’s needs and your existing network structure.

NETWORK RTUS (HSS002-X ONLY)

Overview

In this configuration, data is passed between an Ethernet client network or a stand-alone workstation, and a system of Network (FIM-based) Remote Terminal Units (RTUs). Each RTU contains a Fiber Interface Module (FIM) that is responsible for communications between the primary HSM and the station's function modules. The Network RTUs connect to the HSS via a rack-mount media converter.

NOTE: Although the diagram below shows a non-redundant HSS, connections for both the HSS002-1 and HSS002-2 are identical when connecting to a system of Network RTUs. For an HSS002-2, assume that the illustration only shows the unit’s top backplane.

Figure 6-1, "Illustration of Network RTU System"


PSM

NSM

NFM

VOID

HSM


WorkstationRack MountMedia Converter

Net

wor

k RT

U

PSM

FIM

CAT 5

U

DIN-rail mountedNetwork SurgeArrestor

Rack Mount Switch

VOID

Net

wor

k RT

U

PSM

FIM

Net

wor

k RT

U

PSM

FIM

Net

wor

k RT

U

PSM

FI

M

Net

wor

k RT

U

PSM

FIM

Fiber Optic Cable

Fiber Optic Cable

CAT 5


54

In a Network RTU, a Fiber Interface Module (FIM) is installed in the Radio Interface Module (RIM) slot of the RTU. No connector changes are necessary; the FIM and the RIM are keyed the same.

The RTU must be addressed between 1 (one) and 250. If the RTU is being converted from a RIM-based to a FIM-based unit, the RTU must be readdressed if it is currently addressed between 255 and 512.

Communication between the HT3 system and the RTU’s function modules takes place over a network via an HT3 NIM driver. This provides high-speed communication and a more efficient polling loop for in-plant configurations. In this configuration, the Network RTUs and the HSS must be on the same local area network.

The FIM supports and can communicate with 9600- or 1200-baud modules. To obtain the most efficient polling rate, we recommend that 9600-baud modules be used.

Functions and Features

Reduced Polling Time

Polling time is greatly reduced when a FIM replaces a RIM in an in-plant RTU that was using a “rubber duck” antenna. The polling rate of any external (out-of-plant) RTUs is also improved, because the amount of information being processed via radio has been reduced.

Similar I/O

The I/O of the RIM and the FIM are basically the same. The only difference is that the FIM has additional termination points to enable RS-232 communications.

Serial Tunneling

The DOS-based network CPU on FIMs provides network communication logic that allows each module to communicate over a network as if it were a radio. This function is referred to as serial tunneling. Serial tunneling – via COM1 and COM2 – allows the FIM to communicate with RS-232 devices, including Modbus devices.

COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Both COM1 and COM2 are used only as a stand-alone serial tunnels; there is no buss communication.


COM2: Pin 8=RXD, Pin 10=TXD, Pin 12=GND, Pin 14=RTS, Pin 16=CTS.

Telemetry System Setup

55

Program Updates

The DOS-based program on the FIM can be remotely updated through a driver-initiated download. This is accomplished through the Module Patching tool included with HT3. See the HT3 User Guide for more information.

The module’s on-board processor is in-socket programmable. The processor controls the power going to the CPU and any network hardware (for example, converters or switches) mounted on the module.

Automatic IP Addressing

The NIM/FIM features automatic IP addressing. The modules obtain their network address from the NIM driver and the station address strap. The first three octets of the address come from the driver; the last octet comes from the address strap. This assumes a class C subnet mask. If you need a different subnet mask, contact DFS’ Service department for assistance.

When the NIM/FIM module boots up, it receives a broadcast from the NIM driver that contains its subnet. The FIM reads its subnet, mates it with the station address, and begins to “talk” at that IP address. [IMPORTANT: The NIM/FIM cannot be addressed greater than 250. If the RIM that is being replaced was addressed greater than 250, you must readdress the module slot at 250 or less.]

Power Monitoring Functions

Monitors RTU Power and DC Bias from the Power Supply Module (PSM). Powers the buss through the startup plate (magnetic switch on front plate). Shuts down the PSM for battery test. Powers network hardware (one-port media converter or four-port switch). Cycles power to network hardware and the CPU if communications stop for more

than two minutes. This is done continuously until communications resume.

Test Mode

When a network interface module (FIM or NIM) is placed in test mode, its service port shows traffic to function modules. This information can be viewed using WinRTU Test’s Inject or Antenna forms. WinRTU Test’s Module, Module Config, and ROM Patch forms can be used to communicate with function modules.

To place a network interface module in test mode:

1. Power down the RTU by disconnecting the battery and then powering down the PSM.

2. On the network interface module, press and hold the test button while powering up the PSM. Press and hold the test button until the network interface module’s transmit and receive LEDs start flashing and its Test LED comes on.

3. When the Test LED comes on and remains constant, the module is in test mode.

To exit test mode, power down the network interface module and then power up without pressing the test button.


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The Fiber Interface Module (FIM) has an RJ-45 Ethernet jack and is designed to communicate over a 10base-T Ethernet network. If your local area network is a 100mbs network and you will be distributing the network from the RTU, the media converter on the FIM can be upgraded to a 10/100Mbps auto-negotiating model (FIM001-10/100).

When installing a network interface module in an RTU, it is highly recommended that the RTU be isolated from the rest of the network utilizing fiber optic cable. The Fiber Interface Module (FIM) was designed for this purpose; the FIM has an attached media converter for converting twisted pair copper to fiber.

IMPORTANT: When dealing with a large number of networked RTU's, it isn’t financially practical to try to bring all networking into the HSS. For this reason, a centralized location is needed to convert the fiber back to copper and to connect the RTU(s) to the Hyper SCADA Server. It is recommended that the fiber from all the RTUs be run to a common location (for example, a server or telephone room) in which a large media converter has been installed. This larger unit, which typically mounts into a network hardware “rack,” would have a single power supply and 8-12 fiber to CAT5 converters. In addition, this central location would require a larger switch to accommodate each converted fiber and must provide access to the HSS and the local area (client). A UPS must be used to provide battery back up for all this network hardware.


Speed of the local area network Distance between the HSS and rack-mount media converter to which the system’s

Network RTUs are connected

Cable Selection


Converter Selection

The standard converter used on the Fiber Interface Module (FIM) is a 10Mbps Ethernet Media Converter that accepts multi-mode fiber. The FIM’s converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the Network RTUs. Additionally, both the FIM and the NFM can be ordered with converters that accept single-mode fiber (refer to the specifications in “Appendix A: Technical Specifications” when selecting a converter for important information on operating environment and fiber length).


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Baud Rate Considerations

To have the FIM communicate at its fastest speed, all of the station’s I/O modules must be able to communicate at 9600 baud. I/O modules that meet this requirement are the AMM002, ACM002, DMM002, and all versions of the DCM003.

If any one module at the station communicates at 1200 baud, the entire station can only communicate at that speed. The exception to this is when the station contains a PLC (PLCs communicate at 9600 baud; function modules communicate with the rest of the system through the PLC). In this situation, the communication speed of the I/O modules that are downstream from the PLC is irrelevant.

What you will need:

One Fiber Interface Module (FIM). One Network Switch Module (NSM) (optional; only required if using 10/100Mbps

auto-negotiating converters.) One CAT 5 patch cable terminated with RJ-45 connectors. Fiber-optic cable of sufficient length to cover the distance from the RTU to the

connection to the local area (client) network. In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters.

Electrostatic discharge wrist strap (this must be worn while working inside the RTU).

NOTE: These instructions provide details on converting an existing radio-based RTU to a network-based RTU. If you are creating an original network-based RTU, disregard references to removing the RIM and readdressing the station.

