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Kingfisher Plus+ Hardware Manual

KINGFISHER PLUS+ Modular RTU Hardware Reference Manual 7.17


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Revision History

Version Number Date Summary

7.0 7.1

7.12

28/10/2011

Update: adaptor ADP-22B (include Wavecom extend) Update: temp sensor is white / white with a black strip Update: power requirements of T option board Update: power calculation tables Update: Comms option boards selection table Update: safety warnings Update: Lenses for PS-12 and PS-22 Update: Lens for MC-31 Proposed ‘Linked Backplane Example’ chapter removed Update: Various errors found in first release

7.13 3/9/2012

Corrected IO-5 power consumption Added CP-12 power consumption Added CP-30/MC-30/MC-31 to compatibility chapter Corrected various spelling and grammatical mistakes Outlined A3 / T3 simultaneous master and slave limitation in rare use-cases Added IO-5 Power Consumption Corrected RJC-ADP30 Diagram, RJ45 wiring error corrected Updated T3 temp range Added block diagrams for all IO Modules Added Option Board installation guide PS-x2 nominal voltage at low temperatures extended to 15°C after further testing Logo updated

7.14 24/10/2014

Added new modules. Added block diagrams for various modules. Modules specifications reviewed and updated. Safety warnings updated. Non-operational hyperlinks updated. Logo and the document style updated. Various corrections and updates.

7.15 18/11/2014

MC-10/11/30 modules added. PS-11 and PS-21 modules added. Option Board T2 added. Various corrections and updates.


7.16 27/05/2015

PS-x2 specifications adjusted IO-5 temperature rating increased to -40...+85 °C DO-1, DO-2 and TEL-REL_00x installation instructions updated IO-2, IO-3 and IO-4 specifications updated (for Digital Outputs) Dual Isolated Serial Option Board introduced Information about environmental standards compliance added Power consumption for Line and HART Option Boards updated with more accurate figures (#557) IO-4 wiring diagram corrected (#2496) IO-2 wiring diagram corrected (#2506) The Maxon Intermax to Kingfisher Serial Port cable pinout corrected (#2433) Accuracy specification for AI-1, IO-3 and IO-4 modules expanded for the whole operating temperature range (#2424) RJC-ADP-30 drawing corrected to show resistor value (#2505) Information about cables strain relief use added to the System Installation section (#1203) References to battery protection fuse type added (#1162)

7.17 26/10/2015

Incorrect SRAM size fixed for CP-30 v2.x (#2525) PS-x2 Battery Voltage Range corrected (#1332) ADP-04 pinout corrected (#2557) ADP-05 pinout corrected (#2574) DI-5 wiring diagram corrected (#2722) A 2,000 m altitude limit added to the Option Board L and Option Board D specifications Grounding recommendation added for those cases when more than three AC Power Supplies are installed A3OB marked as “Class I LED Product” “Class II” and “Class II with Functional Earthing” symbols explained in the Glossary chapter


CONTENTS 1. INTRODUCTION ..................................................................................... 10

2. BACKPLANES ....................................................................................... 16 Overview .................................................................................................................... 16 BA-x-PLUS Backplanes .............................................................................................. 18

2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor ................................................ 18 2.2.2 BA-40-PLUS: 4-slot Backplane ............................................................................. 19 2.2.3 BA-6-PLUS: 6-slot Backplane ............................................................................... 20 2.2.4 BA-12-PLUS: 12-slot Backplane ........................................................................... 21

BP-x-PLUS Backplanes .............................................................................................. 22 Backplane Connectors ............................................................................................... 27 Linking Backplanes .................................................................................................... 28

2.5.1 Creating Racks ..................................................................................................... 28 2.5.2 Backplane Cables ................................................................................................. 29 2.5.3 Setting Bus Terminators ....................................................................................... 30 2.5.4 Setting Rack Number ............................................................................................ 30 2.5.5 Setting Slot Number Range .................................................................................. 33

3. POWER SUPPLY MODULES ................................................................... 35 Overview .................................................................................................................... 35 PS-x2 and PS-x1 Power Supply Modules ................................................................... 35

3.2.1 Overview .............................................................................................................. 35 3.2.2 Options and Ordering Info ..................................................................................... 38 3.2.3 Theory of operation ............................................................................................... 40 3.2.4 Battery Charging ................................................................................................... 41 3.2.5 Module LEDs ........................................................................................................ 42 3.2.6 PS-x2 Specifications ............................................................................................. 45 3.2.7 PS-x1 Specifications ............................................................................................. 47 3.2.8 Wiring Diagrams ................................................................................................... 49

PSU-x AC Power Supply Unit ..................................................................................... 53 Calculating Power Requirements................................................................................ 57

3.4.1 Total Current Consumption ................................................................................... 57 3.4.2 5 V Rail Overload Check ....................................................................................... 59 3.4.3 Total Power Load.................................................................................................. 61 3.4.4 Battery Backup ..................................................................................................... 61

4. PROCESSOR MODULES ........................................................................ 62 Overview .................................................................................................................... 62 PC-1: Power & Processor Module .............................................................................. 63

4.2.1 Overview .............................................................................................................. 63 4.2.2 Part Numbers ....................................................................................................... 64 4.2.3 PC-1 Module LEDs ............................................................................................... 65 4.2.4 PC-1 Specifications .............................................................................................. 66 4.2.5 PC-1 Pinout .......................................................................................................... 68


CP-12 Processor Module ........................................................................................... 69 4.3.1 Overview .............................................................................................................. 69 4.3.2 CP-12 Reset Procedures ...................................................................................... 69 4.3.3 CP-12 Module LEDs ............................................................................................. 70 4.3.4 CP-12 Specifications ............................................................................................ 71 4.3.5 CP-12 Ports .......................................................................................................... 72

CP-30: High Performance Processor Module ............................................................. 73 4.4.1 Overview .............................................................................................................. 73 4.4.2 CP-30 Options and Ordering Info .......................................................................... 73 4.4.3 Backup Battery / Reset to Factory Defaults........................................................... 75 4.4.4 CP-30 Module LEDs ............................................................................................. 78 4.4.5 CP-30 Specifications ............................................................................................ 81 4.4.6 CP-30 Ports .......................................................................................................... 82

5. COMMUNICATIONS MODULES ............................................................... 83 Overview .................................................................................................................... 83 MC-10/11/30 Communications Modules ..................................................................... 84

5.2.1 Overview .............................................................................................................. 84 5.2.2 MC-10/11/30 Module LEDs ................................................................................... 84 5.2.3 MC-10/11/30 Specifications .................................................................................. 85 5.2.4 MC-10/11/30 Block Diagram ................................................................................. 86 5.2.5 MC-10/11/30 Ports ................................................................................................ 86

MC-12 Communications Module ................................................................................ 87 5.3.1 Overview .............................................................................................................. 87 5.3.2 MC-12 Module LEDs ............................................................................................ 88 5.3.3 MC-12 Specifications ............................................................................................ 89 5.3.4 MC-12 Ports ......................................................................................................... 90

MC-31 Communications Module ................................................................................ 91 5.4.1 Overview .............................................................................................................. 91 5.4.2 MC-31 Options and Ordering Info ......................................................................... 91 5.4.3 MC-31 Module LEDs ............................................................................................ 92 5.4.4 MC-31 Specifications ............................................................................................ 95 5.4.5 MC-31 Ports ......................................................................................................... 96

6. COMMUNICATIONS OPTION BOARDS .................................................... 97 Overview .................................................................................................................... 97 Compatibility ............................................................................................................... 97 Installing and removing Option Boards ....................................................................... 98 Option Board I: Isolated Serial .................................................................................. 101

6.4.1 Overview ............................................................................................................ 101 6.4.2 Serial Option Board Connections ........................................................................ 102

Option Board I2: Dual Isolated Serial ........................................................................ 104 6.5.1 Overview ............................................................................................................ 104 6.5.2 Dual Serial Option Board Connections ................................................................ 105

Option Board F: Fibre Optic Serial Board ................................................................. 106 Option Board D: 33.6 kbps Dial Option Board .......................................................... 107 Option Board L: Line/Analogue Radio Interface ........................................................ 109


6.8.1 Line Board Connections...................................................................................... 109 6.8.2 Connecting a Radio ............................................................................................ 110 6.8.3 2-Wire Line, point-to-point ................................................................................... 111 6.8.4 2-Wire Line, multi-drop........................................................................................ 111 6.8.5 4-Wire Line, point-to-point ................................................................................... 112 6.8.6 4-Wire Line, multi-drop........................................................................................ 112

Option Board H: HART Interface .............................................................................. 115 6.9.1 HART Board Connections ................................................................................... 115

Option Boards T3 & T2: 10/100 Ethernet Controller................................................ 118 Option Board A3: Fibre Optic Ethernet ................................................................... 119 Option Board R2: Australian Spread Spectrum Radio ............................................ 120 Option Board R3: International Spread Spectrum Radio ......................................... 122 Option Board R4: US/Canada Spread Spectrum Radio .......................................... 124

7. PC-1 OPTION BOARDS ........................................................................ 126 PC-1 Serial Option Board ......................................................................................... 126 PC-1 Modem Board PL: Two Wire Line .................................................................... 127 PC-1 Modem Board: Analogue Radio Interface ........................................................ 128

8. IO MODULES OVERVIEW ..................................................................... 129

9. ANALOGUE INPUT MODULES .............................................................. 133 AI-1: 8 Channel Analogue Current Input Module ...................................................... 133

9.1.1 Overview ............................................................................................................ 133 9.1.2 AI-1 Module LEDs ............................................................................................... 135 9.1.3 AI-1 Specifications .............................................................................................. 136 9.1.4 AI-1 Wiring Diagram ........................................................................................... 137

AI-10: 8 Channel High Impedance Analogue Input Module ...................................... 139 9.2.1 Overview ............................................................................................................ 139 9.2.2 AI-10 Module LEDs ............................................................................................. 142 9.2.3 AI-10 Specifications ............................................................................................ 143 9.2.4 AI-10 / AI-10-V Wiring Diagram ........................................................................... 144

10. ANALOGUE OUTPUT MODULE ........................................................... 146 AO-3: Analogue Output Module .............................................................................. 146

10.1.1 Overview........................................................................................................... 146 10.1.2 AO-3 Module LEDs ........................................................................................... 148 10.1.3 AO-3 Specifications .......................................................................................... 149 10.1.4 AO-3 Wiring Diagram ........................................................................................ 150

11. DIGITAL INPUT MODULES ................................................................. 152 Overview ................................................................................................................ 152 DI-5: DC Input 16 Channel Digital Input Module ..................................................... 152

11.2.1 Overview........................................................................................................... 152 11.2.2 DI-5 Module LEDs ............................................................................................ 153 11.2.3 DI-5 Specifications ............................................................................................ 154 11.2.4 DI-5 Wiring Diagram ......................................................................................... 155


DI-10: AC or DC Input, 16 Channel ........................................................................ 157 11.3.1 Overview........................................................................................................... 157 11.3.2 DI-10 Options and Ordering Info ....................................................................... 158 11.3.3 Theory of operation ........................................................................................... 159 11.3.4 Configurable Functions ..................................................................................... 160 11.3.5 Sequence of Events Recording ......................................................................... 161 11.3.6 GPS Time Synchronisation (Optional) .............................................................. 161 11.3.7 DI-10 Module LEDs .......................................................................................... 163 11.3.8 DI-10 Specifications .......................................................................................... 165 11.3.9 DI-10 Wiring Diagram ....................................................................................... 168

12. DIGITAL OUTPUT MODULES .............................................................. 170 Overview ................................................................................................................ 170 Switching Inductive Loads ...................................................................................... 170 DO-1: 8 Channel Isolated Relay Output Module ..................................................... 172

12.3.1 Overview........................................................................................................... 172 12.3.2 DO-1 Module LEDs ........................................................................................... 174 12.3.3 DO-1 Specifications .......................................................................................... 175 12.3.4 DO-1 Wiring Diagram ....................................................................................... 176

DO-2: 16 Channel Relay Output Module ................................................................ 178 12.4.1 Overview........................................................................................................... 178 12.4.2 DO-2 Module LEDs ........................................................................................... 180 12.4.3 DO-2 Specifications .......................................................................................... 180 12.4.4 DO-2 Wiring Diagram ....................................................................................... 181

DO-6: 16 Channel Open Drain Output Module ....................................................... 183 12.5.1 Overview........................................................................................................... 183 12.5.2 DO-6 Module LEDs ........................................................................................... 184 12.5.3 DO-6 Specifications .......................................................................................... 184 12.5.4 DO-6 Wiring Diagram ....................................................................................... 185

13. RELAY EXPANSION BOARDS ............................................................ 187 Overview ................................................................................................................ 187 TEL REL 002: SPDT Relay Board .......................................................................... 189

13.2.1 Overview........................................................................................................... 189 13.2.2 TEL REL 002 Specifications ............................................................................. 189 13.2.3 TEL REL 002 Wiring Diagram ........................................................................... 191

TEL REL 003: SPST Relay Board .......................................................................... 193 13.3.1 Overview........................................................................................................... 193 13.3.2 TEL REL 003 Specifications ............................................................................. 193 13.3.3 TEL REL 003 Wiring Diagram ........................................................................... 194

TEL REL 004: DPDT Relay Board .......................................................................... 196 13.4.1 Overview........................................................................................................... 196 13.4.2 TEL REL 004 Specifications ............................................................................. 196 13.4.3 TEL REL 004 Wiring Diagram ........................................................................... 198

14. COMBINATION IO MODULES ............................................................. 200 IO-2: Combinational Digital IO Module ................................................................... 200

14.1.1 Overview........................................................................................................... 200


14.1.2 IO-2 Module LEDs ............................................................................................ 202 14.1.3 IO-2 Specifications ............................................................................................ 202 14.1.4 IO-2 Wiring Diagram ......................................................................................... 203

IO-3: Combinational Analogue/Digital IO Module .................................................... 205 14.2.1 Overview........................................................................................................... 205 14.2.2 IO-3 Module LEDs ............................................................................................ 207 14.2.3 IO-3 Specifications ............................................................................................ 208 14.2.4 IO-3 Wiring Diagram ......................................................................................... 210

IO-4: Combinational Analogue / Digital IO Module .................................................. 213 14.3.1 Overview........................................................................................................... 213 14.3.2 IO-4 Module LEDs ............................................................................................ 215 14.3.3 IO-4 Specifications ............................................................................................ 216 14.3.4 IO-4 Wiring Diagram ......................................................................................... 218

IO-5: Combinational Analogue / Digital IO Module .................................................. 220 14.4.1 Overview........................................................................................................... 220 14.4.2 IO-5 Module LEDs ............................................................................................ 223 14.4.3 IO-5 Specifications ............................................................................................ 224 14.4.4 IO-5 Wiring Diagram ......................................................................................... 226

15. ADAPTORS AND CABLES .................................................................. 228 Overview ................................................................................................................ 228 RTU Test Cables .................................................................................................... 230 Device Cables and Adaptors .................................................................................. 231

16. ACCESSORIES .................................................................................. 242 MBR-3: 19” Rack Mounting for BA-12-PLUS .......................................................... 242 TEL-RAK-002: 19” Rack Mounting for BA-4/6/40 .................................................... 243 Battery Bracket: 7 Ah Battery Mounting Bracket ..................................................... 244

17. GLOSSARY ........................................................................................ 245

18. APPENDIX A: SYSTEM INSTALLATION .......................................................... 247


1. INTRODUCTION This manual details the specifications for each type of module, option board, cable and accessory available for use with a Kingfisher Plus+ Remote Terminal Unit (RTU).