1. Remove power from the RTU. 2. Remove the RIM. Note that the RTU’s module address blocks do not require any

changes unless the address is above 250. 3. Install a FIM in the RTU’s RIM slot. The FIM requires no jumpers. 4. Address the FIM if required. The FIM must be addressed less than 250 (1-250). The

station must be readdressed if it originally contained a RIM that was addressed between 256 and 512. This address is the node portion of the Network RTU’s IP address.

The address is calculated by adding up the bits that are OPEN, or OFF. The figure at right is an example of how to set the station address for a network RTU. It shows the setting for addressing a FIM at 208. The 128, 64, and 16 switches have been placed in the OPEN position (128 + 64 +16 = 208).

See “Appendix D: Addressing Modules” for more information on module addressing.

G25

6

128

64 32 16

8 4 2 1

Open

Closed

Station Address

Figure 6-2, "FIM Addressed at 208"

NOTE: Modular RTU only – 256 bit is inverted.


58

5. Connect the FIM’s media converter to its DOS-based network CPU using a CAT 5 patch cable terminated with RJ-45 connectors.

6. (Optional) If your configuration requires use of 10/100Mbsp auto-negotiating media converters, install a NSM in any unused module slot in the RTU. Jumpers must be placed between pins 3 and 5 and also between pins 43 and 25 on the NSM. Punch out the module address for the NSM’s corresponding module slot.

Using CAT5 cable, connect the FIM’s media converter to the NSM; Also connect the FIM itself to the NSM.

7. Connect the RTU to the local area (client) network (refer to the drawings on the next page).

Using 10Mbps media converters: Connection to the network is through a fiber-optic cable that is attached to the FIM’s media converter (TX and RX connectors). In most circumstances, multi-mode fiber can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode fiber and appropriate converters.

Using 10/100Mbps auto-negotiating media converters: Connection to the network is through a CAT5 cable connected to the NSM.

8. Restore power to the RTU. 9. Add and configure a NIM driver in HT3. For instructions on adding a NIM driver, see

the HT3 User Guide. 10. Configure this station in HT3. (NOTE: If this is an RTU that is being converted from

radio to network communications, you can copy the existing station – and its related module and point configurations – from the DFS driver to the newly created NIM driver. You can then delete the station from the DFS driver.) For instructions on configuring stations, see the HT3 User Guide.


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FIB

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001

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FIBER NETWORK

CAT5

CA

T5

NETWORK RTU (10Mbps Converter)

FU

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TIO

N M

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FU

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Figure 6-3, "Network RTU (10Mbps Converters)"

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FIBER NETWORK /HYPER SCADA SERVER

F/O

CAT5

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T5

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LOCAL AREANETWORK

FU

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CAT5CAT5

CA

T5

FIB

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NETWORK RTU (10/100Mbps Converter)

Figure 6-4, "Network RTU (10/100 Mbps Converters)"


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Figure 6-5, "Network RTU Address Settings"


61

TUNNEL CTU

Overview

In this configuration (HSS – Tunnel CTU), data is passed between a local area (client) network (or a master workstation) and a Tunnel CTU. A Tunnel CTU is a radio-based CTU that uses a Fiber Interface Module for serial tunneling - a process that enables serial (radio) data to be sent over a network.

An HSS-Tunnel CTU system uses a CTU that includes both a FIM and a RIM. Communications are sent to the FIM via the network. The FIM translates the network data into serial (radio) data and passes this information to the CTU’s RIM, which then transmits it to radio-based RTUs. A Tunnel CTU requires that a radio-type driver instead of a NIM driver be configured.

Network interface modules provide a serial tunnel (COM1) from the client network to the local RIM’s bus. An optional second tunnel (COM2) is provided to the card connector. See "Two Serial Tunnels" on the next page for more information. (IMPORTANT: There is no test mode function when the FIM’s second serial tunnel port is used.)

Figure 6-6, "Illustration of Tunnel CTU System"


PSM

NSM

NFM

VOID

VOID

HSM


WorkstationCentral Terminal Unit

PSM

RIM

FIM

VOID

VOID

VOID

RemoteTerminal

Unit RemoteTerminal

Unit

RemoteTerminal

Unit

FiberOpticCable

Category 5Cable

U

DIN-rail mountedNetwork SurgeArrestor

Category 5Cable


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Functions and Features

Installs in CIM Slot

If an existing system is being upgraded to the Hyper SCADA Server, the CTU’s Computer Interface Module (CIM) must be replaced with a FIM.

The illustrations below show the placement of the FIM in a CTU.

If the CTU is a 202 box, the FIM must be placed in the far left module slot (opposite end from the PSM).

For a 204 box, place the FIM directly beside the RIM.

When replacing a CIM with a FIM, remove all CIM jumpers. Place a jumper across pins 15 and 21 on the FIM and configure the FIM with a valid station address (information provided in the section “Installation and Configuration Procedure” beginning on page 63).

Figure 6-7, "CTU in 202 or 204 Box"

Drivers

The operation of this setup is identical to a radio system, and supports both DFS and Modbus radio drivers. A NIM driver is not applicable when a FIM is being used as a tunneling device.

Two Serial Tunnels

The first serial tunnel (COM1) goes over the CTU’s buss to the Radio Interface Module (RIM). This tunnel enables the transfer of data between the network and the radio. The driver’s Tunnel IP Address would be configured in HT3 as x.xxx.xxx.AAA.1, where xxx.xxx.xxx defines the subnet of the network interface module, AAA represents the network interface module’s station address, and 1 represents the COM port number the RIM is connected to.

For example, for a CTU with an IP address of 205.242.61 with a default connection using COM port 1 of a FIM addressed at 247, you would configure a DFS Driver in HT3. The driver’s CTU Tunnel IP Address would be 205.242.61.247.1.


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When used as a stand-alone tunnel device (not with DFS RTU equipment), COM1 provides five-wire RS-232 serial communications, including RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking.

The network interface modules also provide an optional second serial tunnel (COM2). This second tunnel enables one network interface module to poll two different types of devices. The COM2 port is used only as a stand-alone serial tunnel; there is no buss communication. COM2 also includes RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. (NOTE: The test port is disabled if the second serial tunnel port is used.)

For example, the first tunnel can be communicating through COM1 to a DFS RIM, while the second tunnel is communicating through COM2 to a Modbus PLC. In this example, a second radio driver (Modbus driver) would have to be configured for the second device. In HT3, the Tunnel IP Addresses for both drivers would be identical except for the last octet, which represents the COM port number. The second driver’s address would be xxx.xxx.xxx.AAA.2, indicating that it is communicating via the second COM port. Following our example above, this device would require that a Modbus driver be configured with a Tunnel IP Address of 205.242.61.247.2.

See the HT3 User Guide for more information on configuring drivers..

Service Port and Test Mode

With a tunneling network interface module, Test mode does not supply a function. In this configuration, where the first serial port (tunnel 1) is being used for tunneling, the service port automatically shows tunnel 1’s traffic. Tunnel 1’s traffic can be viewed using the WinRTU Test software provided by DFS. Connect a laptop to the network interface module’s service port and use WinRTU Test’s Inject or Antenna form to view the communication traffic.

Note: If the second serial port (optional tunnel 2) is being used, there is no service port function.




Speed of the local area network. Distance between the HSS and the CTU.

Cable Selection


Converter Selection

The standard converter used on the Fiber Interface Module (FIM) is a 10Mbps Ethernet Media Converter that accepts multi-mode fiber. The converter can be


64

upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU. Additionally, the FIM can be ordered with converters that accept single-mode fiber (refer to the specifications in “Appendix A: Technical Specifications” when selecting a converter for important information on operating environment and fiber length).

What you’ll need:

One Fiber Interface Module (FIM). (See “Appendix A: Technical Specifications - Fiber Interface Module” on page 89 when selecting a Fiber Interface Module.)

(Optional) One Network Switch Module (NSM) (required only if using 10/100Mbps auto-negotiating media converters).

CAT 5 patch cable terminated with RJ-45 connectors (one cable required if using 10Mbps converters; two cables required if using 10/100Mbps converters).

Fiber-optic cable (multi-mode or single-mode depending on required fiber distance) of sufficient length to cover the distance from the Tunnel CTU to the Hyper SCADA Server or HT3 central computer.

Configuration jumpers (black #16 stranded wire can be used for making jumpers). Electrostatic discharge wrist strap (this must be worn while working inside the

CTU).

These instructions provide details on converting an existing CIM-based CTU. If you are creating an original Tunnel (FIM-based) CTU, disregard references to removing the CIM.

Wiring diagrams are provided beginning on page 66 to assist you with set up. See Figure 6-12, "Tunnel CTU Jumper and Address Settings" on page 67 to view a diagram of jumper and address settings for the Tunnel CTU.

Note: If your system requires use of the 10/100 auto-negotiating media converter and the additional Network Switch Module, you must use the 204 CTU box.

1. Power down the unit. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure.

2. Remove the CIM and all CIM jumpers. 3. Insert the FIM in the vacated CIM slot. The first three module slots are unused if using

a 204 box; the second module slot is unused if using a 202 box. See Figure 6-7, "CTU in 202 or 204 Box" on page 62.

4. (Optional; this step only required when using 10/100Mbps auto-negotiating converters). Insert the NSM in a vacant module slot. Jumpers must be placed between pins 3 and 5 and also between pins 43 and 25 on the NSM. Punch out the module address for the NSM’s corresponding module slot.

5. Swap the buss to the RIM by placing a jumper across pins 15 and 21 of the FIM. 6. Bypass the startup plate by placing a jumper across pins 3 and 5 on both the FIM and

the RIM. 7. Configure the FIM with a valid station address. Place a jumper across the appropriate

pins to set the FIM at the desired address. [IMPORTANT: The address cannot already be in use by any other network device, including other network RTUs or CTUs.) See Figure 6-8, "FIM Addressing Examples" (below). Note that only pins 27-43, which are


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used for addressing the FIM, are drawn; the entire card is not shown. See “Appendix D: Addressing Modules” for more information on module addressing.

43

41

39

37

35

33

31

29

27

43

41

39

37

35

33

31

29

27

127 239

43

41

39

37

35

33

31

29

27

247

Figure 6-8, "FIM Addressing Examples"

8. The RIM maintains a CTU address 0 or 251-254. See Figure 6-9, "RIM Addressed at

254" (below). More information on module addressing can be found in Appendix D: Addressing Modules.

If your system uses an FTU (Forward Telemetry Unit), note that the FTU station address does not have to be configured in HT3, but it is recommended for easier troubleshooting. An FTU contains two RIMs (one RIM addressed as a station, usually 500-511 to communicate with the central site and the other RIM addressed as a CTU to communicate with all the remote sites.

G25

6

128

64 32 16

8 4 2 1

Open

Closed

Station Address

Figure 6-9, "RIM Addressed at 254"

9. Remove the module address block between the FIM and the last unused module slot. In

a 204 box, the module address block between the first and second unused slots may be removed or left as is.

(…continued on next page)


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10. Select the appropriate step below depending on the type of media converter you are using: 10Mbps converters: Connect the FIM’s media converter to its DOS-based network

CPU using a CAT 5 patch cable terminated with RJ-45 connectors. 10/100Mbps converters: Use CAT5 cable to connect the FIM’s DOS-based

network CPU to a port on the NSM; use a second CAT5 cable to connect the FIM’s media converter to a port on the NSM.

11. Connect the CTU to the network or directly to the HSS. Connection to the network/HSS is through a fiber-optic cable attached to the FIM’s media converter (TX and RX connectors). In most circumstances, multi-mode fiber can be used. If the distance to be covered is greater than 2 km, single-mode fiber and different converter types must be used.

12. Restore power to the CTU. 13. Add and configure a DFS RTU driver in HT3. The CTU Tunnel IP Address field

must show the IP address of the FIM. For instructions on configuring drivers, see the HT3 User Guide.

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TUNNEL CTU (10Mbps Converter)

CA

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Figure 6-10, "Tunnel CTU with 10Mbps Converter"

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TO LOCAL AREA NETWORK

Figure 6-11, "Tunnel CTU with 10/100Mbps Converter"


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Figure 6-12, "Tunnel CTU Jumper and Address Settings"


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SERIAL DEVICES (HSS001)

The Hyper SCADA Server (HSS001) features two ports (COM1 and COM2) for connecting serial-type devices, including Modbus devices. These ports are connected to the HSS' NIM, which allows the serial devices to pass their data to network devices. This is accomplished through a process called serial tunneling.

In serial tunneling, the HSM bundles serial data into network packets and forwards it to the NIM. When the NIM sees an incoming packet, it switches to serial tunnel mode, extracts the serial data, and sends the data out the appropriate COM port. When a serial device sends data to one of the NIM’s COM ports, the NIM bundles the data into network packets and forwards them to the HSM. Both the HSM and the NIM are capable of bundling serial data into network packets, and disassembling these packets and extracting their data when they are received.

COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Additionally, both COM1 and COM2 are used only as a stand-alone serial tunnels; there is no buss communication.



1 2 + -

HSM001

NIM001

NSM001

PSM003

TELEPHONELINES

AUDIOOUT

SO

UR

CE

LO

AD AC

POWER

BATTERY

TO SERIAL DEVICE 1

TO SERIAL DEVICE 2

COM1COM2

Figure 6-13, "HSS001 Connected to Serial Devices"

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Chapter 7: WORKSTATION CONFIGURATION

After the Hyper SCADA Server (HSS) has been installed, and the telemetry system has been wired and configured, the client workstations that will be accessing the HT3 SCADA software must be configured. Since the HSS itself does not include a console interface (monitor, keyboard, and mouse), client computers on the network, or a master workstation connected directly to the HSS, are used to access HT3 via its browser-based interface.

Although more than one client workstation can be used to access HT3, we recommend that one computer be designated as the “primary” workstation. This workstation would be used to maintain a constant connection to HT3, and would be used for recording voice alarms and playing alarm announcements. The primary workstation is also used as a backup location for the HSS. Information on critical data redundancy is provided in “Chapter 8: Critical Data Redundancy” and in the HT3 User Guide in the section titled “Configuring Your System: Critical Data Redundancy.”

Each computer that will be used to access HT3 must meet specific system requirements and be set up to connect to the HSS.

SYSTEM REQUIREMENTS

All computers that will be using the HT3 SCADA software must meet the following requirements:

Windows XP with SP2, or newer IE 8.0 or newer Java 1.5

*A microphone for recording voice alarm announcements is optional.

WORKSTATION CONFIGURATION

The instructions below provide details on how to configure a Windows workstation to communicate with the HSM. Workstations communicate with the HSM via HT3, Data Flow Systems’ network-based SCADA software.

HT3 monitors and controls in-plant, as well as remote, unmanned stations from a central telemetry server – the Hyper Server Module (HSM). HT3 is installed on the HSM; users access HT3 from Windows-based workstations using a Java-enabled Internet browser.

The only software installed on each workstation is Internet Explorer 8.0 or newer, a Java Policy file, and Java 1.5.

After starting HT3, you can learn more about the software by reading the release notes (select “About HT3” from the HT3 Help menu). To read descriptions of the software’s functions and instructions on their use, select “HT3 Online Help” from the HT3 Help menu.


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Configuration consists of the following steps:

Take the following steps to configure a Windows workstation to access HT3:

1. Edit the Hosts file 2. Change Browser settings 3. Install plug-ins and Java Policy File 4. Start HT3

Editing the Hosts File

The hosts file allows you to associate a name (for example, ht3) with an IP address. Editing the hosts file as described below is necessary to allow HT3's applications, such as Screen Builder and Logic Builder, to save files on the workstation (a Java Policy file is also required). Adding an entry for HT3 to the hosts file also allows you to use the host name instead of an IP address to connect to your Hyper SCADA Server through HT3.