A Kingfisher Plus+ Modular RTU is a highly configurable device that can monitor and control a wide range of equipment. Kingfisher Plus+ modular RTUs are easy to install and configure, can be large or small, use interchangeable modules, have advanced communications, and support powerful programming languages.

RTU Features • Two-, four-, six- and twelve-slot backplanes. • Backplanes can be linked together vertically or horizontally providing up to 64 modules

per RTU. • AC (100 to 240 VAC) and DC (20 to 60 VDC) power supply modules. • Battery backup and built-in battery charger. • Powerful 32-bit Industrial CPUs. • Up to 16 communication ports. • Eight-channel analogue input modules. • Four-channel analogue output modules. • Eight and sixteen channel digital input/output modules. • High speed scanning of I/O-signals. • Electrical isolation of I/O and communication circuits. • Designed and tested to comply with International Environmental (climatic) Standards

(IEC 60068-2-1, IEC 60068-2-2, IEC 60068-2-78). • Full support for IEC 61131-3 via the ISaGRAF™ programming environment. • Multiple pre-defined function blocks for communications and diagnostics. • Support for multiple protocols including – Modbus, DNP3, Allen Bradley® DF1, and

User Defined. • Event logging of data (time and date stamped). • Redundant Power Supplies, Processors and Communications • Self-configuring of I/O modules at start up. • PC based configuration and diagnostic software – Toolbox PLUS software with

ISaGRAF™ Workbench. • Local and remote configuration. • Low power operation – suitable for low cost solar installation.

Product Description The Kingfisher Plus+ RTU offers many desirable features in addition to the abovementioned items, including small physical size for ease of mounting and handling, changeable port types (e.g. RS232/422/485, PSTN, Ethernet, private line etc), front panel LED status and diagnostic display.

Kingfisher Plus+ RTUs may be configured to user I/O, communication circuit requirements, power supply requirement and processing functionality by selecting the appropriate modules

Hardware Manual Version 7.17 http://www.servelec-semaphore.com/

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from the available range. Selected modules are simply installed on the backplanes and secured with a single screw.

Larger modular RTUs are configured using one or more backplanes together with a processor module, a power supply module(s) and optional I/O and communication modules.

The RTU size permits flexible and simple mounting in industry standard enclosures. An RTU using a 12-slot backplane can be 19” rack mounted with the aid of additional brackets.

RTU Configuration Options Each modular RTU requires a backplane, a power supply and a CPU module. There are three types of Kingfisher Plus+ modular RTUs identified by the processor module they contain: PC-1, CP-12 or CP-30.

PC-1 CP-12 CP-30

A PC-1 RTU is powered using an external AC/DC power supply. A PC-1 processor module is only used on a BA-4 PLUS backplane (4 slot).

A CP-12 or CP-30 RTU is powered using a power supply module (or modules) and utilizes one of three backplanes: a BA-40-PLUS (4 slot), a BA-6-PLUS (6 slot) or a BA-12-PLUS (12 slot). A Powered Backplane (BP-x-PLUS) can also be used.

An RTU can also have any combination of I/O and communication modules as required. Modular RTUs support up to 64 modules and 1008 I/O (input/output) points. To obtain more communications ports, one or more communications modules can be added to the RTU.

Examples of various RTU configurations are shown below.




BP-2-PLUS – based RTU BA-40-PLUS – based RTU

BA-6-PLUS – based RTU

Small RTUs examples

Medium RTU example




Large RTU example (only one processor module is required for the entire RTU)




Kingfisher Plus+ RTU Components Each RTU requires a Processor module installed into a backplane and a Power Supply source as a minimum. Communications and I/O modules are optional. The modules that are currently available are listed below:

Module Description

BACKPLANES

BA-4-PLUS Backplane, 4-slot (for PC-1 processor only)

BA-40-PLUS Backplane, 4-slot



BP-2-PLUS Backplane with integrated 5 V power supply, 2-slot



POWER SUPPLIES

PS-12-0 AC-DC Power Supply Module Input 100-240 VAC / 50-60 Hz

PS-22-0 DC-DC Power Supply Module Input 20-60 VDC

PS-12-C AC-DC Power Supply Module Input 100-240 VAC / 50-60 Hz, additional 24 Volt Auxiliary Output

PS-22-C DC-DC Power Supply Module Input 20-60 VDC, additional 24 Volt Auxiliary Output

PSU-3 AC-DC Power Supply Unit Input 90-260 VAC / 50-60 Hz, 40 W



PROCESSOR MODULES

PC-1 Power and Processor Module Integrated Power Supply, 16 MHz 16-bit CPU, Fixed Serial Port + 1x Optional Port

CP-12 Processor Module 40 MHz 16-bit CPU, Fixed Serial Port + 2x Optional Ports

CP-30 Processor Module 166 MHz 32-bit CPU, Fixed Ethernet Port + 2x Optional Ports

COMMUNICATIONS MODULES

MC-12 Communications Module up to 3 communications ports (incl. fixed serial port)

MC-31 Communications Module up to 3 communications ports (incl. fixed Ethernet port)




Module Description

ANALOGUE MODULES

AI-1 Analogue Input Module 8 analogue current inputs, 1 common per module

AI-10 Analogue Input Module 8 analogue high impedance inputs, 1 common per module

AO-3 Analogue Output Module 4 analogue 0-20 mA / 4-20 mA outputs, 4 commons per module

DIGITAL MODULES

DI-5 Digital DC Input Module Bipolar dry contact inputs, 16 Points, 1 common per module

DI-10 Digital AC/DC Input Module Intelligent AC/DC inputs, 16 Points, 1 common per module

DO-1 Digital Relay Output Module NO/NC (SPDT), 8 Points, 4 commons per module

DO-2 Digital Relay Output Module NO (SPST), 16 Points, 2 commons per module

DO-6 Digital Solid State Module Open Drain Outputs, 16 Points, 2 commons per module

I/O MODULES

IO-2 Combination Digital I/O Module 8 digital inputs / 8 digital outputs, 2 commons per module

IO-3 Combination Analogue/Digital I/O Module 4 relay outputs / 4 analogue inputs / 4 digital inputs / 1 analogue output, 4 commons per module

IO-4 Combination Analogue/Digital I/O Module 2 relay outputs / 2 analogue inputs / 8 digital inputs, 3 commons per module

IO-5 Combination Analogue/Digital I/O Module 4 analogue inputs / 1 analogue output / 4 digital inputs / 4 sinking outputs, 4 common per module

EXPANSION BOARDS

TEL REL 002 SPDT Relay Expansion Board 16 SPDT relay outputs, 1 common per channel

TEL REL 003 SPST Relay Expansion Board 16 SPST relay outputs, 1 common per channel

TEL REL 004 DPDT Relay Expansion Board 16 DPDT relay outputs, 2 commons per channel




2. BACKPLANES

Overview The purpose of a backplane is to host all Kingfisher Plus+ modules that make an RTU and to allow the processor module to communicate with all other modules within the same RTU. The backplane also distributes power to each module. Some backplanes can be linked together to create an RTU containing up to 64 modules.

There are two families of Kingfisher Plus+ backplanes available:

• BA-x / BA-x-PLUS – passive backplanes that require a power supply module to be installed in one of the slots to make the RTU working. These backplanes range is a flexible solution for creating medium- to large-scale RTUs of any desired configuration.

• BP-x-PLUS – backplanes with an integrated 5 V power converter that require only one external +12 VDC power supply to run the RTU. These backplanes have limited expansion and configuration capabilities and mainly aimed for building small-scale low-cost RTUs.

Seven versions of backplanes are available in total:

BA-4 / BA-4-PLUS 4-slot backplane for use with PC-1 processor module

BA-40 / BA-40-PLUS 4-slot backplane



BP-2-PLUS 2-slot backplane with integrated 5 V power supply



Note: Where the number of slots is not important, the backplanes will be referred to as ‘BA-x-PLUS’ (for all passive backplanes) and ‘BP-x-PLUS’ (for all backplanes with a built-in power supply) further in this document. The part numbers with the ‘-PLUS’ suffix use the green pluggable terminal blocks for the inter-rack data connectors, while the old (will be referred to as ‘BA-x’) backplanes use black crimp connectors (Harwin Datamate M80) for that purpose.

All Kingfisher Plus+ backplanes are designed to be surface mounted. Mounting brackets (2 pieces) are supplied for user fitting. The backplanes can also be mounted in a 19" rack (see “Accessories” chapter for details).




Module Dimensions

Module mounted on a backplane

Installing Modules onto a Backplane




BA-x-PLUS Backplanes

2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor A BA-4-PLUS backplane is designed to be used with a PC-1 power and processor module. The PC-1 is installed into the leftmost slot and any other modules can be installed in the remaining 3 slots.

Please use a BA-40-PLUS backplane if requiring a 4-slot backplane for use with a CP-xx processor and a PS-xx power supply.

BA-4-PLUS backplane

For information on the BA-4-PLUS backplane connectors please refer to the “Backplane Connectors” section below.




2.2.2 BA-40-PLUS: 4-slot Backplane A BA-40-PLUS backplane is identical to a BA-4-PLUS backplane but with the J6 Power Connector and the PC-1 Power Connector are removed.

This backplane is designed to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.

BA-40-PLUS backplane





2.2.3 BA-6-PLUS: 6-slot Backplane A BA-6-PLUS six-slot backplane is designed to support any power supply, IO or communications module in any slot position. This backplane is intended to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.

BA-6-PLUS backplane





2.2.4 BA-12-PLUS: 12-slot Backplane A BA-12-PLUS twelve-slot backplane is designed to support any power supply, IO or communications module in any slot position. It is intended to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots.

BA-12-PLUS backplane


2.2.5 BA-x-PLUS-Specifications

Specifications of the BA-x-PLUS backplanes are summarised in the table below.

PARAMETER VALUE

Operating Temperature Range -40 to +85 °C

Rack Number 1 - 4




BP-x-PLUS Backplanes BP-x-PLUS backplanes are available as two-, four- and six- slot versions (BP-2-PLUS, BP-4-PLUS and BP-6-PLUS correspondingly).

The BP-x-PLUS backplanes serve the same purpose as the BA-x-PLUS backplanes, the main difference is that these backplanes have an integrated 5 VDC / 5 A power converter on board and, as a result, do not require a PS-xx power supply for the RTU to work. In order to operate, the BP-x-PLUS backplanes need only be powered from a single external 12 VDC power source. If a backup power source is required then a 12 V lead-acid battery can be connected in parallel with an input power supply with its output adjusted to 13.8 V level. The BP-x-PLUS backplanes do not provide any battery charging means by themselves.

BP-2-PLUS backplane




BP-4-PLUS backplane

BP-6-PLUS backplane

For information on the BP-x-PLUS backplanes connectors please refer to the “Backplane Connectors” section below.




The BP-x-PLUS backplane provides switchable 12VAUX output for powering extra circuits (e.g. an external radio) with its voltage derived directly from the BP-x-PLUS input and therefore not regulated. The output is in ON-state by default and can be controlled by the Toolbox PLUS software or user logic (implementation pending).

The status of BP-x-PLUS power rails is indicated by corresponding LED indicators shown on the figure below.

BP-x-PLUS LED Indicators

5V-rail status (top row of LEDs):

• Green (left) LED — 5 VDC power is normal. • Red (right) LED — 5 VDC level is out of range due to overload or circuit fault.

12VAUX-rail status (bottom row of LEDs):

• Green (left) LED — 12 VDC AUX power is turned ON and is normal. • Red (right) LED — 12 VDC AUX level is out of range due to overload or circuit fault. • Both LEDs OFF — 12 VDC AUX power is turned OFF.

The BP-x-PLUS backplanes offer the following protection features:

• Input is protected from overvoltage and reverse polarity (crowbar protection level set to 18 VDC), and from overcurrent (a polyfuse rated at 6 A @ 25 °C).

• 5 VDC output is protected from overload (5 A maximum output current).

• 12 V AUX output is protected from overload (2 A maximum output current).




Note that the crowbar protection circuit will latch when its voltage is either below -0.5 V or above +18.5 V (approximately). It will clamp the input power rail voltage to a very low value: ± (0.5 – 2.5) V depending on the clamp current supplied by a power source. If the power source can provide current exceeding a polyfuse trip current (3-24 A depending on the ambient temperature), it may trip also, limiting the clamp current to several milliamperes.