Note to Users Upgrading from HyperTAC II: You do not need to edit the hosts files of existing workstations. HT3's Java Policy file also recognizes the host name hypertacii used by existing HyperTAC II systems.

1. On the Windows taskbar, click the Start button, and then click Run. 2. In the Run box, type one of the following (depending on your OS level) and click OK:

For Windows XP and newer, type

edit c:\windows\system32\drivers\etc\hosts

For Windows 2000 / NT, type

edit c:\winnt\system32\drivers\etc\hosts.

3. In the hosts file, place your cursor on a line below the file's comments - lines preceded by a pound sign (#) - and do the following:

A. Type xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the Hyper SCADA Server's IP address)

B. Press the Tab key

C. Type ht3

4. Select Save As from the File menu. Verify that the name hosts appears in the File Name field and click OK.

Workstation Configuration

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Test Connection to Hyper SCADA Server

After the host file has been edited and saved, use the ping command to verify that your workstation can connect to the Hyper SCADA Server using the assigned host name.

1. On the Windows taskbar, click the Start button, and then click Run. 2. Type ping ht3 in the Run dialog box and click OK.

3. A DOS window appears on screen and indicates if a reply has been received from the Hyper SCADA Server.

Change Browser Settings

Several changes must be made to Internet Explorer's security settings before you can successfully run HT3.

1. Start Internet Explorer. 2. Select Internet Options from the Tools menu. 3. Click the Security tab and select the Local intranet zone. 4. Click Custom Level... 5. In the Security Settings dialog box, enable the following:

All of the options listed under ActiveX controls and plug-ins All of the options listed under Cookies

6. Click OK at the Security Settings dialog box. 7. Click OK at the Internet Options dialog box.


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Install Plug-Ins and Java Policy File

1. Start Internet Explorer. 2. In Internet Explorer's Address box, type ht3 (the host name assigned to your Hyper

SCADA Server). 3. If the necessary plug-ins are not already installed, the HT3 Plug-Ins page is loaded.

(Note: If the HT3 Plug-Ins page does not automatically load, type http://ht3/ht3/plugins/index.html in Internet Explorer's Address box.)

4. Follow the instructions on the page to install the required HT3 files and plug-ins..

Start HT3

1. When installation of the plug-ins and the Java policy file is complete, type ht3 in Internet Explorer's Address box.

2. On the HT3 login page, enter your Login and Password and click OK. 3. Bookmark HT3 in your browser or create a shortcut to HT3 on your Windows desktop.

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Chapter 8: CRITICAL DATA REDUNDANCY

CONFIGURING REMOTE SYSTEM BACKUP

HT3 features an automated backup routine that protects your system from critical data loss. Data is copied and stored locally in a designated backup folder on the Hyper Server Module (HSM).

As an additional protection against data loss, a Windows workstation can be configured as a remote backup location. A remote backup site protects you from loss of data in the event of an HSM hardware failure (the HSM itself stops functioning). The designated backup workstation should be equipped with a hard drive large enough to hold all of the system's backup data and must be configured as a remote backup location. See “Configuring Remote System Backup,” below for instructions on configuring a remote backup site.

HT3 performs an automated backup procedure daily at a few minutes after midnight. The system first makes a local copy of the data (stored on the Hyper Server Module). It then attempts to locate the remote backup computer.

For remote backup to occur, the designated Windows workstation must be on and running. It is recommended that all power management be disabled (i.e., the network card is not allowed to sleep).

If HT3 does not find the remote location, it skips the creation of a remote copy. It will not attempt another remote backup until the following midnight. An entry is made in the current day's Access Log to indicate if the previous day's backup succeeded or failed.

When the system performs a backup, all of the configuration databases, and the logs and journals for the previous day are backed up. The configuration databases are kept for one week in directories named for each day of the week (e.g., Monday's data is placed in a backup directory named Mon).

Logs and journals are backed up daily and kept until the hard drive reaches full capacity. Data is archived and condensed based on the purge settings configured in HT3 (see “Critical Data Redundancy: Configuring Purge Schedules” in the HT3 User Guide). When the amount of hard drive space used approaches 100 percent, HT3 deletes the oldest logs and journals.

If you need to keep older data (configurations, logs, journals), copy it to external media prior to it being deleted. For example, data can be copied to a folder on the backup Windows workstation or to a flash drive.

If you need to restore backed up data, contact DFS’ Service Department.

Procedure for Configuring Backup Site

NOTE: We recommend that the remote Windows backup machine have at least 5 gigabytes of free disk space.

1. If the backup directory is to be on a Windows NT/2000, or Windows XP or newer machine, it is recommended that a new user account be created on the machine.

2. Create a backup folder, or directory, on the Windows workstation that has been designated as the remote backup.


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3. Share the backup folder. (Refer to your Windows Help for information on sharing folders.)

Windows 98 / ME:

A. Select Full for Access Type. B. Enter HSS for the Shared as name. C. Enter a password in the Full Access Password box.

Windows 2000 / NT, or Windows XP or newer

A. Change the share name of the folder to HSS. B. Set all shared folder permissions to Full Control. C. Give the user account created in step one, above, Full access to the shared folder.

4. Login to HT3 and open the System Backup tool by clicking Configure on the HT3 main menu and then clicking Backup on the Configure submenu.

5. Configure the following: Enable Remote Backup - Select this option to turn on automated backup. Remote Machine Name - Enter the IP address of the Windows workstation that

has been designated the remote backup location. Remote Share Name - Enter the share name of the backup folder. This should

be HSS. Remote User Name - Enter the name of the user account created in step 1,

above (Windows 2000/NT or Windows XP or newer machines only). Remote Share Password

Windows 98/ME: Enter the Full Access Password assigned to the shared backup folder.

Windows 2000/NT or Windows XP or newer: Enter the password of the user account created in step one, above.

6. Verify that all of the above information is correct and click Ok.

Critical Data Redundancy

75

PRINCIPLES OF REDUNDANCY FOR AN HSS002-2

A redundant system uses an HSS002-2, which is a Hyper SCADA Server (HSS) with two Hyper Server Modules (HSMs). The goal of redundancy is to allow the two HSMs to operate as one.

One HSM acts as primary and runs HT3 and the MySQL database server.

The other HSM runs in secondary mode and monitors the primary HSM.

Implementing redundancy requires that you have three (3) unused IP addresses on the same class network: one for each HSM and one designated as the shared IP. The primary HSM always uses a shared IP address as well as a dedicated IP address.

If the secondary HSM senses a loss of telemetry from the primary HSM, the secondary HSM reboots the primary, assumes the shared IP address, and begins to run the HT3 and MySQL servers. The roles of primary and secondary are not dependent upon the HSM's configured IP address or the backplane in which the HSM is installed. Either can operate as the primary or secondary server.

You can determine the current role of an HSM (primary or secondary) by viewing the flashing pattern of the HSM's ACT LED.

Single Flash – A single flash indicates that the HSM is the primary server.

Double Flash – A double flash indicates that the HSM is the secondary server.

The sections below provide an overview of redundancy. For more information on configuring HT3 for a redundant system, see “Onfiguring Your System: Critical Data Redundancy” in the HT3 User Guide.

Primary Server

The HSM acting as the primary server runs the HT3 SCADA software, including infoserver, all drivers, web server, MySQL server, and the remote file distribution (rdist) process.

The function of the remote file distribution (rdist) process is to backup/copy specific data between two hard drives over a network. In the Hyper SCADA Server, the primary server is responsible for backing up all configuration data to the secondary server. The remote file distribution (rdist) process takes place every 10 minutes, and keeps the secondary up to date in case a switch over (redundancy takeover) is required.

The primary also performs normal routines including backups to the remote windows computer and system purges. A single-flashing ACT LED on the HSM indicates that it is the acting primary server.