To recover protective circuit after tripping, the input voltage should be removed completely. A 5-10 s pause before re-applying input power may be required to allow for the polyfuse to cool down if it has tripped.

WARNING. Install BP-x-PLUS as close to the power source as practically possible. To avoid tripping of the overvoltage / reverse polarity protection circuit, that may occur due to voltage overshoots caused by the parasitic inductances of the long wires, the power wires length should not exceed 3 m. Install a 330 - 1000 µF (rated 25 V minimum) capacitor as close as practical to the input power terminals of the BP-x-PLUS backplane if high levels of electromagnetic interferences may be present at the installation site.

There are no adjustable or serviceable parts on the BP-x-PLUS backplanes. Since these backplanes are not configurable, their rack number is always fixed to #1 and their slot numbering always starts from 1. Therefore, only one BP-x-PLUS backplane can be used in the RTU. However, Power and/or Data Connectors to extend the RTU using BA-x-PLUS backplanes are available.

Block-diagram of the BP-x-PLUS backplanes is shown in the figure below.

BP-x-PLUS backplane Block Diagram




Specifications of the BP-x-PLUS backplanes are summarised in the table below.

PARAMETER VALUE COMMENT

Operating Temperature Range -40 to +85 °C

Input Power Rating 10-16 VDC; 5 A

Output Power Rating (5V output)

5 VDC ± 5%; 5 A max

Derated at high temperatures, refer to the “BP-x-PLUS 5V Output Derating Curve” graph below for details.

Output Power Rating (12V AUX output)

10-16 VDC; 2 A max

Non-regulated. The output is ON by default but can be controlled by processor software1.

Rack Number 1 Not configurable.

Slot Numbers

1 - 2 2-slot version (BP-2-PLUS). Not configurable.



Notes: 1) Implementation pending.

BP-x-PLUS 5V Output Derating Curve

The BP-x-PLUS backplanes are fully compatible with all other Kingfisher Plus+ modules except Power Supply units (PS-xx). Although accidental installation of PS-xx module into a powered backplane will not cause any damage, this is not recommended as the BP-x-PLUS modules are intended to supply power independently and not designed to share power with other power sources.




Backplane Connectors There are several connectors located at the right-hand side of the Kingfisher Plus+ backplanes which are used for wiring power and/or signals outside of a backplane. The type and quantity of the connectors depend on the model of the backplane. Please refer to the pictures of the backplanes shown earlier in this chapter and/or the connector reference designators to determine which connectors exist on your backplane. All connectors are described in the table below.

Designator Connector Type Connector Pinout

J14 6-pin 4.2 mm male header (white).

Molex P/N 39-28-8060 (mating part P/N 39-01-2065).

Note: the ‘24V’ pin may be used for other purposes such as time-synchronisation between backplanes.

J13, J15* 7-pin 3.5 mm male header (green).

Phoenix P/N 1843651 (mating part P/N 1840418).

J6 9-pin 5.08 mm male header (orange).

Weidmuller P/N 1520260000 (mating part P/N 1716390000).

J5 4-pin 3.5 mm male header (green).

Phoenix P/N 1843622 (mating part P/N 1840382).

* - J15 for BA-x-PLUS backplanes only; not present on BP-x-PLUS units.

It is recommended to cover all unused backplane connectors in harsh environmental conditions (e.g. by fitting the mating connector). The parts suitable for the Power and Data connectors are listed in the table above. The suitable mating parts for the 32-pin module slot connectors are listed below:

1. Oupiin P/Ns: 9001-3532 / 9001-3520 / 9001-3732 / 9001-3720.

2. Harting P/Ns: 09 22 132 7922 / 09 22 132 6922 / 09 22 132 2922 / 09 22 132 7921 / 09 22 132 6921 / 09 22 132 2921.




Linking Backplanes

2.5.1 Creating Racks A single RTU can consist of up to 64 modules by using a six-bit number adopted in the Kingfisher Plus+ systems:

In order to organise connection of up to 64 modules into one RTU, backplanes should be linked together into ‘racks’. Each rack can have a maximum of 16 slots. A single RTU can support up to 4 racks thus providing a total of 64 module slots.

The figure below shows one full rack (16 slots) consisting of a BA-40-PLUS linked to a BA-12-PLUS.

The BA-x-PLUS backplanes have an IN and an OUT connectors (J13 and J15 described earlier in the “Backplane Connectors” section) linking them to the RTU data bus. The BP-x-PLUS backplanes have only one (OUT) connector linking them to the RTU data bus (J13). The reason for this is that the BP-x-PLUS backplane must always be the first in an RTU.




2.5.2 Backplane Cables While building an RTU, it may become necessary to organise signals and/or power connections between backplanes. To implement the required interconnections the cables will be required that can be either assembled (based on the data on the backplane connectors provided above) or ordered from Semaphore. The following cables are available for order:

Order Code Description To be used with Backplanes (Connectors)

POW ER CABLES

BPC-01 Interrack 6-way Power Cable, 0.6 m All (J14 to J14)

BPC-02 Interrack 6-way Power Cable, 1.1 m All (J14 to J14)

COMM CABLES

BAC-01 Interconnect cable, 0.5 m, 8-pin clip on both ends BA-x (J13/J15 to J13/J15)

BAC-02 Interconnect cable, 1.0 m, 8-pin clip on both ends BA-x (J13/J15 to J13/J15)

BAC-INT-01 Interconnect cable, 0.5 m, 8-pin clip to 7-pin terminal plug

BA-x (J13/J15) to BA-x-PLUS (J13/J15) BA-x (J13/J15) to BP-x-PLUS (J13)

BAC-INT-02 Interconnect cable, 1.0 m, 8-pin clip to 7-pin terminal plug

BA-x (J13/J15) to BA-x-PLUS (J13/J15) BA-x (J13/J15) to BP-x-PLUS (J13)

BAC-PLUS-01 Interconnect cable, 0.5 m, 7-pin terminal plug on both ends

BA-x-PLUS (J13/J15 to J13/J15) BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)

BAC-PLUS-02 Interconnect cable, 1.0 m, 7-pin terminal plug on both ends

BA-x-PLUS (J13/J15 to J13/J15) BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)

SPECIAL CABLES

BPC-02-GPS

Interrack 2-way Cable, 1.1 m (24V / SYNC and GND pins only) To distribute GPS time-sync pulse across racks without power distribution

All (J14 to J14)

BPC-SPLIT BPC Splitter Cable, 6-way, 0.1 m All (J14) to 2x BPC-0x / BPC-02-GPS cables




2.5.3 Setting Bus Terminators Each BA-x-PLUS backplane has data bus terminators (resistors) that can be Enabled or Disabled by the first six switches of the DIP-switch installed on the backplane PCB (please refer to the information printed on the backplane board surface for exact details on possible switch configurations). A chain of backplanes requires the terminators to be switched ON (Enabled) for the first and the last backplane in the chain. All intermediate backplanes must have terminators switched OFF (Disabled). The BP-x-PLUS backplanes have their terminating resistors always enabled as they are designed to be the first backplane in a rack.

IO-bus terminators control switches CM-bus terminators control switches

2.5.4 Setting Rack Number While the rack number value of the BP-x-PLUS backplanes is always fixed (and equal to #1), the BA-x-PLUS backplanes allow that their rack number to be configured with the switches #7 and #8 of the on-board DIP-switch (please refer to the information printed on the backplane board surface for exact details on possible switch configurations).

Rack Number control switches

The following table outlines the DIP switch configuration required for the most recent hardware revisions of the BA-backplanes (v2.x and v3.x). For previous hardware versions please refer to the Superseded Products manual available on Semaphore Helpdesk.



http://helpdesk.servelec-semaphore.com/semaphore/Knowledgebase/Article/View/144


Total Number of Racks in RTU

Switch Settings 1 Rack 2 Racks 3 Racks 4 Racks

1st Rack

2nd Rack

3rd Rack

4th Rack




Backplane Switch Configuration Example (revision 2.x and 3.x):

Note that supplementary to the data bus connections shown, each backplane requires either a Power Supply Module installed or a power cable connected to J14.

For previous backplane hardware revisions please refer to the Superseded Products Manual.




2.5.5 Setting Slot Number Range Backplanes have hard-coded slot numbers which, for the BA-x-PLUS modules, can be set to four different ranges determined by the rack number (please refer to the ‘Setting Rack Number’ section of this chapter for details). The BP-x-PLUS backplanes slot numbering range is not configurable and always starts from #1.

The BP-x-PLUS, BA-6-PLUS and BA-12-PLUS backplanes occupy the start of each rack, while the BA-4-PLUS (and BA-40-PLUS) occupies the last four slot numbers in each rack (e.g. #13 to #16 in Rack 1). Starting from v3.3, the BA-4-PLUS / BA-40-PLUS backplanes can be used in the beginning of the rack as well. To achieve this, the BA-4-PLUS / BA-40-PLUS backplanes are equipped with an extended 10-way DIP-switch. Switches #9 and #10 are used to configure the desired slot numbering range (see the figure below for possible switch configurations).

Slots numbered from 1 to 4 (for Rack 1) Slots numbered from 13 to 16 (for Rack 1)

Slot Number Range control switches (BA-4-PLUS & BA-40-PLUS only)

The configuration when both #9 and #10 switches are turned ON (factory default setting) is equal to the left picture above (Slots are numbered from 1 to 4 for Rack 1) but increases current consumption from the 5V rail by 3 mA approximately. The configuration with both #9 and #10 switches turned OFF should not be used as the slot numbering setting becomes undefined.

An example of the possible RTU configuration, explaining rack and slot numbering sequence, is shown on the picture below.




3. POWER SUPPLY MODULES

Overview The Kingfisher Plus+ Power Supply Modules allow real time monitoring of currents, voltages and temperatures supplied to the RTU and the backup battery. The monitoring capability also allows the RTU to determine when a supply has failed if in a redundant configuration.

If fitted, auxiliary supplies can be overridden manually or by logic to allow for external equipment or sensor loops to be shut down or reset.

PS-x2 and PS-x1 Power Supply Modules

3.2.1 Overview • Monitoring of rail voltages, supply & battery currents and temperature • AC or DC input • Support for redundancy (several supplies per backplane) • Isolated DC output • Sealed Lead Acid battery connection with charging/monitoring and low voltage

protection • Software controlled power to the Backplane and Aux Outputs

Note: PS-x1 is a SUPERSEDED product and is not being manufactured currently.

Fire Risks

A supply voltage outside the specified limits may cause fire.

Risques d'Incendie

Une tension d’alimentation en dehors des limites spécifiées peut provoquer un incendie.




Electrical Hazards

Only appropriately qualified and trained personnel can install and service this equipment.

Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide

appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit

breaker, depending on installation) before performing any operation on this product.

Disconnect power cord from the Power Supply Module before wiring, removing or servicing.

Failure to do so may cause fire and may result in a serious personnel injury or even death.

Risques Électriques

Seul le personnel qualifié et formé peut installer et entretenir cet équipement.

L’alimentation secteur doit être raccordée conformément aux règles et réglementations nationales de câblage locales. Les

équipements du bâtiment doivent assurer une protection appropriée contre les courts-circuits.

Toujours enlever la tension d’alimentation (en débranchant le cordon d’alimentation de la prise d’alimentation secteur ou en

coupant le disjoncteur externe en fonction de l’installation) avant d’effectuer toute opération sur ce produit.

Débranchez le cordon d’alimentation du module d’alimentation avant le câblage, le retrait ou l’entretien.

Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves du personnel ou même la mort.

Warning

The Earth Terminal in the mains power inlet provides only FUNCTIONAL EARTH connection.

It cannot be relied upon for safety purposes.




Avertissement de Sécurité

Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE.

On ne peut pas compter sur lui pour assurer la sécurité.

Warning

If an RTU has more than three AC Power Supplies (PS-1x) installed then the Earth Terminals in the mains power inlets must be connected to PROTECTIVE EARTH in accordance with local

safety requirements.

Refer to Appendix A for wiring recommendations.


Si une unité terminale distante (RTU) a plus de trois alimentations alternatives (PS-1x) installées alors les connections de terre des

prises d’alimentations secteurs doivent être reliées à la TERRE DE PROTECTION conformément aux exigences de sécurité locales.

Reportez-vous à l’annexe A pour les recommandations de câblage.

The PS-x2/PS-x1 modules provide AC-DC (PS-12 and PS-11 only) or DC-DC conversion from mains power into 12 VDC and 5 VDC for the backplane, as well as 12 VDC and optional 24 VDC auxiliary outputs. Both auxiliary outputs can be controlled by the RTU logic configuration.

An isolated 24 VDC output rated at 6 W (250 mA) is an option available for powering a limited number of analogue loops or digital circuits. It cannot be used with inductive loads such as coils, contactors etc. Power for these is to be provided from a separate supply.

The PS-x2/PS-x1 is supplied with an internal temperature sensor to monitor its PCB temperature and an optional external temperature sensor to monitor a backup battery. When the battery is connected, the supplied external sensor should be mounted in the vicinity of the battery negative terminal to ensure correct temperature compensation. If readings from the external temperature sensor are out of range, internal sensor data is used. Boost charge is disabled when external temperature sensor is faulty, not connected or if the battery temperature is out of range. Please note the charge circuitry is designed for float operation and short term boost of batteries already charged and in good condition. Use of this supply on flat or fully discharged batteries may cause damage to the module.

The 12V Rail Voltage, Supply Current, Battery Current, internal and, optionally, external temperature monitoring circuits, various status and controls registers enable the RTU to




monitor and to control all functions of the PS-x2/PS-x1 module. The Processor Module has access to many of these values as analogue and digital points in the system.