Secondary Server

The HSM acting as the secondary server only runs the client portion of remote file distribution process. The secondary server accepts distributed files from the primary, continuously checks for proper network connectivity, and checks for telemetry responses from the primary server. A double-flashing ACT LED on the HSM indicates that it is the acting secondary server.


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IP Sharing

Redundancy uses a function called IP sharing that allows two or more network devices to communicate at one shared IP while retaining their own unique address. In the HSS002-2 application, the primary HSM "masquerades" as the shared IP address. Additionally, client computers are configured to communicate with the primary HSM using the shared IP (not the configured address).

NOTE: Both HSMs can be accessed via their configured IP. The acting primary HSM can be accessed using either its configured IP or the shared IP. This may be useful during troubleshooting or when doing system maintenance.

IP sharing makes redundancy virtually transparent to devices on the network, because they communicate with the primary HSM at the shared IP address not its configured address. When the primary and secondary HSMs switch roles, the new primary begins masquerading as the shared IP; there is no need to reconfigure clients to communicate with the new primary HSM.

With a redundant server, all clients should access the server using the shared IP address and not the configured IP address for either HSM. Clients should set up their hosts file to associate the name ht3 with the shared IP address.

Safe IP Address

A Safe IP is the IP address of a device that is always “up” and is on the same network as the HSS. The secondary HSM uses this IP to determine if it should take over as primary after not getting a response from the acting primary. When it pings the Safe IP, it is trying to determine where the communication problem originated: with the primary HSM or with itself.

If a gateway is configured on the HSM, it should be used as the Safe IP address. Examples of other Safe IPs are the addresses of routers, print servers, and voice-over-DSL devices.

A workstation computer, although valid, is not the best selection since it can be easily turned off. A workstation computer can be used if no other devices are available, but it is important that it remain on at all times.

Switch Over Process

In a redundant system, the secondary HSM listens to the telemetry signal coming from the primary HSM. If the secondary does not detect telemetry from the primary for a period of 210 seconds, it initiates a takeover. If there is a response from the Safe IP, the secondary uses the hardware sledgehammer function to reboot the primary.

While the primary HSM is rebooting, the secondary HSM will switch to primary mode, start all servers, and begin to masquerade the shared IP address. As the original primary reboots, it notices the partner HSM running as primary and enters secondary mode.

Alternatively, if the secondary HSM does not get a response from the Safe IP, the problem may be with the secondary HSM itself. In this case, no switch over takes place, the timers are reset, and the secondary begins listening for the primary again. The secondary will not take over the primary role if it cannot successfully ping the Safe IP address.

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77

HT3 DATA RECOVERY

If you need to restore backed up data, contact DFS’ Service Department.


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Notes

79

Chapter 9: SYSTEM TESTING & TROUBLESHOOTING

TROUBLESHOOTING TOOLBOX

The following items are necessary for troubleshooting a network interface module (NIM or FIM)-based system:

Laptop computer with serial port and Ethernet adapter RIM/NIM communication cable HyperTerminal, or similar terminal program

A Network Switch Module (NSM) is optional, but is useful for obtaining a connection to the network. Becoming a client on the network enables you to perform tasks such as:

Pinging the server to verify ability to connect Accessing HT3 from a remote location

A NSM can be installed in any unused module slot of an RTU. For more information on this, see “Access Network via Network Distribution Module,” below.

NOTE: The following paragraphs refer only to Fiber Interface Modules (FIMs), but the same information also applies to the Network Interface Module (NIM).

ACCESS NETWORK VIA NETWORK DISTRIBUTION MODULE

Overview

This setup is typically used in conjunction with a Hyper SCADA Server (HSS) to provide a point of distribution for networking. A Network Switch Module (NSM) or Network Fiber Module (NFM) is installed in any unwired module slot of a network-based Remote Terminal Unit (Network RTU) to provide additional network switch ports or media conversion. This configuration is useful for troubleshooting purposes, or to use a NSM to provide a network connection for a laptop computer that is being used to program a PLC.

Installs in Module Slot

In this application, the NSM or NFM is not placed in the RTU’s RIM slot. It is inserted in any other unused module slot, and it must be addressed at 256. To address the module at 256, place a jumper between card connector pins 43 and 25. The NSM or NFM must be addressed at 256 to identify it as a network distribution module (network module without a DOS-based network CPU).

Power Distribution

The “skeleton board” used as the base of all network modules provides power to the attached network hardware (switch or media converter). The NSM or NFM, because it is wired to the RTU’s backplane, obtains power from the RTU and benefits from the RTU’s battery backup function.


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Service Port

The service port on network distribution modules provides no function.


What you’ll need:

Network Switch Module (NSM) or Network Fiber Module (NFM). Configuration Jumpers (black #16 stranded wire can be used for making jumpers). CAT 5 patch cable terminated with RJ-45 connectors and/or fiber-optic cable

(depending on the application). Electrostatic discharge wrist strap (this must be worn while working inside the

unit).

Refer to Figure 9-1, "Jumper and Address Settings for Network Hardware in RTU" (next page) for a wiring and configuration diagram. (NOTE: This configuration does not require changes to any HT3 configurations.)

1. Power down the RTU. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure.

2. Insert a NSM or NFM in any empty or unused module slot in the RTU. (IMPORTANT: If the slot contained a module at one time and any field wiring remains, the field wiring must be removed. Failure to remove any field wiring terminated to the module slot could result in damage to the NSM/NFM, the backplane, or the installer.)

3. The NSM or NFM must be addressed at 256 to identify it as a network distribution module (network module without a DOS-based network CPU). To address the NSM or NFM at 256, place a jumper across pins 43 and 25. See “Appendix D: Addressing Modules” for more information on module addressing.

4. Bypass the startup plate by placing a jumper across pins 3 and 5 on the NSM / NFM. 5. Use the patch cable and/or fiber-optic cable to make network connection. 6. Restore power to the RTU.

NOTE: If the NSM/NFM was installed for temporary use, remove all jumpers after removing the NSM/NFM.

System Testing & Troubleshooting

81

Figure 9-1, "Jumper and Address Settings for Network Hardware in RTU"


82

POTENTIAL PROBLEMS AND SUGGESTED TROUBLESHOOTING STEPS

My Network RTU is offline!

If you find that your network RTU is offline, verify the following:

Physically check

Is the FIM powered? Is the FIM’s media converter powered? Is the media converter fiber linked?

Verify by obtaining a console to the FIM (see procedure on next page)

Is the FIM addressed < 250? Is the FIM’s DOS-based CPU booting? Is the FIM seeing its station address? Is the FIM getting a network address from HT3

Verify through HT3

Has a NIM driver been configured and is it polling? Has the station been configured under the NIM driver and is it being polled?

My Tunnel CTU is not Polling!

If you find that your tunnel CTU is not polling, verify the following:

Physically check

Is the FIM powered? Is the FIM’s media converter powered? Is the media converter fiber linked? Is there a jumper placed across pins 15 and 23 on the FIM? Is the RIM addressed as a CTU (0 or 251 - 254)?

Verify by obtaining a console to the FIM (see procedure on next page)

Is the FIM addressed < 250? Is the FIM’s DOS-based CPU booting? Is the FIM seeing its station address? Is the FIM getting a network address from HT3?

Verify through HT3

Has a NIM driver been configured to poll the correct NIM address?


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OBTAINING A CONSOLE TO A FIM

Connecting a laptop computer to a FIM enables you to:

Verify that the FIM’s CPU is functional Determine the version of DOS code that the FIM is running Determine the version of firmware running on the FIM’s processor Determine the station address to which the FIM is set Determine the network address, or subnet, that is being broadcast by HT3 Determine the settings (baud rate, data bits, parity, stop bits) of the NIM driver

under which the FIM has been configured

NOTES:

A console cannot be accessed if both serial ports on the FIM are being used for tunneling.

This is not the test mode operation of the FIM that is used to monitor buss communication. Test mode does not require setting the console to noquiet and is designed to function with WinRTU Test at 9600 7 O 2.