If the Mains power interrupted and the system is powered from the backup battery, the PS-x2/PS-x1 enters Low Battery Shutdown when battery voltage drops below 10.6 V. All outputs are switched OFF for battery preservation, including Backplane power as well – effectively meaning that the whole RTU will be shut down. PS-x2/PS-x1 switches itself to the lowest power consumption mode possible, further preserving the battery from deep discharge. PS-x2/PS-x1 checks rail voltage regularly, and the Backplane power will be restored when +12V_RAIL voltage rises above 12.4 V (if no Mains present) or 11.2 V (if Mains present).

Besides various hardware protection features, PS-x2/PS-x1 firmware provides additional protection from overload. If output power exceeds its maximum specified power, the Switch-mode Power Supply (SMPS) will enter an Overload Mode. Its output voltage will be ramped down and, if overload still persists when it reaches 10.0 V (minimal output voltage), it will switch all outputs off, similar to Low Battery Shutdown. PS-x2/PS-x1 will attempt to switch the Backplane ON again regularly. RTU power will be restored permanently when overload condition is removed.

Several Power Supply modules of any type can be installed on a backplane thus providing redundant and alternative power source configurations. Note, however, that while some load sharing does occur naturally if more than one Power Supply Unit is active on a backplane, the PS-x2/PS-x1 modules do not support true load sharing with output currents balancing. For this reason, several Power Supplies can be installed in parallel for the purpose of redundancy only, and the total power budget should not exceed the limits specified for a single (least capable) Power Supply Unit present in a system.

PS-x2/PS-x1 modules can be swapped while RTU is running, providing that there is an alternative power source in the system for the RTU to be powered during such swap – e.g. another (redundant) PS-xx module.

3.2.2 Options and Ordering Info Since PS-x1 modules are superseded, this section does not contain ordering information for PS-11 and PS-21 modules.

Unless explicitly noted, all hardware versions of PS-x2 modules are described in this manual. The newer PS-x2 version (v1.5) has some differences in the module features and specifications comparing with its predecessor (v1.3); in particular the available current for the 5V rail has increased from 3 A to 5 A and the operating temperature range has been extended to -40 °C to +85 °C.

The PS-x2 modules with ‘-C’ suffix in their Order Code have an additional isolated DC-DC converter board DC-10 installed into the main PS-x2 board. It provides isolated 24 V power to the 24VAUX output.

PS-x2 options, ordering info and main specification differences are summarised in the table below:




Order Code H/W version

Mains Input Power

24VAUX power

5 V max current, A

Operating temperature, °C

3.0 5.03 -20 - +70 -40 - +85

PS-12-0 v1.31

100–240 V, 50-60 Hz

or 96-300 VDC

v1.52

PS-12-C v1.31

v1.52

PS-22-0 v1.31

20-60 VDC

v1.52

PS-22-C v1.31

v1.52

Notes: 1) And earlier versions (here and further in this Manual). 2) And later versions (here and further in this Manual). 3) Linearly derated to 4.0 A from +60 °C to +85 °C.




3.2.3 Theory of operation A combined block-diagram of the PS-x2 and PS-x1 modules is shown on the picture below.

PS-x2/PS-x1 Block Diagram

When Mains power is supplied to the SMPS, it generates a DC output voltage on the internal +12V_RAIL of the PS-x2/PS-x1. Voltage level on this rail is controlled by the microcontroller (MCU). Supply Current Sensor is used to measure current supplied by the SMPS.

When 12VBP SWITCH is activated, power from the internal rail is fed to the backplane and to the 5VBP converter that powers 5VBP rail on the backplane, providing power to all modules installed there. Both 12VBP and 5VBP outputs are connected to the backplane outputs via ideal diodes that allow for redundant connection of the PS-x2/PS-x1 modules.

24VAUX ISOLATED Converter (option ‘-C’ only) and 12VAUX SWITCH can be switched ON and OFF with user logic, providing power to the corresponding outputs of the field connector as required.

Any device connected to the ‘B’ terminals of the Field Connector (J22 for PS-x2; ), including a battery, is connected directly to the internal +12V_RAIL of the PS-x2/PS-x1. Battery Current Sensor is used to measure current flowing to or from ‘B’ terminals. Assuming that a battery is connected to these terminals, positive current flows into the battery when it is charged and negative current flows out of the battery when it supplies power to the RTU.

The PS-x2/PS-11 battery input has a crowbar protection circuit with series polyfuse to protect it from over-voltage and reverse-polarity connection. The crowbar protection circuit will latch when its voltage is either below -0.5 V or above +18.5 V (approximately). It will clamp the input power rail voltage to a very low value: ± (0.5 – 2.5) V depending on the clamp current supplied by a power source. If the power source can provide current exceeding a polyfuse trip current (2-16 A depending on the ambient temperature, see the RUE(F)400 fuse specifications for further details), it may trip also, limiting the clamp current to several milliamperes. To recover protective circuit after tripping, the input voltage should



http://www.te.com/catalog/pn/en/RF2561-000


be removed completely. A 5-10 s pause before re-applying input power may be required to allow for the polyfuse to cool down if it has tripped.

3.2.4 Battery Charging PS-x2/PS-x1 power supply modules are designed with provisions for the backup battery charging and monitoring. They can charge 12 V Sealed Lead Acid (SLA) batteries with the capacity from 6 Ah to 25 Ah connected to the ‘B+’ and ‘B-’ terminals. SLA batteries of higher capacity or unsealed (wet) lead-acid batteries can be used if required but the PS-x2/PS-x1 will not be able to fully charge them and to maintain / properly calculate its internal charge level (required for making correct decisions by charging control algorithms). As a result, their performance cannot be guaranteed.

When more than 100 mA is drawn out of (or is supplied to) ‘B’ terminals (e.g. when a battery is connected), the PS-x2/PS-x1 logic assumes that a fully discharged battery has just been connected and starts its Boost charge. Boost charge is not possible if external temperature sensor is not connected, or it is faulty, or when battery temperature is below -20 °C or above +60 °C. After boost charging the battery for the estimated time (3-10 hours, BATT DET and BATT BST LEDs ON, see below for details), the power supply will switch to Float charging (BATT DET and BATT FLT LEDs ON).

PS-x2/PS-x1 maintains an estimated charge level of the attached battery and this value is used for making a decision for switching to the Boost charge when the battery charge level drops below 40% of its nominal capacity. For this algorithm to work properly, a correct battery capacity should be provided to the PS-x2/PS-x1 via the Toolbox software configuration setup. When battery is initially detected, it is assumed to be fully discharged. Boost charging time mentioned earlier is calculated based on the provided battery capacity value. Estimated battery charge level is increased by integrating measured charge current flowing into the battery over the time till it reaches the stated battery capacity. When battery current becomes negative (for instance, if Mains power is out and the RTU runs from the battery), this current is integrated over the time and subtracted from the estimated battery charge level till it reaches zero.

Please note that PS-x2/PS-x1 is not able to distinguish between the real battery connection and the connection of any other (generic) load or power source to the battery terminals, as it detects such connections only by measuring the Battery Current. As a result, all battery status related LEDs may exhibit several various patterns depending on kind of load / source connected to the ‘B’ terminals.




3.2.5 Module LEDs

PS-x2 LEDS

PS-12-x PS-22-x

LED State Description

OK

ON Module operating normally.

960 ms ON, 80 ms OFF No communications with RTU Processor Module.

OFF Power off or Module fault.

VIN ON Mains present / SMPS running1,2.

OFF Mains not present / SMPS not running.

OVLD

65 ms ON, 450 ms OFF

In Overload Mode. Output voltage is being ramped down (when powered from Mains).

OFF PS-x2 is not in Overload Mode.

Tx ON The PS-x2 is sending data to Processor Module via Backplane.

OFF No data being sent to Processor Module.

Rx ON Any RTU module sends data via Backplane.

OFF No data being sent by other modules.

BATT (Battery) LEDs

DET ON Battery or load or DC source connected to B terminals.

OFF No battery nor load nor DC source connected to B terminals3.

FLT ON Battery is slow (float) charging.

OFF Battery is not in Float Charge mode.

BST

ON Battery is fast (boost) charging.

10 ms ON, 2.0 s OFF

Boost charge is not possible (either external temperature sensor not connected or it is faulty or battery temperature is out of -20 °C to +60 °C).

OFF Battery is not in Boost Charge mode.





SUPP ON Battery sources current of more than 0.1 A4 to the PS-x25.

OFF Battery does not supply current to the PS-x2.

LOW

ON +12V_RAIL voltage has fallen below 11.5 V5.

40 ms ON, 5.0 s OFF Battery Low Shutdown.

OFF +12V_RAIL voltage has raised above 12.4 V5.

OUT (Outputs) LEDs

12BP ON Backplane power is switched ON.

OFF Backplane power is switched OFF (either start-up or shutdown).

5BP ON Backplane power is switched ON.


12AUX ON 12VAUX is switched ON.

OFF 12VAUX is switched OFF.

24AUX ON 24ViAUX is switched ON.

OFF 24ViAUX is switched OFF.

FAULT LEDs

12BP ON Backplane power is switched ON and 12VBP is below 9 V5.

OFF Backplane power is switched OFF or it is ON and 12VBP is above 9 V5.

5BP ON Backplane power is switched ON and 5VBP is below 2 V5.

OFF Backplane power is switched OFF or it is ON and 5VBP above 2 V5.

12AUX ON 12VAUX is switched ON and it is below 9 V5.

OFF 12VAUX is switched OFF or it is ON and above 9 V5.

24AUX ON 24ViAUX is switched ON and it is below 18 V5 (or no DC-10 / Option –C

module installed).

OFF 24ViAUX is switched OFF or it is ON and above 18 V5.

Notes: 1) May keep switching ON and OFF intermittently at a very light or no load (v1.3 only). 2) May keep switching ON and OFF intermittently at very heavy loads (hardware hick-up mode). 3) Short flashes every 2 s may indicate that PS-x2 is trying to detect battery. 4) Current value given to the Processor Module is negative. 5) Approximate values.




PS-x1 LEDS

PS-11-x PS-21-x


OK1

ON Module operating normally.

960 ms ON, 80 ms OFF No communications with RTU Processor Module.

OFF Power OFF or Module fault.

Vsup1,2 ON Mains present / SMPS running

OFF Mains not present / SMPS not running.

Vb1 ON Battery detected (the current into or out of the battery exceeds 100 mA)

2.0 s ON, 40 ms OFF

No battery nor load above 100 mA nor DC source connected to B terminals.

5V1 ON Backplane power is switched ON.


Vaux1 ON Auxiliary 24 V supply is installed, switched ON and output voltage is OK

OFF Auxiliary 24 V supply is either not installed or switched OFF or output voltage is out of range

BATT CHG1

ON Battery is being charged (current into battery > 100 mA)

OFF Battery is not being charged (current into battery < 100 mA or negative)

FL1 ON Battery is in slow charging (Float Charge) mode.

OFF Battery is not in Float Charge mode.

BO1 ON Battery is fast (Boost Charge) charging mode.

OFF Battery is not in Boost Charge mode.

LO1 ON Battery voltage has reached discharge condition (< 11.5 V ± 0.2 V)

OFF Battery voltage has reached charged condition (> 12.4 V ± 0.2 V)

Notes: 1) Redundant Power Supply will have all LEDs turned ON when the Power Supply module is switched OFF. 2) If the input supply source is disconnected from the redundant Power Supply, the Vsup LED will go OFF.




3.2.6 PS-x2 Specifications PS-12 and PS-22 Power Supply Modules Specifications

Mains Power

Input PS-12-x PS-22-x

AC Rated Voltage Range (Maximum Input Current)

100 - 240 V, 50 - 60 Hz (1.5 A) Not applicable

DC Rated Voltage Range (Maximum Input Current)

96 - 300 VDC (1.5 A)

20 - 60 VDC (4.0 A)

Power Inlet

Connector PS-12-x PS-22-x

Terminal Block Plug (7.62 mm) Phoenix PC 4/3-ST-7.62 Dinkle EC762V-03P Phoenix GMSTBA 2.5/3-G-7.62

Cable Housing (optional) Phoenix KGG-PC 4/3 (plastic)

or PS-AC-COVER-S (rubber)

Not available

PCB Header (7.62 mm) Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P

Phoenix GMVSTBR 2.5/3-ST-7.62

‘B’ Input / Output


10.5 – 16.0 VDC (4.5 A)

Backup Battery Type Sealed Lead-Acid (SLA)

Maximum Battery Capacity 25 Ah1

Output Power

Total Rated Output Power 60 W2

Output Voltage Range Maximum Current Protection Logic

Control

12 V Backplane3 10.5 - 15.6 V 4.5 A Firmware No

5 V Backplane 5 V ± 5% 3.0 A (v1.3) / 5.0 A (v1.5)4 Electronic No

Battery3 10.5 - 15.6 V 4.5 A

Polyfuse with crowbar over-voltage and reverse polarity

protection

No

12 V aux3 10.5 - 15.6 V 2.0 A Polyfuse (v1.3) / Electronic (v1.5) Yes

24 V Isolated aux5 24 V ± 5% 0.25 A Polyfuse Yes

Field Connector

Terminal Block Plug (5.0 mm) WECO 120-M-111/07 Phoenix MSTB 2.5/7-G

PCB Header (5.0 mm) WECO 120-A-111/07 Phoenix MSTB 2.5/7-ST




PS-12 and PS-22 Power Supply Modules Specifications

Monitoring

Parameter Range Accuracy

Rail Voltage (12 VBP, Battery, 12 VAUX) 9.0 - 15.6 V ± 2%

Supply Current 0.0 - 4.0 A ± 10%

Battery Current6 ±4.0 A ± 10%

External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C

Internal Temperature -20 to +80 °C ± 2 °C typ @ 25 °C

Safety Isolation / Maximum Working Voltage

Primary (Mains) to Secondary (Backplane, Field, Functional Earth) isolation

3.0 kVRMS / 4.2 kVDC In accordance with IEC 60950

Maximum Working Voltage on any contact of the Field Connector

42.4 VPEAK / 60 VDC relative to system (backplane) ground

Environment

Operating Temperature -20 to +70 °C (v1.3) -40 to +85 °C (v1.5)

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Altitude 2000 m max

Notes: 1) Batteries exceeding quoted maximum capacity can be used. However, full charging and estimated battery charge level cannot be guaranteed. 2) For PS-12 the total output power is linearly de-rated to 30 W from +65 °C to +85 °C (de-rating factor is 1.5 W / °C above +65 °C). 3) Nominal value is 13.8 V @ 25 °C. These voltages are electrically linked and are controlled by the PS-x2 module when charging a battery. They will depend only on backup battery voltage when RTU runs from the battery (e.g. when there is a Mains outage). 4) Linearly de-rated to 4.0 A from +60 °C to +85 °C (de-rating factor is 40 mA / °C above +60 °C). 5) Linearly de-rated to 100 mA from +70 °C to +85 °C (de-rating factor is 10 mA / °C above +70 °C). 6) Negative: current flows from the battery (battery supplies power)

Positive: current flows to the battery (battery is charged).




3.2.7 PS-x1 Specifications PS-11 and PS-21 Power Supply Modules Specifications

Mains Power

Input PS-11-x PS-21-x

AC Rated Voltage Range (Maximum Input Current)

100 - 240 V, 50 - 60 Hz (1.5 A) Not applicable


96 - 300 VDC (1.5 A)

20 - 60 VDC (4.0 A)

Power Inlet

Connector PS-11-x PS-21-x

Mains Connector Plug Phoenix PC 4/3-ST-7.62 Dinkle EC762V-03P

JST VHR-3M (housing) JST SVH-41T-P1.1 (contact)

Cable Housing (optional) Phoenix KGG-PC 4/3 Not available

Mains Connector PCB Header Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P JST S3P-VH

‘B’ Input / Output


12.0 – 15.0 VDC (4.5 A)

Backup Battery Type Sealed Lead-Acid (SLA)

Maximum Battery Capacity 25 Ah1

Output Power

Total Rated Output Power 60 W2

Maximum total current 4.5 A

Output Voltage Range Maximum Current Protection Logic

Control

12 V Backplane3 10.2 - 14.4 V 4.5 A PS-11 : Electronic PS-21 : No No

5 V Backplane 5 V ± 5% 3.0 A Electronic No

Battery3 10.8 - 15.0 V 4.5 A Polyfuse4 No

12 V Auxiliary3 10.8 - 15.0 V 4.0 A PS-11 : Electronic PS-21 : No Yes

24 V Auxiliary Isolated 24 V ± 5% 0.25 A Polyfuse Yes

Field Connector

Terminal Block Plug (5.0 mm) WECO 120-M-111/07 Phoenix MSTB 2.5/7-G

PCB Header (5.0 mm) WECO 120-A-111/07 Phoenix MSTB 2.5/7-ST




PS-11 and PS-21 Power Supply Modules Specifications

Monitoring

Parameter Range Accuracy

Rail Voltage (12 VBP, Battery, 12 VAUX) 9.0 - 15.6 V ± 2%

Supply Current 0.0 - 4.0 A ± 10%

Battery Current5 ±4.0 A ± 10%

External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C

Internal Temperature 0 to +80 °C ± 2 °C typ @ 25 °C

Safety Isolation / Maximum Working Voltage

Primary (Mains) to Secondary (Backplane, Field, Functional Earth) isolation

3.0 kVRMS / 4.2 kVDC In accordance with IEC 60950

Maximum Working Voltage on any contact of the Field Connector

42.4 VPEAK / 60 VDC relative to system (backplane) ground

Environment

Operating Temperature -20 to +70 °C



Notes: 1) Batteries exceeding quoted maximum capacity can be used. However, full charging

and estimated battery charge level cannot be guaranteed. 2) For ambient temperatures for up to +50 °C. 3) Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and are

controlled by the PS-x1 module when charging a battery. They will depend only on backup battery voltage when RTU runs from the battery (e.g. when there is a Mains outage).

4) In addition to polyfuse, the PS-11 module has a crowbar over-voltage and reverse polarity protection. The battery input of the PS-21 module does not have auto-resetting protection against reverse-polarity. Please ensure the battery is connected correctly.

5) Negative: current flows from the battery (battery supplies power) Positive: current flows to the battery (battery is charged).




3.2.8 Wiring Diagrams

Safety Warning

Ensure that the power cord is disconnected from the power source before uncoupling it from the PS-x2/PS-x1 mains power inlet.

Disconnect power cord from the PS-x2/PS-x1 before wiring, removing or servicing the module.

Connect PS-x2/PS-x1 to Mains supply in accordance with the relevant requirements of national wiring regulations.

Mains connections of PS-x2/PS-x1 must comply with all installation requirements listed in this Manual.


Assurez-vous que le cordon d’alimentation est débranché de la source d’alimentation avant de le débrancher de l’entrée

alimentation secteur du module PS-x2/PS-x1.

Débranchez le cordon du module PS-x2/PS-x1 avant le câblage, le retrait ou la réparation du module.

Connectez le module PS-x2/PS-x1 à l’alimentation secteur en respectant toutes les règles applicables des réglementations et

normes électriques locales.

L’alimentation secteur connexions du module PS-x2/PS-x1 doit se conformer à toutes les exigences d'installation répertoriées dans ce

manuel.




Power Supply with battery backup

PS-x2/PS-11 Wiring Diagram

PS-21 Wiring Diagram




Notes: 1. The PS-12 and PS-11 modules can be powered using either AC (100 – 240 VAC) or DC (96 – 300 V). The modules cannot be powered simultaneously via both AC and DC sources. 2. AC mains power can be supplied to the PS-12 and PS-11 modules only. WARNING. Supplying AC mains power to a PS-22 or PS-21 module will destroy it. 3. DC mains power to the PS-12 and PS-11 modules can be supplied in any polarity. 4. DC mains power to the PS-22 and PS-21 modules can be supplied only as shown on the diagrams above. WARNING. Supplying DC mains power to the PS-22 or PS-21 module in reverse polarity may severe damage the modules, as there is no protection against reverse polarity on this input. 5. External temperature sensor should be installed directly onto the battery near its negative terminal. Connect the negative sensor wire to B- or R- contact of the Field Connector. WARNING. Connecting the temperature sensor in reverse polarity will cause permanent damage to the sensor. 6. The polarity of the temperature sensor wires are colour-coded. One of the following colour pairs will be supplied based on availability:

Positive Terminal (+) connected to TS

Negative Terminal (-) connected to B- or R-

Black striped White Black

Grey Black

White Black

Red Black

Black Black striped Grey




Powered from 12 – 16 VDC Supply:

PS-x2/PS-x1 Wiring Diagram

Notes: 1. A battery, a solar system or any other low voltage DC supply can be connected to the ‘B’ terminals to power the PS-x2/PS-x1 module.




PSU-x AC Power Supply Unit The PSU-x AC to DC power supply module is intended to be used as a standalone unit to provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-x units do not have any power monitoring functions. Power monitoring is performed by the PC-1 processor module.

The range of supplied PSU-x modules consists of three unit types (PSU-3, PSU-4 and PSU-5), specifications of each are shown below.

Fire Risks

A supply voltage outside the specified limits may cause fire.

Risques d'Incendie

Une tension d’alimentation en dehors des limites spécifiées peut provoquer un incendie.

Warning

The Earth Terminal in the mains power inlet provides only FUNCTIONAL EARTH connection.

It cannot be relied upon for safety purposes.


Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE.

On ne peut pas compter sur lui pour assurer la sécurité.




Electrical Hazards


Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide

appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit

breaker, depending on installation) before performing any operation on this product.

Disconnect power cord from the Power Supply Module before wiring, removing or servicing.




L’alimentation secteur doit être raccordée conformément aux règles et réglementations nationales de câblage locales. Les

équipements du bâtiment doivent assurer une protection appropriée contre les courts-circuits.

Toujours enlever la tension d’alimentation (en débranchant le cordon d’alimentation de la prise d’alimentation secteur ou en

coupant le disjoncteur externe en fonction de l’installation) avant d’effectuer toute opération sur ce produit.

Débranchez le cordon d’alimentation du module d’alimentation avant le câblage, le retrait ou l’entretien.

Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves du personnel ou même la mort.




Specifications

PSU-x Power Supply Modules Specifications

Parameter PSU-3 PSU-4 PSU-5

Input Supply 90 to 260 VAC 50/60 Hz, 125 to 370 VDC

Output Voltage Adj. Range 13.5 to 16.5 VDC

Output Voltage (factory preset) +13.8 VDC

Max Output Current* 2.8 A 4 A 5 A

Load Capacity* 40 W 60 W 70 W

Isolation (AC input to DC output) 3 kVAC

Isolation (AC input to Functional Earth) 1.5 kVAC 2 kVAC 1.5 kVAC

Connector Screw Terminals

Operating Temperature* -10 to +60 °C -25 to +70 °C

Storage Temperature (at 10 – 95 % RH) -20 to +85 °C -40 to +85 °C


Weight (without mounting bracket) 440 g 510 g 410 g

*) Refer to the “PSU-x Output Derating Curve” graph below.

PSU-x Output Derating Curve




PSU-x Block Diagram The block diagram of the PSU-x modules is shown below.

PSU-x Block Diagram

PSU-x Mounting

PSU-x Mounting and Connections




Calculating Power Requirements This chapter aims to assist you in selecting an appropriate power supply module/s and backup battery for your RTU. It also allows the power requirements of the RTU to be checked to ensure the power supplies are not overloaded.

Note that there is an Excel™ spreadsheet that can perform the following calculations automatically available from “Kingfisher RTU Power Budget, Backup Battery and Solar Panel Calculator”.

3.4.1 Total Current Consumption

PS-22 Typical current consumption at various DC voltages (mA)

Input Voltage 20 V 40 V 60 V

Basic Module, no options 34 20 19

24 VDC Aux Converter Installed 49 27 25

PS-12 Typical efficiency at various AC supply voltages

Input Voltage 100 V 170 V 240 V

Efficiency 85% 87% 88%

Note: No DC-DC converter installed.

Communications/Processor Modules current consumption (mA at 13.8 VDC)

Item CP-12 / MC-12 CP-21 CP-30 / MC-31

Basic Module, no options 70 147 135

PC-1 Typical current consumption (mA at 13.8 VDC)

Bare Module 24 V Aux Converter Installed

Option S Board Installed

Option R Board Installed

Option P Board Installed

54 +53 59 62 59

For Communications Option Boards please refer to the 5 V Rail Overload Check chapter.






IO Module typical current consumption (mA at 13.8 VDC)

Part number

24 V Converter

OFF

24 V Converter

ON

Extra current

per Analogue Input ON

Extra current

per Analogue

Output ON

Extra current

per Digital

Input ON

Extra current

per Digital Output

ON

Absolute maximum

current draw

AI-1 11 80 +50 [+0] - - - 480

AI-10 v1.x 25 185 +62 [+3] - - - 681

AI-10 v2.x 15 50 +38 [+0] - - - 354

AO-3 5 180 - +50 - - 380

DI-5 23 - - - +7 [+2] - 135

DI-10 40 - - - +11 [+5] - 216

DO-1 7 - - - - +31 255

DO-2 7 - - - - +13 215

DO-5/6 3 - - - - +1 19

IO-2 5 - - - +7 [+3] +12 157

IO-3 10 53 +46 [-1] +42 +10 [+1] +12 367

IO-4 8 44 +44 [-2] - +9 [+1] +12 228

IO-5 13 97 +89 [0] +42 +14 [2] +12 389

Note: Values shown are for inputs powered by the IO module itself when power is available from the 13.8 VDC supply. Values in square brackets ‘[ ]’ denote current consumption when inputs are powered by an external supply.

Relay Output Modules power consumption:

Item Per Output Maximum Consumption

TEL-REL 02 530 mW 8.5 Watts



Superseded Communications Modules current consumption (mA at 13.8 VDC)

Item CP-11 / MC-11 / MC-30

Basic Module, no options 165

Superseded IO Module typical current consumption (mA at 13.8 VDC)

Part number

24 V Converter

OFF

24 V Converter

ON

Extra current per Analogue

Input ON

Extra current per Analogue

Output ON

Extra current per Digital Input ON

Extra current per Digital Output ON

Absolute maximum

current draw

AO-2 11 115 - +55 - - 335




MC-xx / CP-xx Option Board typical 5 V Rail consumption (mA at 13.8 VDC)

Option Board Type Port label Consumption

A3 Fibre Optic Ethernet Board A3 272

Dial (PSTN) D 75

Fibre Optic Serial F 23

HART H 9

Isolated Serial (RS-232) I 32

Dual Isolated Serial I2 43

Private Line or Analogue Radio Interface L 9

2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving

R3

41 35

900 MHz (1 W) Spread Spectrum Radio: Transmitting Receiving

R2 / R4

275 41

T3 Ethernet Option Board T3 136

3.4.2 5 V Rail Overload Check The PS-12 and PS-22 modules supply 5 VDC to the backplane for powering modules. A maximum of 3 A (5 A for PS-x2 v1.5 or above) can be drawn on the 5 VDC rail from each power supply module.

Please ensure that this limit is not exceeded by totalling the 5 V current requirements for your RTU.