To obtain a console:

1. Connect the laptop’s serial port to the FIM’s service port using a RIM/NIM cable. 2. Configure your terminal program (HyperTerminal or a similar program) to connect

directly to the FIM’s serial port at 9600 8 N 1 3. Press Ctrl + C while powering up the FIM. 4. Type noquiet 5. Type boot

The following information is provided (see screenshot on the next page):

The initial boot screen verifies that the FIM’s CPU is functional Version of DOS code running on the FIM’s CPU Version of firmware running on the FIM’s processor Station address at which the FIM is set Network address (subnet) that is being broadcast by HT3 Baud rate, data bits, parity setting, and stop bits (in that order) required to access

the console of the FIM’s DOS CPU.

IMPORTANT: When you have finished the troubleshooting session, you must return the FIM to quiet mode to re-enable the FIM’s second serial tunnel.


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85

REPLACING THE HSM

IMPORTANT: This should only be done by DFS-authorized personnel or under their direct supervision. You must have an HSM preconfigured with your system’s settings and data before beginning this procedure.

NOTES:

Step 7, below, instructs you to connect a keyboard and monitor to the HSM. If your HSM was preconfigured at the factory and you do not need to configure its IP address, disregard step 7.

After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed

1. Press the power down button on the HSM, the shutdown LED (SDN) begins to flash indicating that the shut down process has begun.

2. SDN then goes constant indicating that services to the HSM have been turned off. 3. After a few moments, the CPU power LED (+CPU) goes out indicating that it is now

safe to remove power. 4. Disconnect the battery. 5. Turn off the PSM. The HSS is now deactivated. 6. Remove the HSM and install a new HSM. 7. Connect a keyboard and monitor to the HSM. Ports for connecting a keyboard and

monitor to the HSM are easily accessible and clearly marked. 8. Turn on the PSM. 9. Reconnect the battery. The HSS is now activated. 10. It is not necessary to power up the HSM; it will automatically power up when it senses

power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly.



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Notes

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Appendix A: TECHNICAL SPECIFICATIONS

HYPER SCADA SERVER

HSS001

Model Number HSS001

Part Number DFS-00387-008-01

Enclosure Size 13”W x 13”H x 7”D

Board Size 5.25" x 6.88"

Supply Voltage 115 VAC - 60 Hz

Power Consumption 100 Watts

Environment 41° - 86° F (5° - 30° C), moisture-free

Network Interface 10/100base-TX

Network Protocol TCP/IP

Dial-up Connection PPP

Communication Protocols DFS TAC II, DFP (DFS’ new high speed protocol), Modbus ASCII, Modbus RTU, Modbus TCP

HSS002

Model Number HSS002-1 (one MBP); HSS002-2 (two MBPs)


Enclosure Size 24”W x 30”H x 8”D


Supply Voltage 115 VAC, 60 Hz

Supply Current 200 Watts

Environment 41° - 86° F (5° - 30° C), moisture-free


Network Protocol TCP/IP

Dial-up Connection PPP

Communication Protocols DFS TAC II, DFP (DFS’ new high speed protocol), Modbus ASCII, Modbus RTU, Modbus TCP


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HYPER SERVER MODULE

Model Number HSM002



Supply Voltage 11.8 to 13.4 VDC

Supply Current 1.5 Amps


NETWORK INTERFACE MODULE

Model Number NIM001


Board Size 5.25” X 6.88"

Service Port RS-232 (ASCII)

Circuit Protection Transorb

Power Requirements 12 to 14 VDC; 579 mA

Network Interface 10base-T

Network Protocol TCP/IP (UDP Datagram)

Serial Interfaces Two external serial interfaces with four modes of operation. Interfaces are configurable at the connector.

CPU DOS-based network CPU

Environment 0°- 40° C (32°- 104° F) with a relative humidity of 5%-95% (noncondensing)

Technical Specifications

89

FIBER INTERFACE MODULE

FIM001

Model Number FIM001



Service Port RS-232 (ASCII)



Network Interface 10base-T or 10/100base T (determined by model selected)


Serial Interfaces Two (2) external serial interfaces with four (4) modes of operation. Interfaces are configurable at the connector.

CPU DOS-based network CPU

Media Converter 10Mbps Ethernet media converter or 10/100Mbps auto-negotiating Ethernet media converter (determined by model selected)

LEDs Power, receive data, transmit data, network link, network traffic, COMM2, microprocessor fault, test mode

Environment 0°- 40° C (32°- 104° F) with a relative humidity of 5%-95% (noncondensing)

Models

FIM001-10: 10 Mbps; multi-mode fiber applications up to 2 km FIM001-10/100: 10/100 Mbps; multi-mode fiber applications up to 2 km FIM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-SM-10/100: 10/100 Mbps; single-mode fiber applications from 2-15 km


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NETWORK FIBER MODULE

NFM001

Model Number NFM001





Network Interface: 10base-T

Network Protocol: TCP/IP (UDP Datagram)

Media Converter: 10Mbps Ethernet media converter or 10/100Mbps auto-negotiating Ethernet media converter (determined by model selected)

Environment: 0°- 40° C (32°- 104° F) with a relative humidity of 5%-95% (noncondensing)

Models

NFM001: 10 Mbps; multi-mode fiber applications up to 2 km NFM001-F: 10/100 Mbps; multi-mode fiber applications up to 2 km NFM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-FSM: 10/100 Mbps; single-mode fiber applications from 2-15 km

NETWORK SWITCH MODULE

Model Number NSM001





Network Interface 10base-T


Network Switch 10/100 Mbps Fast Ethernet 5-port UTP switch

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Appendix B: PIN DEFINITIONS

HYPER SERVER MODULE PIN DEFINITIONS

Name Pin Name CONFIGURATION GROUND 43

42 SYSTEM DC+ CONFIGURATION BIT 0 41

40 SYSTEM GROUND CONFIGURATION BIT 1 39

38 REDUNDANT DC+ CONFIGURATION BIT 2 37

36 UNUSED UNUSED 35

34 UNUSED UNUSED 33

32 A/C POWER UNUSED 31

30 NIM POWER DOWN UNUSED 29

28 UNUSED UNUSED 27

26 UNUSED UNUSED 25

24 I/O +V UNUSED 23

22 TRANSIENT GROUND UNUSED 21

20 I/O GROUND UNUSED 19

18 ALARM SILENCE INPUT UNUSED 17

16 ALARM LIGHT OUTPUT UNUSED 15

14 ALARM BELL OUTPUT UNUSED 13

12 CPU ACTIVITY OUTPUT LINE 1 TIP (Default call out) 11

10 SLEDGEHAMMER INPUT LINE 1 RING (Default call out) 9

8 SLEDGEHAMMER OUTPUT LINE 2 TIP (Default call in/maintenance) 7

6 OUTPUT 1 LINE 2 RING (Default call in/maintenance) 5

4 OUTPUT 2 AUDIO OUTPUT + 3

2 OUTPUT 3 AUDIO OUTPUT - 1


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NETWORK INTERFACE MODULE PIN DEFINITIONS*

Name Pin Name STATION ADDRESS GROUND 43

42 SYSTEM V+ =key=

STATON ADDRESS BIT 7 41 40 SYSTEM GROUND

STATION ADDRESS BIT 6 39 38 POWER DOWN

STATION ADDRESS BIT 5 37 36 REQUEST TO SEND

STATION ADDRESS BIT 4 35 34 CLEAR TO SEND

STATION ADDRESS BIT 3 33 32 RECEIVE DATA

STATION ADDRESS BIT 2 31 30 TRANSMIT DATA

STATION ADDRESS BIT 1 29 28 (PSM) POWER SUPPLY V+

STATION ADDRESS BIT 0 27 26 (PSM) POWER SUPPLY GROUND

STATION ADDRESS BIT 8 25 24 (PSM) POWER SUPPLY CONTROL

PROGRAM STRAP 3 23 22

PROGRAM STRAP 2 21 20 (PSM) / RTU POWER OK

PROGRAM STRAP 1 19 18 (PSM) / BIAS OK

PROGRAM STRAP 0 17 16 232 CTS 2

PROGRAM STRAP GROUND 15 14 232 RTS 2

232 CTS 1 13 12 232 GND 2 =key=

232 RTS 1 11 10 232 TXD 2

BATTERY GROUND 9 8 232 RXD 2

BATTERY V+ 7 6 232 GND 1

/ POWER UP 5 4 232 TXD 1

REDUNDANT POWER SUPPLY GROUND 3 2 232 RXD 1 =key=

REDUNDANT POWER SUPPLY V+ 1

* These pin definitions apply to all versions of the network modules (NIM, FIM, NSM, and NFM)

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Appendix C: LED STATUS AND ERROR CODES

SDN – Shutdown

ACT – Activity

SH OUT – Sledgehammer out

+CPU – CPU voltage

+5V – Module voltage

HRN – Alarm horn

LITE – Alarm light

OUT1 – Reserved for future use



RXD1 – Receive Data (COM 1; Line 1)

TXD1 – Transmit Data (COM 1; Line 1)

RXD2 – Receive Data (COM 2; Line 2)

TXD2 – Transmit Data (COM 2; Line 2)

SDN – Indicates the shutdown or startup status of the primary server (HSM).

Solid on – Power has been removed from the server and the server is no longer responsive.

Initial slow single blink that accelerates – Server is starting up. (IMPORTANT: Server cannot be shut down until the LED stops blinking.)

Initial fast double blink that decelerates – Server is in the process of shutting down. (IMPORTANT: Server cannot be restarted while the LED is blinking or within 10 (ten) seconds after the blinking has stopped.)

ACT – Heartbeat monitor provided by the server via HSUport to confirm that processes are running. If there is a pause greater than 30 seconds between blinks, the CPU’s firmware assumes the server has seized and issues a cold boot by shutting down the system and restarting it. (NOTE: The SDWN indicator will function as normal.)

SH OUT – Indicates that the redundant HSM (if present) is disabled or is in the process of being disabled. The sledgehammer (disable) process is controlled by HSUport and HT3.

+CPU – Indicates that voltage is being applied to the server’s microprocessor.

+5V – Indicates that +5V is being applied to the module (HSM). If the LED is not lit, the module is not receiving adequate voltage.


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HRN – Indicates that the alarm horn is active (sounding off).

LITE – Indicates that the alarm light is active (lit).

OUT1, OUT2, OUT3 – Reserved for future use.

RXD1 – Indicates that COM 1 (Line 1) is receiving serial communications.

TXD1 – Indicates that COM 1 (Line 1) is transmitting serial communications.

RXD2 – Indicates that COM 2 (Line 2) is receiving serial communications.

TXD2 – Indicates that COM 2 (Line 2) is transmitting serial communications.

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Appendix D: ADDRESSING MODULES

With regards to addressing, modules are one of two types: those addressed by placing a jumper across two pins or those addressed by moving DIP switches.

Each pin or DIP switch has an assigned bit value. The station address is derived by totaling the values of the bits that are not grounded.

A pin is grounded if a jumper has been placed across it and pin 43 (ground).

A DIP switch is grounded if it is in the CLOSED, or ON, position.

DIP Switch Example Pins/Jumper Example

ON

OFF

BIT VALUE

G256128

6432168421

43

41

39

37

35

33

31

29

27

25

1

2

4

8

16

32

64

128

Ground

256

PIN # BIT VALUE

DIP Switches

In the DIP switch example above, we arrive at the station address by totaling the bit values of the switches that are OFF, or OPEN.

128 + 64 + 16 = 208

Therefore, the DIP switch example above shows a station address of 208.

Pins/Jumper

In the pins/jumper example, we arrive at the station address by totaling the bit values of the pins that are not jumpered to Ground.

128 + 64 + 32 + 8 + 4 + 2 + 1 = 239

The pins/jumper example above shows a station address of 239.

If we want to address the module at 256, we place a jumper across pins 43 and 25. The NSMs and NFMs in the HSS must be addressed at 256 to identify them as network distribution modules.


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Notes

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Appendix E: SUPPORT, SERVICE, AND WARRANTY INFORMATION

SUPPORT AND SERVICE

Data Flow Systems, Inc. offers support services nationwide from its home office and through authorized Value Added Resellers (VARs) and System Integrators.

Contact your local Data Flow Systems, Inc. representative for:

Sales and order support Product technical training Warranty support Support service agreements

If you are unsure of whom to contact, call DFS’ Melbourne headquarters at 321-259-5009 and ask for the Sales Department. Alternatively, send email to [email protected].

TECHNICAL PRODUCT ASSISTANCE

Please review the information in Chapter 8: System Testing & Troubleshooting, before contacting Data Flow Systems, Inc. If you need further assistance, visit the DFS Help Desk (available from the DFS website, www.dataflowsys.com) or contact your local Data Flow Systems representative. If you are unsure who to contact, call DFS’ Melbourne headquarters at 321-259-5009 and ask for the Service Department. Alternatively, send email to [email protected].

RETURN AUTHORIZATION (RA) PROCEDURE

Data Flow Systems’ function modules are designed to be robust and highly reliable. We back this performance with a 3-year full warranty see our warranty statement for details). In the event that a function module fails, during or after the warranty period, it may be returned to Data Flow Systems to be repaired or replaced.

All RA’s will be subject to standard shipping and handling charges. Minimum handling charge will be assessed, in most cases, for work such as Radio Tuning, Backplanes, “No Problem Found,” and other minor repairs. Handling charges will be waved on warranty equipment. Standard shipping and charges will be based on UPS ground, please advise if other arrangements are needed (UPS Red, FedEx, Pickup, Freight…). Standard cost of repairs and shipping charges can be obtained by contacting our RA Department by phone or e-mail.

STEP 1: Replace the failed module with a spare module of the same type, if one is available.


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STEP 2: Contact Data Flow Systems Inc. in one of the following ways to receive an RA#.

E-mail – An RA# can be received by e-mailing DFS at [email protected] and must include the following information.

Customer/Utility Name and Ship to Address Contact Name and Phone Number Products to be returned and Serial Numbers Detailed description of failure PO#

Phone – RA# will be issued over the phone by calling DFS at 321-259-5009 during normal operating hours. The following information will be needed.

Customer/Utility Name and Ship to Address Contact Name and Phone Number Products to be returned and Serial Numbers Detailed description of failure PO#

Note The lack of “Detailed description of failure” could result in the return of equipment due to the inability to properly determine the nature of the failure or testing resulting in “No Problem Found”

STEP 3: Place the function module(s) individually in an electrostatic discharge bag and then wrap with foam or bubble wrap. Pack the wrapped module(s) in a sturdy box filled with popcorn-type or bubble wrap packing material. Include a packing slip with the following information:

Module(s) model, serial number, probable cause of failure, and the RA number Shipping address Shipping instructions (shipping costs greater than UPS ground are charged to

the customer)

STEP 4: Address the box to:

RA Department # {the RA number you received here} Data Flow Systems, Inc. 605 N. John Rodes Blvd. Melbourne, FL 32934-9105

STEP 5: Ship the box to DFS using any typical shipping carrier (for example, UPS, FedEx, etc.). If circumstances permit, have a DFS employee hand carry the package to the headquarters for you. (Note: DFS employees are not permitted to hand carry unpacked modules.)

Modules are typically repaired and shipped back to the customer within a 2-week period starting at the time the module reaches the RA Department. If additional information is required during the repair of the module(s), the DFS service department will contact you.

To get information on the progress of any of your equipment in for repair, contact the DFS - RA Department at [email protected] or 321-259-5009.