CP-xx and MC-xx typical 5 V Rail current consumption (mA from 5 VDC)

CP-11 MC-11 MC-30

CP-12 MC-12 CP-21 CP-30

MC-31

310 150 360 290




CP-xx and MC-xx Option Boards typical 5 V Rail consumption (mA from 5 VDC)

Option Board Type Port label Consumption

ACTIVE

A3 Fibre Optic Ethernet A3 600

Dial (PSTN) D 165

Fibre Optic Serial F 50

HART H 20

Isolated Serial (RS-232) I 70

Dual Isolated Serial I2 95

Private Line or Analogue Radio Interface L 20

2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving

R3

100 85

900 MHz (1 W) Spread Spectrum Radio: Transmitting Receiving

R2 / R4

670 100

T3 Ethernet T3 300

SUPERSEDED

10/100 Base-T Ethernet ENET-T 130

100 Base-FX (Fibre Optic) Ethernet ENET-A 650

10/100 Base-T Ethernet ENET-T2 310

10/100 Base-T Ethernet ENET-E 0 idle / 850 max

Serial (RS-232) SER-S 5

Line (original version) L(1) 120

Image Capture J 1000




IO Module 5 V Rail current consumption (mA from 5 VDC) Module All IO inactive All IO active and powered by module

AI-1 22 27

AI-10 15 66

AO-2 22 28

AO-3 9 30

DI-5 6 40

DI-10 54 85

DO-1 15 27

DO-2 9 39

DO-5/6 48 39

IO-2 10 37

IO-3 26 36

IO-4 23 37

IO-5 37 151

3.4.3 Total Power Load The total current required to power the RTU is as follows:

𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝑇𝑇𝑇𝑇𝐿𝐿 = 𝐼𝐼𝑃𝑃𝑃𝑃𝑇𝑇𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑇𝑇𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝑀𝑀𝑀𝑀−𝑥𝑥𝑥𝑥 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑇𝑇𝐿𝐿𝑀𝑀𝑇𝑇𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 Total Power load is therefore:

𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑃𝑃𝑇𝑇𝑃𝑃𝑃𝑃𝑃𝑃 [𝑊𝑊𝑇𝑇𝑇𝑇𝑇𝑇𝑊𝑊] =13.8 [𝑉𝑉] × 𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝑇𝑇𝑇𝑇𝐿𝐿 [𝑚𝑚𝑚𝑚]

1000

• The Total Current Load for a PS-12/22 should not exceed 4.5 A. • The Total Current Load for a PC-1 should not exceed 4 A. Loads greater than 4 A will

require a PS-12/22 supply to be installed. • Users should be mindful of the current draw on the 5 VDC rail. See the “5 V Rail

Overload Check” chapter for more details.

3.4.4 Battery Backup To maximise the service life of the battery, the depth of its discharge should not exceed 50% of available capacity. E.g. for a 7 Ah battery, there is 3.5 Ah of backup power. Therefore the battery can supply 3.5 Amps for 1 hour or 1 Amp for 3.5 hours etc. The size of the backup battery required depends on how long the RTU needs to be able to run without mains power. In addition to the Total Current Load above, a backup battery will also need to power the PS-12/22 if present (not applicable if using a PC-1 processor).




4. PROCESSOR MODULES

Overview The processor module is the core part of any RTU. It is responsible for running user logic and facilitating inter-module interactions (via backplane) and communications with the SCADA system and other RTUs and various 3rd party devices (via communications ports) as required. The amount of memory, speed, and flexibility of an RTU is determined by the processor module selected.

There are three processor modules available in the Kingfisher Plus+ modular RTU range. Each of them has one resident communications port, with an ability to add up to two additional communications ports.

Processor modules summary:

Parameter / Feature PC-1 CP-12 CP-30

Processor Speed 16 MHz 40 MHz 166 MHz

Flash Memory 128 KB 512 KB 16 MB

SDRAM - - 64 MB1

NV RAM 256 KB 512 KB 512 KB2

Port 1 (resident) RS-232 RS-232 10BASE-T / 100BASE-TX Ethernet

Optional Ports 13 24 24

Programming Languages Ladder Logic Ladder Logic Structured Text, Ladder Diagram, Function Block Diagram, Instruction List, Sequential

Function Chart and Flow Chart

Notes: 1) 32 MB for CP-30 v1.x. 2) 128 KB for CP-30 v1.x. 3) See PC-1 Option Boards for available options. 4) See the Communications Options Boards chapter for available options and compatibility.

Lithium Battery

This product contains a lithium battery. Risk of explosion if battery is replaced by an incorrect type. Dispose of used batteries in accordance with local regulations or return to the supplier.

Pile au Lithium

Ce produit contient une pile au lithium. Il y a un risque d’explosion si la pile est remplacée par un modèle incorrect. Jetez les piles

usagées conformément aux réglementations locales ou retournez-la au fournisseur.




PC-1: Power & Processor Module

4.2.1 Overview • Monitoring of battery and input supplies • Isolated DC Outputs • 16 MHz Processor • DC Input Supply • Up to two communications ports • Low Voltage Battery Protection • 256 KB SRAM

The PC-1 is well suited to small and mid-size installations as it features an integrated power supply, reduces the system complexity by negating the need for additional power supply modules.

With remote installations in mind the PC-1 was designed to be capable of running from a backup battery, and has a fully isolated low power DC output for external equipment.

To configure the PC-1, a PC running the Toolbox 32 software is required. The Toolbox 32 software allows the user to implement ladder logic.

The PC-1 can only be installed in the first slot of a 4-slot backplane (BA-4) and operates from a nominal +12 VDC supply (typically 13.8 VDC). The module has one fixed RS-232 port and one option port.

With a special firmware update, the existing PC-1 module can be converted to a Power Supply unit (PC-1-PS) compatible with new CP-12 and CP-30 processor modules. This provides a simple and low cost upgrade path from PC-1 to CP-12 or CP-30 processors that allows existing installations to remain physically untouched. The firmware, along with technical note explaining how the modified PC-1-PS will behave, can be downloaded from a Knowledgebase article.



http://helpdesk.servelec-semaphore.com/semaphore/Knowledgebase/Article/View/568/0/


A PC-1 has two links that can be accessed from the rear of the module as shown below.

The SRAM battery is enabled at shipping time by the factory. The user can clear the SRAM by removing the SRAM link for five minutes. This will clear the RTU configuration and ladder logic.

4.2.2 Part Numbers The PC-1 is available with 3 options (A, P, M) as detailed below.

PC - A P M

Device: 24 V 10 W Auxiliary Supply Converter

Port 2 Option Board Type

Memory

Part Number: 0 = Not Fitted C = Fitted

0 = Not Fitted R = Radio, V.23 FSK* P = 2-Wire Line, V.23 FSK S = Serial RS-232/RS-485

0=128 KB RAM (obsolete) 1=256 KB RAM (standard)

* Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait radios. Please indicate which Radio you are using when ordering a radio option card.

Example: PC-1-CR1 is a PC-1 with 24 VDC auxiliary converter, radio option port and extra RAM.




4.2.3 PC-1 Module LEDs

PC-1

Both of the communications ports have Tx, Rx, RTS and CD LEDs in a vertical group as shown above.

PC-1 LED Description

OK ON when module is functioning OK

DC +5V ON when the internal 5 V supply is OK. This LED should always be on

+12V ON when the internal 12 V supply is OK. This LED should always be on (software controlled)

T1 Test LED 1. Flashes during Power Down mode.

+Vs ON when the Auxiliary 24 V supply is OK (will only display if the 24 V converter is installed).

BATT CHG* ON when the battery is being charged

DIS* ON when the battery is being discharged

LO ON when the battery voltage is low (For a PC-1 this occurs when the supply voltage is less than about 11.2 VDC)

T2 Test LED 2. Not currently used.

Tx ON when port is transmitting

Rx ON when port is receiving

RTS Request to send. Set ON to begin transmitting

CD Carrier detect: ON while a communications signal is detected.

WD Processor Watchdog Timer. Set ON when the processor is reset.

* The battery charging (BATT CHG) and battery discharging (DIS) LEDs will sometimes flicker on and off when the battery is charged to the optimum level or if no battery is connected.




4.2.4 PC-1 Specifications PROCESSOR SPECIFICATIONS

Processor Type Intel 80C188

Word Size 16 Bit internal data bus 8 Bit external data bus

Clock Speed 16 MHz

BIOS Yes

Flash Memory 128 KB Total. 28 KB for firmware drivers.

SRAM 256 KB

Real-t ime Clock Accuracy 1 minute per month (± 20 ppm)

Watchdog Timer Yes

Status Indication Yes

Battery Type Lithium. Not rechargeable.

Battery Life (module unpowered) 7 years @ 25°C

Communications Ports 2

Port 1 (RS-232) Serial, 300 to 115200 Baud

Port 2 (Optional) Serial, Analogue Radio Interface, 2-Wire Line or 4-Wire Line 300 to 115200 Baud (depending on port type)

Modem Port 2 CCITT V23 (Optional) 1200 Baud

Configuration Software Toolbox 32

Diagnostics Software Yes

Basic Configuration Auto on power-up

RTU Address Range 1 – 249

Communications Protocol Kingfisher, DNP3, Modbus, plus many more…

Analogue Block Processing Yes

PID Block Processing Yes

Redundant Power Supplies Not supported

Redundant Processors Not supported

Redundant Communications Yes

Internal Power Consumption 120 mA from +5 VDC

I/O Bus Data Rate 250 kbps

CM Bus Data Rate 83 kbps

Cyclic Redundancy Port 1 and 2







Hot Swap Not supported. Removing the PC-1 will power down the RTU.

PC-1 POWER SUPPLY SPECIFICATIONS

Input Supply to PC-1 11.5-15 VDC / 4 A maximum (60 W) Typically 13.8 VDC if backup battery connected

Outputs From PC-1

+5 VDC / 1 A maximum (5 W) to Backplane +12 VDC / 4 A maximum to Backplane* +12 VDC / 2 A maximum to Vr* +24 VDC / 400 mA (10 W) Optional Auxiliary Output (3 kV Isolation)#

Backup Battery 12 V

Deep Discharge Protection RTU Shutdown at 10.6 V RTU Start-up at 11.8 V

Supply Fuse 7 A (Maximum Current into the PC-1)

Battery Fuse 7 A (Maximum Current into or out of battery)

Combined Vr and 24 VDC Fuse 3 A Polyfuse

Monitoring

Parameter Accuracy

Battery Current PC-1 Supply Voltage PC-1 Supply Current

PC-1 Temperature

± 10% ± 5% ± 10% ± 5%

* Note: backplane rail voltages are dependent on power supply to the PC-1. Most PC-1s are powered using the 40 W PSU-3 Power Supply set to 13.8 VDC when using a 12 VDC backup battery. # the +24 V converter is optional and must be ordered with the PC-1.




4.2.5 PC-1 Pinout

Port 1 Pins Direction RS-232 signal

1 OUT DTR

2 OUT +12 V low power

3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RXD

8 OUT TXD

Please refer to the PC-1 Option boards for more information regarding port 2 option boards.




CP-12 Processor Module

4.3.1 Overview • Support for Processor and Communications Redundancy • Up to 3 communications ports • 40 MHz x86 CPU

The CP-12 processor module has up to three independent communications ports. Ports 2 and 3 can house option boards while port 1 is a fixed serial port (RS-232).

This processor is targeted at the application space that is too complex for the PC-1 but does not required the additional features made available with a CP-30 based system. The CP-12 has extended functionality over the PC-1 such as redundant processor and communications modules support, and is compatible with Ethernet based boards.

The CP-12 uses the same configuration software as the PC-1 processor, and as such is programmable with ladder logic.

The CP-12 has 512 KB of flash memory for operating code and system parameter storage, and 512 KB of battery backed SRAM for all configuration and event storage data.

4.3.2 CP-12 Reset Procedures

The SRAM battery is enabled from the factory by default. The user can clear the SRAM by removing the SRAM link for five minutes.

This will clear the RTU configuration and Ladder Logic.

Behind the LED lens of the CP-12 there is a diagonally mounted jumper. This is a hardware feature unique to the CP-12 processor.

When the jumper pins are shorted while the module is being reset (or power cycled), the processor will enter Monitor Mode (the Kingfisher bootloader) and perform a read/write test of the SRAM. This will forcefully clear SRAM, having the same effect as removal of the SRAM link on the back of the CP-12 module.

Monitor Mode is a deterministic and efficient way of clearing a Processor as the module does not need to be removed from the Backplane, and as the SRAM is forcibly overwritten.




Note: The RAM test is extremely fast. The CP-12 will clear the RAM nearly instantly. To exit monitor mode, remove the short and power cycle the unit again.

4.3.3 CP-12 Module LEDs

CP-12 LED Description

OK ON when Processor is functioning correctly

MON ON when Processor is in Monitor mode

WDT ON when Processor watchdog timer overflows, such as in the event of a software crash.

RST ON when in reset. Will be lit for 200 ms when cold starting.

TxD ON when transmitting data on corresponding Port

RxD ON when receiving data on corresponding Port

RTS ON when asserting Request To Send on corresponding Port

DCD ON when Data Carrier Detect affirmed on corresponding Port

10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port


LINK ON when Ethernet Link is established

COL ON when Ethernet Collision is detected

IOTX IORX

Intensity is proportional to load on backplane IO Bus (this bus is used to poll all IO modules)

CMTX CMRX

Intensity is proportional to load on load on backplane Communications Bus (this bus is used for communications modules data transmission)




4.3.4 CP-12 Specifications PROCESSOR SPECIFICATIONS

Processor 40 MHz x86

Word Size 16 bit data bus

BIOS Yes

Flash Memory 512 KB

SRAM 512 KB

Battery Type Lithium Primary (not rechargeable)

Battery Life (module unpowered) 7 years @ 25°C

Real-t ime Clock Accuracy 1 minute per month (+/- 20 ppm)

Watchdog timer Yes


Communications Ports 1-3 (1 fixed, 2 option ports)

Port 1 (RS-232) 300 to 115200 Baud (factory default 9600 8-N-1)

Ports 2 and 3 (Optional) For supported port types, please see the Option Boards chapter


RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)

Communications Protocol Kingfisher, Modbus + many more

Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)


PID Block Processing Yes

Redundancy Yes. Two CP-12 modules can be installed in the one RTU. One processor module must be installed in an odd numbered slot and one in an even numbered slot.