Replacement of equipment may be necessary in the event that the equipment and/or parts are unrepairable. Warranty equipment will be replaced with out prior notification as

Support, Service, and Warranty Information

99

warranty replacement. The customer will be notified by phone, if equipment not under warranty cannot be repaired, with information of available options.

DFS reserve the right to return any material received without an RA# or not conforming to the requirements of this RA process.

WARRANTY

Data Flow Systems, Inc. (DFS) offers a one (1) year on-site warranty covering defects in materials and workmanship. All DFS “plug-in” function modules, Pump Control Units (PCU), Hyper Server Modules (HSM), Network Interface Modules (NIM), Fiber Interface Modules (FIM), Network Switch Modules (NSM), Network Fiber Modules (NFM), and Back Pack Radios (BPR) carry an extended two (2) year return-to-factory warranty. This extended warranty does not cover misuse, vandalism, or Acts of God. However, these items are warranted against damage due to lightning for the entire three-year period.

QUESTIONS OR COMMENTS ON THIS MANUAL

If you find a problem with any of the information in this manual or have suggestions on how it could be improved, please contact us at the address below:

Data Flow Systems, Inc. Documentation Department 605 N. John Rodes Blvd. Melbourne, FL 32934

Alternatively, e-mail us at:

[email protected]


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Notes

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INDEX

+ +5V LED, 93 +CPU LED, 93

A AC power. See power ACT LED, 93 alarm horn

HSS001, 32 HSS002, 33–34

alarm LED, 32 alarm light

HSS001, 32 HSS002, 32–33

alarm options alarm horn

HSS001, 32 HSS002, 33–34

alarm light HSS001, 32 HSS002, 32–33

alarm silence button, 35 audio device, 30–31 dial out/dial in, 27–29

alarm silence button, 35 audio device for alarms, connecting, 30–31

B backing up data. See data backup battery backup, 11 baud rate of network RTU stations, 57

C call out/call in. See dial out/dial in COM1. See serial devices COM2. See serial devices critical data redundancy. See data backup CTU. See tunnel CTU

D data backup

remote system backup, configuring, 73–74 See also data recovery; redundancy.

dial out/dial in, 27–29 HSS001, 27–28 HSS002, 29 overview, 27

DIP switch, use in station addressing, 95

E electrostatic discharge, protecting against, 18

equipment, receiving, 19 Ethernet. See network

F Fiber Interface Module. See FIM FIM001

applications, 14 as troubleshooting tool, 83–84 description, 14–15 features, 14 models, 15 pin definitions, 92 specifications, 89

H HMI, 6

See also workstation. hosts file, editing, 70 HRN LED, 94 HSM002

as primary server, 75 as secondary server, 75 battery backup, 11 description, 8 features, 9 interface, 10 IP address, configuring, 42, 46, 51 LEDs, 93–94 pin definitions, 91 power monitoring, 11 reboot procedure, 46, 51 replacing, 85 specifications, 10, 88 voltage monitoring, 11

HSS test workstation connection to HSS, 71

HSS001 alarm horn, 32 alarm led, 32 alarm light, 32 COM1. See serial devices COM2. See serial devices description, 3–4 dial out/dial in, 27–28 features, 3 mounting to wall, 21 network, installing on, 39–43 power, wiring, 21–22 receiving equipment, 21 serial devices, connecting, 68 specifications, 87

HSS002 alarm horn, 33–34 alarm led, 32 alarm light, 32–33 alarm silence button, 35

Index

102

description, 4–6 dial out/dial in, 29 modules, installing, 23–24 mounting to wall, 22 power, wiring, 24–25 receiving equipment, 22 specifications, 87 typical configuration, 37 See also HSS002-1; HSS002-2.

HSS002-1 features, 4 network, installing on, 43–46

HSS002-2 features, 5 network, installing on, 47–51 redundancy, 75–76

HT3, 6 HT3 Mobile, 6 HT3 Public, 6 remote system backup, configuring, 73–74 start, 72

human machine interface. See HMI Hyper SCADA Server

description, 3–6 See also HSS001; HSS002.

Hyper Server Module. See HSM002

I installing the HSS

overview, 19 safety

general precautions, 17 static electricity, 18 using the HSS, 18 working inside the HSS, 17

site selection, 18 IP address

HSM002, 42, 46, 51 NIM001, 40

L LEDs, HSM002, 93–94 light. See alarm light LITE LED, 94

M Modbus devices. See serial devices modules

addressing, 95 installing in HSS002, 23–24

mounting to wall HSS001, 21 HSS002, 22

N network

distribution, 38

HSS001, installing on, 39–43 HSS002-1, installing on, 43–46 HSS002-2, installing on, 47–51 isolation, 38 tunneling, 38, 54, 62

network distribution modules. See NFM001, NSM001

network fiber module. See NFM001 Network Interface Module. See NIM001 network interface modules. See FIM001, NIM001 network modules, 12–16

applications, 16 power, 38 resetting remotely, 39 using for testing and troubleshooting, 79–81 See also FIM001; NFM001; NIM001;

NSM001. network RTU, 7

baud rate, 57 installing, 56–60 IP addressing, automatic, 55 power monitoring, 55 serial tunneling, 54 station address, 57 system overview, 53–55 test mode, 55 troubleshooting, 82

network switch module. See NSM001 NFM001

applications, 15 description, 15 features, 15 models, 15 pin definitions, 92 specifications, 90

NIM001 applications, 13 description, 13 features, 13 IP address, configuring, 40 pin definitions, 92 specifications, 88

NSM001 applications, 16 description, 16 features, 16 pin definitions, 92 specifications, 90

O OUT1 LED, 94 OUT2 LED, 94 OUT3 LED, 94

P PA system. See audio device pin definitions

FIM001, 92 HSM002, 91 NFM001, 92

Index

103

NIM001, 92 NSM001, 92

pins, use in station addressing, 95 power

HSS001, wiring, 21–22 HSS002, wiring, 24–25 network modules, 38

power monitoring, 11 primary server in redundant system, 75

R reboot procedure for HSM002, 46, 51 receipt of equipment, 19 redundancy, 75–76

IP sharing, 76 primary server, 75 safe IP address, 76 secondary server, 75 switch over process, 76

replacing the HSM002, 85 resetting network modules, 39 RTU, network. See network RTU RXD1 LED, 94 RXD2 LED, 94

S safety precautions for installing, service, or

replacing HSS components, 17–18 SCADA system options, 7–8

network RTUs, 7 tunnel CTU, 8

SDN LED, 93 secondary server in a redundant system, 75 serial devices, connecting to HSS001, 68 serial tunneling, 38, 54, 62 service. See support service port, tunnel CTU, 63 SH OUT LED, 93 silence button. See alarm silence button site selection, 18 speakers. See audio device specifications

FIM001, 89 HSM002, 10, 88 HSS001, 87 HSS002, 87 NIM001, 88 NSM001, 90

static electricity, protecting against, 18 station address

network RTU, 57 procedure for addressing modules, 95 tunnel CTU, 65

support obtaining, 97–99 return authorization procedure, 97–99

T telephone. See dial out/dial in test mode

network RTU, 55 tunnel CTU, 63

testing, using network module for, 79–81

troubleshooting, 79–84 network RTU, 82 tools required, 79 tunnel CTU, 82 using FIM001 for, 83–84 using network module

for, 79–81 tunnel CTU, 8

installing, 63–67 overview, 61–63 serial tunnel, 62 service port, 63 station address, 65 test mode function, 63 troubleshooting, 82

tunneling. See serial tunneling TXD1 LED, 94 TXD2 LED, 94

U user interface. See HMI

V voltage monitoring, 11

W warranty information, 99 workstation

configuration, 69–72 hosts file, 70

HSM002, test connection to, 71 requirements, 69

Data Flow Systems, Inc.

605 N. John Rodes Blvd. Melbourne, FL 32934

321-259-5009 www.dataflowsys.com

hsu installation and operation manual · 2012. 6. 20. · the hss002 features a 24”x30”x8”...

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