Internal Power Consumption (without Option Boards) 150 mA from +5 VDC bus on backplane






Hot Swap Yes*

*) When 2 processors are present on the backplane, one processor can be swapped while the RTU is still running. However, a hot swap will cause a Warm Start of the remaining processor. All ports will be re-initialized and ready for communications within 6 seconds. New data received during the changeover may be lost. To preserve data and for more information please see the Redundancy appendix in the Toolbox 32 manual.




4.3.5 CP-12 Ports The CP-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Communications Option Boards Chapter.

Port 1 Pins Direction RS232 signal

1 OUT DTR

2 - n/c

3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RxD

8 OUT TxD




CP-30: High Performance Processor Module

4.4.1 Overview • Compliant with IEC-61131 programming languages • Up to 3 communications ports • Supports Communications and Processor Redundancy

The CP-30 is a high performance processor module that can provide exceptional speed, memory and functionality to your RTU.

Targeting large RTU systems, the CP-30 is equipped with a 166 MHz ARM9 CPU, capable of running all IEC-61131-3 certified languages, and utilises an Ethernet port as the default connection and configuration medium.

To configure the CP-30, a PC with an Ethernet port and the Toolbox PLUS software is required.

Toolbox PLUS features ISaGRAF™ software, which provides logic programming in the IEC-61131 standard languages: Structured Text, Ladder Diagram, Function Block Diagram, Instruction List, Sequential Function Chart and Flow Chart.

The processor module has up to three independent communications ports. Ports 2 and 3 can use plug-in option boards while port 1 is fixed as Ethernet (both 10 Mbps and 100 Mbps modes are supported).

RTUs can use a second CP-30 module to provide processor redundancy. One processor must be installed in an even-numbered backplane slot (the active processor on power up) and the other in an odd-numbered backplane slot (the passive processor on power up). The active processor continuously scans all backplane slots (among other tasks) so that it can detect, control and monitor all other RTU modules. The passive (standby) processor will switch to active mode when it detects that communications on the backplane stopped for longer than a predefined maximum time that may be caused (but not limited to) by:

• Failure, removal or reset of the active processor • Download of the configuration, logic or firmware to the active processor

The CP-30 flash memory is used for the storage of all operating code, RTU configuration and event logs. It also has 32 MB (v1.x) / 64 MB (v2.x) of SDRAM for program operation and general data storage and 128 KB (v1.x) / 512 KB (v2.x) of battery backed SRAM for non-volatile data such as retained variables and system log.

The module is powered from the +5 VDC rail on the backplane.

4.4.2 CP-30 Options and Ordering Info Unless explicitly noted, the description in this manual apply to all hardware versions of the CP-30 module. The new CP-30 version (v2.3) has some different features and specifications from the previous version (v1.6); in particular the amount of battery backed SRAM has increased from 128 KB to 512 KB, the amount of SDRAM has increased from 32 MB to 64 MB, a quick reset to factory defaults has been added, the backup battery has been made user replaceable, and the operating temperature range has been extended to -40 °C to +85 °C.




Note that despite the changes, all versions of CP-30 modules remain fully compatible with each other and with all other hardware. This means that any version of CP-30 firmware can be loaded onto any version of the CP-30 processor (as long as all CP-30 and MC-31 modules in a system use the same firmware version), any combination of CP-30 modules can be used for making a redundant configuration, and any version of CP-30 module can act as a plug-in replacement for any other version.

CP-30 options, ordering info and main specification differences are summarised in the table below:

Order Code Item

H/W version

v1.61 V2.32

CP-30-x3y4

BB RAM size 128 KB 512 KB

SDRAM size 32 MB 64 MB

Backup Battery Soldered User Replaceable

Factory Reset Module has to be removed from the slot (takes 5 min

waiting time minimum)

From the front of the module (quick)

Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C

Maximum current consumption from +5VDC rail on backplane 290 mA 200 mA

Notes: 1) And earlier versions (referred to as v1.x further in this Manual). 2) And later versions (referred to as v2.x further in this Manual). 3) ‘x’ designates a code of the communications option board installed on Port 2. 4) ‘y’ designates a code of the communications option board installed on Port 3.

Communications Option Boards codes:

Code Short Description Code Short Description

0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud

A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)

A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz

D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)

F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps

H HART Interface T21 Ethernet, Copper, 10/100 Mbps

I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps

I2 Dual Isolated Serial RS232/422/485

Notes: 1) Discontinued products.




4.4.3 Backup Battery / Reset to Factory Defaults CP-30 modules include lithium coin backup battery for Real Time Clock operation and for preserving content of the battery backed SRAM when power is removed from the module.

Backup battery on v1.x is soldered to the PCB assembly of the CP-30 module. A battery retainer is used on v2.x, allowing the user to replace the battery without any special tools.

CAUTION: After removing and re-installing the SRAM link or after replacing the battery, ensure that the CP-30 is powered up for at least 1 s.

This will assure the backup battery functioning for the specified life span.

Battery Backed RAM is connected to the backup battery via SRAM link located on the back of the CP-30 module as shown on the diagram below. The SRAM link is installed at shipping time by the factory.

The user can perform reset to factory defaults / clear the battery backed SRAM. Note. Reset to factory defaults clears RTU configuration and user logic but it will not clear the system log.

To perform reset to factory default using the SRAM link:

1. Remove CP-30 module from the backplane.

2. Remove the SRAM link for at least 5 min.

3. Install the SRAM link back on its header.

4. Install CP-30 on the backplane.

5. Switch backplane power ON (if it was OFF).

An alternative way of resetting the module to factory defaults has been added to the CP-30 v2.x hardware. It allows performing a quick reset to factory defaults:

1. Switch off power to the corresponding RTU rack.

2. Short together pins of the 2-pin header (located underneath LED display, on the front edge of the module) using a jumper link or another suitable conductive object (e.g. a metal screwdriver, ball-point pen, etc.).




3. Keeping the pins shorted, turn on the RTU power.

4. The short can be removed any time after that.

WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit board components.

CP-30 v2.x modules allow for a backup battery to be replaced by the user:

1. Obtain (purchase or order from Semaphore) a new battery. WARNING. Only CR2450N batteries from Renata are specified for operating temperature range from -40°C to +85°C.

2. Disassemble the CP-30 module and pull the PCB out from enclosure as per ‘Installing

and Removing Option Boards’ (steps 1 to 5). WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit board components.




3. Remove old battery and safely dispose it of in accordance with your local regulations.

4. Insert the new battery all the way in into the battery holder observing correct polarity (negative terminal of the battery should face PCB surface). WARNING. Inserting battery in reverse polarity may permanently damage CP-30 module.

5. Reassemble the module as per ‘Installing and Removing Option Boards’ (steps 7 and 8).




4.4.4 CP-30 Module LEDs

CP-30-xy (v1.x) CP-30-xy (v2.x)


OK1,2

ON Normal operation.

0.5 s ON, 0.5 s OFF Firmware/configuration update in progress.

OFF Power off or module faulty.

F11,2

0.25 s ON, 0.25 s OFF Port 2 configuration error.

OFF Normal operation.

F21,2



F31,2

ON Normal operation (active CP-30).

1 s ON, 1 s OFF Normal operation (standby CP-30).

OFF

One of the following may be indicated: • Module is booting up. • Initial synchronisation with standby processor in progress. • Module fault (ISaGRAF™ not started). • Logic cycle is longer than normal (blinks momentarily, on active

CP-30 only).

F4 – F73 n/a Reserved for future use.





P1 (Port 1) LEDs

104

ON Linked at 10 Mbps (no data activity).

Flashing Data activity (transmit or receive) at 10 Mbps.

OFF Port not connected or no link at 10 Mbps.

1005




LNK6 ON Linked at either 10 or 100 Mbps.

OFF Port not connected or no Ethernet link established.

COL6 ON Ethernet collision(s) detected.

OFF No collisions detected.

P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options

Tx6 TxD / 10ACT3

Flashing Port is transmitting serial data.

OFF Port is not transmitting.

Rx6 RxD / 100ACT3

Flashing Port is receiving serial data.

OFF Port is not receiving.

RTS6 RTS / LINK3

ON Request to Send output is asserted. It is usually asserted to signal readiness to transmit data to a serial device.

OFF Request to Send output is not asserted.

CD6 DCD / COL3

ON Carrier Detect input is asserted by a connected serial device.

OFF Carrier Detect input is not asserted.





P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options

Tx6 TxD / 10ACT3


OFF No data activity at 10 Mbps.

Rx6 RxD / 100ACT3



RTS6 RTS / LINK3

ON Linked at either 10 or 100 Mbps.


CD6 DCD / COL3

ON Ethernet collision(s) detected.


Notes: 1) Progressively set ON during booting sequence. After a successful start-up: OK is ON; F1 and F2 are OFF; F3 is ON (for active processor) or flashing (for standby processor). 2) Flash rapidly to indicate firmware upgrade error. 3) CP-30 v2.x only. 4) Duplicated by the bottom LED of the Port 1 Ethernet connector. 5) Duplicated by the top LED of the Port 1 Ethernet connector. 6) CP-30 v1.x only.




4.4.5 CP-30 Specifications

CP-30 Processor Module Specifications

Parameter v1.x v2.x

Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus

SRAM (Battery Backed) 128 KB 512 KB

Flash Memory 16 MB

SDRAM 32 MB 64 MB

Real-time Clock Accuracy ±1 min / month (± 20 ppm) max

Backup Battery

Battery type CR2470 with tabs (solder type) CR2450 (coin, user replaceable)

Battery Life (module unpowered) 7 years @ 25 °C

Communications Ports

Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)

Optional 2 (for supported port types, please see the Option Boards chapter)

Input Power

Voltage 5 V ± 5%

Current1 290 mA 200 mA

Isolation

Port 1 Transient Voltage 1 kV

Environment

Operating Temperature -20 to +70 °C -40 to +85 °C



Notes: 1) No communications option cards installed on Ports 2 and 3.




4.4.6 CP-30 Ports

Port 1 Pins Ethernet Signal

1 Tx+

2 Tx-

3 Rx+

4 n/c

5 n/c

6 Rx-

7 n/c

8 n/c




5. COMMUNICATIONS MODULES

Overview Communications modules can be utilized to add additional ports and multiple protocol capability to your RTU. Each module is equipped with two expansion ports that can house a wide range of specialized option boards (for more information regarding option boards and their compatibility, please refer to the Communications Option Boards chapter).

Lithium Battery

These products contain a lithium battery. There is a risk of explosion if battery is replaced by an incorrect

type. Dispose of used batteries in accordance with local regulations or return to the supplier.

Pile au Lithium

Ce produit contient une pile au lithium. Il y a un risque d’explosion si la pile est remplacée par un modèle incorrect. Jetez les piles

usagées conformément aux réglementations locales ou retournez-la au fournisseur.




MC-10/11/30 Communications Modules

5.2.1 Overview • Up to three communications ports per module • Wide range of available option boards • Fixed Serial (RS-232) port on Port 1

Note: MC-10/11/30 is a SUPERSEDED product and is not being manufactured any more.

The MC-10/11/30 multi-communications module provides up to three additional communications ports. Ports 2 and 3 are optional and use plug-in option boards while Port 1 is fixed as a serial (RS-232) port.

This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. The MC-10/11/30 modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane. An RTU can have up to 16 ports.

5.2.2 MC-10/11/30 Module LEDs

MC-10/11/30

LED Description

OK ON when Module is functioning correctly

Tx ON when port is transmitting

Rx ON when port is receiving

RTS Request to send. Set ON when transmitting

CD Carrier Detect. ON while a communications signal is detected

L1, L2 Not used




5.2.3 MC-10/11/30 Specifications MC-10/11/30 Communications Module Specifications

Processor Intel 80C386EX

Word Size 32 bit internal data bus 16 bit external data bus

Clock Speed 25 MHz

BIOS Yes

Flash Memory 1 MB

Static CMOS RAM 1 MB

RTC (Real-Time Clock) Yes

WDT (Watchdog Timer) Yes



Port 1 (RS-232) 300 to 115200 Baud

Ports 2 and 3 (Optional) For supported port types, please see the Communications Option Boards chapter

Communications Protocol Kingfisher, DNP3, Modbus + many more

MC-10/11/30 modules per RTU Maximum of 16 ports per RTU For example, can use 5 MCs if each has 3 ports





Hot Swap

Yes. Module can be swapped while RTU is running. However, Hot Swap will cause a Warm Start of the processor. All ports will be re-initialised and ready for communications within 6 seconds.




5.2.4 MC-10/11/30 Block Diagram

5.2.5 MC-10/11/30 Ports The MC-10/11/30 module features up to three serial ports accessible by RJ45 connectors on the front of the module and covered by the snap on cable cover. Port 1 is at the top for RS232 connections only. Port 2 and 3 can be configured using plug-in option boards.


1 OUT DTR

2 - n/c

3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RxD

8 OUT TxD




MC-12 Communications Module

5.3.1 Overview • Up to 3 communications ports per module • Supports Communications Redundancy • Wide range of available option boards • Fixed Serial (RS-232) port on Port 1

The MC-12 multi-communications module provides up to three additional communications ports. Ports two and three can house option boards while port 1 is fixed as a serial (RS-232) port.

An MC-12 supports a maximum baud rate of 83 kbps between itself and the RTU processor module. This bandwidth can be split across a maximum of 16 ports. Users should be mindful of this limitation when determining the number of ports used simultaneously in one installation.

The MC-12 is identical to the CP-12 with the exception of labelling, the lens cover, and firmware.

The MC-12 module is only for use with PC-1 or CP-10/11/12 based RTUs.

This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. One or more MC-12 modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane.




5.3.2 MC-12 Module LEDs

MC-12 LED Description

OK ON when Module is functioning correctly

MON ON when Module is in Monitor mode

WDT ON when Module watchdog timer is overflows, such as in the event of a software crash.

RST ON when in reset. Will be lit for 200 ms when cold starting.

TxD ON when transmitting data on corresponding Port

RxD ON when receiving data on corresponding Port

RTS ON when Request To Send on corresponding Port is asserted

DCD ON when Data Carrier Detect affirmed on corresponding Port



LINK ON when Ethernet Link is established

COL ON when Ethernet Collision is detected

IOTX IORX

Brightness of each indicates load on backplane IO Bus (this bus is used to poll all IO modules)

CMTX CMRX

Brightness of each indicates load on backplane Communications Bus (this bus is used for communications modules data transmission)




5.3.3 MC-12 Specifications MC-12 Communications Module Specifications

Processor 40 MHz x86

Word Size 16 bit data bus

BIOS Yes

Flash Memory 512 KB

Watchdog timer Yes



Port 1 (RS-232) 300 to 115200 Baud (factory default = 9600 bps)

Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)

Ports 2 and 3 (Optional) For supported port types, please see the Communications Option Boards chapter


RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)

Communications Protocol Kingfisher, Modbus + many more











5.3.4 MC-12 Ports The MC-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Communications Option Boards chapter.


1 OUT DTR

2 - n/c

3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RxD

8 OUT TxD




MC-31 Communications Module

5.4.1 Overview • Up to 3 communications ports • Fixed Ethernet (Twisted Pair) port on Port 1 • Supports Communications Redundancy • Wide range of available communications option boards

The MC-31 Communications Module provides three additional communications ports for an RTU. Port 1 is a fixed Ethernet port while Ports 2 and 3 are optional and can house variety of option boards.

The MC-31 hardware is identical to the CP-30 with the exception of labelling, the lens cover and firmware.

The MC-31 Communications modules can be used only with the CP-30 Processor modules.

They are powered from the +5 VDC rail on the backplane and can be swapped while RTU is running without causing RTU restart. One or more MC-31 modules can be used in the system.

5.4.2 MC-31 Options and Ordering Info MC-31 v1.5 and v1.6 modules have been supplied to the market for several years. At the time of publication of this Manual (3q2014), a new version of MC-31modules, hardware v2.3, has been released for production. This new version has some differences in the module features and specifications; in particular the operating temperature range has been extended to -40 °C to +85 °C.

MC-31 options, ordering info and main specification differences are summarised in the table below:

Order Code Item

H/W version

v1.61 V2.32

MC-31-x3y4 Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C

Notes: 1) And earlier versions (referred to as v1.x further in this Manual). 2) And later versions (referred to as v2.x further in this Manual). 3) ‘x’ designates a code of the communications option board installed on Port 2. 4) ‘y’ designates a code of the communications option board installed on Port 3.




Communications Option Boards codes:

Code Short Description Code Short Description

0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud

A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)

A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz

D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)

F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps

H HART Interface T21 Ethernet, Copper, 10/100 Mbps

I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps

I2 Dual Isolated Serial RS232/422/485

Notes: 1) Discontinued products.

5.4.3 MC-31 Module LEDs

MC-31-xy (v1.x) MC-31-xy (v2.x)


OK1,2

ON Normal operation.

0.5 s ON, 0.5 s OFF Firmware/configuration update in progress.

OFF Power off or module faulty.

F11,2



F21,2







F31,2 OFF Normal operation.

F4 – F73 n/a Reserved for future use.

P1 (Port 1) LEDs

104




1005




LNK6 ON Linked at either 10 or 100 Mbps.


COL6 ON Ethernet collision(s) detected.


P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options

Tx6 TxD / 10ACT3

Flashing Port is transmitting serial data.

OFF Port is not transmitting.

Rx6 RxD /

100ACT3

Flashing Port is receiving serial data.

OFF Port is not receiving.

RTS6 RTS / LINK3

ON Request to Send output is asserted. It is usually asserted to signal readiness to transmit data to a serial device.

OFF Request to Send output is not asserted.

CD6 DCD / COL3

ON Carrier Detect input is asserted by a connected serial device.

OFF Carrier Detect input is not asserted.

P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options

Tx6 TxD / 10ACT3







Rx6 RxD /

100ACT3



RTS6 RTS / LINK3

ON Linked at either 10 or 100 Mbps.


CD6 DCD / COL3

ON Ethernet collision(s) detected.


Notes: 1) Progressively set ON during booting sequence.

After a successful start-up: OK is ON; F1, F2 and F3 are OFF. 2) Flash rapidly to indicate firmware upgrade error. 3) MC-31 v2.x only. 4) Duplicated by the bottom LED of the Port 1 Ethernet connector. 5) Duplicated by the top LED of the Port 1 Ethernet connector. 4) MC-31 v1.x only.




5.4.4 MC-31 Specifications

MC-31 Communications Module Specifications

Parameter v1.x v2.x

Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus

SRAM (Battery Backed) 128 KB 512 KB

Flash Memory 16 MB

SDRAM 32 MB 64 MB

Communications Ports

Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)

Optional 2 (for supported port types, please see the Option Boards chapter)

Input Power

Voltage 5 V ± 5%

Current1 290 mA 200 mA

Isolation

Port 1 Transient Voltage 1 kV

Environment




Notes: 1) No communications option cards installed on Ports 2 and 3.




5.4.5 MC-31 Ports

Port 1 Pins Ethernet Signal

1 Tx+

2 Tx-

3 Rx+

4 n/c

5 n/c

6 Rx-

7 n/c

8 n/c




6. COMMUNICATIONS OPTION BOARDS

Overview The following option boards are available for the CP-12/30 processor modules and the MC-12/31 communications modules (and the LP-3 stand-alone RTU). For PC-1 option boards please see the PC-1 Option Boards chapter.

These are the currently available option boards:

Part Number Option Board Description I Isolated Serial

I2 Dual Isolated Serial

F Fiber Optic Interface

D Dialup Modem (PSTN) V34 33.6 kbps

L Private Line or Analogue Radio Interface

H HART / Bell 202 interface

A3 Ethernet MTRJ Fiber Optic Interface

T3 Ethernet RJ45 Copper – 10/100 Mbps

R2 900 MHz Spread Spectrum Radio for Australia

R3 2.4 GHz Spread Spectrum Radio for International

R4 900 MHz Spread Spectrum Radio for USA

Compatibility Not all option boards are universally compatible with all processors and communications modules. The list of modules that can support a particular Option Board is provided in the corresponding Option Board specifications table. The following table summarises compatibility information to offer a selection guide for assuring the hardware you have selected will function as expected.




Communications Option Boards Compatibility Summary

CPU/Comms Module A A3 D E F H I I2 L R2 R3 R4 T T2 T3

CP-30

MC-31 MC-30 firmware v276 or later CP-11 firmware v1.45b or later CP-10/11 firmware v1.45a or earlier

CP-12

CP-21 MC-10/11 firmware v159 or earlier MC-11 firmware v160 or later

MC-12

PC-1 with MC-10/11

PC-1 with MC-12 Note: The above table was correct at the time of writing. Please refer to Semaphore Helpdesk for any recent changes.

Installing and removing Option Boards

Caution: Follow anti-static procedures

Electronic components can be damaged by even small amounts of static discharge. It is highly recommend that antistatic procedures be used. Avoid touching any components and metal parts. Do not store cards near strong electrostatic, electromagnetic, or radioactive fields.



http://helpdesk.servelec-semaphore.com/semaphore/Knowledgebase/Article/View/144/173/hardware-manual


1. Insert a small screwdriver into the second hole at the bottom of the module case. Lever the side of the case outwards. Release the tab by firmly pulling the corner of the cover.

2. Insert the screwdriver into the second hole on the other side of the module. Lever the side of the case outwards. Release the tab by firmly pulling the corner of the cover.

3. Repeat steps 1 and 2 above for the top of the module.

4. Once all 4 tabs have been released, remove the front cover.

5. Remove the circuit board from the case by using a ‘toggling’ action




6. Unplug the old option board (if applicable) and insert the new option board. Please ensure that all of the option board pins line up with the socket.

7. Slide the circuit board into the channel on the left side of the case. Hook the top of the cover into the case.

8. Press the bottom of the cover onto the case. At the same time, please ensure that the option boards line up with the cutouts. Ensure the cover is fully inserted and that the 4 tabs have all engaged.




Option Board I: Isolated Serial

6.4.1 Overview

The isolated serial option board provides an RS-232, RS-485 or an RS-422 interface. The port is software configurable for any of these modes. When RS-485 is configured for an isolated serial option board, the RTS and CD LEDs are set ON and when RS-422 is configured the RTS LED is set ON (there are no LEDs set on for RS-232). RS-485 requires a 120 Ω terminating resistor at each end of the transmission line and RS-422 requires a 100 Ω terminating resistor at the receiver end of the transmission line only (please see the wiring diagrams at the end of this section).

Option Board I Specifications

Baud rate 300 – 115200 bps

Internal Power Consumption 70 mA from +5 VDC Bus on backplane

Output Power +4.3 V / 100 mA maximum

RS-422 Line drive 10 Receivers


Communications 8 data bits, no parity, 1 stop (8, N, 1)

Isolation Transient voltage: 2.5 kV




RTU Hardware Required

Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4




6.4.2 Serial Option Board Connections RJ45 Pin Direction RS-232 RS-422 / RS-485

1 OUT DTR N/A

2 OUT 4.3 V N/A

3 OUT RTS TX+

4 IN DCD N/A

5 Common GND GND

6 IN CTS RX+

7 IN RxD RX-

8 OUT TxD TX-

RS-232 Wiring Diagram (Null Modem Cable)

Note: maximum recommended RS-232 cable length is 15 meters.




RS-485 Wiring Diagram Each RTU can transmit/receive to any RTU, one at a time. Up to 32 RTUs (or other RS-485 devices) can be connected to the RS-485 bus. Maximum RS-485 wire length: 1200 m.

If the ground wire is not available, each GND terminal can be tied to EARTH locally via 100 Ω 0.5 W resistor. If the 100 Ω resistor is not available, the Ground wire can be connected directly to EARTH.

For short cable runs (less than 5 m) a single 60 Ω terminating resistor can be used at one end of the RS-485 cable.

RS-422 Wiring Diagram The master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to the master RTU, one at a time. Note: outstation RTUs cannot communicate with each other. Up to 10 RTUs (or other RS-422 devices) can be connected to the RS-422 bus. Maximum RS-422 wire length: 1200 m.

If GND wire is not available, each GND terminal can be earthed locally via 100 Ω 0.5 W resistors. If the 100 Ω resistor is not available, the Ground wire can be connected directly to EARTH.




Option Board I2: Dual Isolated Serial

6.5.1 Overview

The dual isolated serial option board provides two independent RS-232, RS-485 or RS-422 interfaces on a single board. The ports are software configurable for any combination of these modes. RS-485 requires a 120 Ω terminating resistor at each end of the transmission line and RS-422 requires a 100 Ω terminating resistor at the receiver end of the transmission line only (please see the wiring diagrams in the “Serial Option Board Connections” chapter).

Option Board I2 Specifications

Baud rate 300 – 115200 bps




Isolation (Field to Backplane) Transient voltage: 2.5 kV




RTU Hardware Required1 Can be installed in any of the following ports:

CP-30 Port 2 or Port 3 MC-31 Port 2 or Port 3

1) Check CP-30 / MC-31 firmware Release Notes for I2 Option Board support details. Older versions of Toolbox Plus software do not support I2 Option Boards configuration either.

I2OB front view

Data transfer activity of the normally operating I2 Option Board ports is indicated by corresponding Tx (for data transmission) and Rx (for data reception) LEDs mounted on the RJ45 connector as shown on the picture above. Activity indication of the Port 1.x is also duplicated on the corresponding front panel LEDs of the hosting CP-30/MC-31 module.




6.5.2 Dual Serial Option Board Connections RJ45 Pin Direction RS-232 RS-422 / RS-485

1 OUT DTR N/A

2 N/A N.C. N.C.

3 OUT RTS TX+

4 IN DCD N/A

5 Common GND GND

6 IN CTS RX+

7 IN RxD RX-

8 OUT TxD TX-

Wiring diagrams for each port of the Dual Serial Option Board are the same as shown in the “Serial Option Board Connections” chapter earlier.




Option Board F: Fibre Optic Serial Board The fibre optic serial option board provides a serial interface via a fibre optic cable. A fibre optic port is treated the same way as a standard serial port except a fibre optic cable is used for the communications medium. A fibre optic link offers excellent electrical isolation and a high data rate. Two fibre optic cables are required for each fibre optic port.

Option Board F Specifications

Maximum Baud rate 115.2 kbps (equivalent to RS-232 port)

Communications 8 data bits, no parity, 1 stop (8, N, 1)

Maximum Fiber Optic Cable Length Approx. 4 km (depends on cable and other factors)

Supported Fiber Optic Cables

Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS

Option Board Connectors (use male connectors on

cable)

Tx: ST female (light grey port) Rx: ST female (dark grey port)

Power Consumption (Tx) 50 mA maximum from +5 VDC Bus on backplane

Line drive 1 Receiver (point to point)

Electrical Isolation 15 kV

Operating Temperature -20 to +70 °C (v1.0) -40 to +85 °C (v1.0.A and above) #



RTU Hardware Required


# Refer to the label on the PCB assembly of the Option Board F which indicates its hardware version. If there is no label then check the PCB silkscreen for the version number of the board.




Option Board D: 33.6 kbps Dial Option Board The dial option board provides a V34 PSTN interface to the Kingfisher Plus+ RTU. The port speed is software configurable, and the dial board is designed to be compliant with telecommunications standards worldwide.

Dial Option Board Connections

RJ45 Pin PSTN Function

1 -

2 -

3 Reserved

4 Line -

5 Line +

6 Reserved

7 -

8 -

Telecommunication Line Cord

To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger telecommunications line cord.

Ligne de Télécommunication Cordon

Pour réduire les risques d’incendie, utilisez seulement du câble d’une section minimale de 0.13 mm² (26 AWG) pour les connections de

télécommunications.




Dial Option Board Specifications

PSTN Modem / Data Rate V.34, 300 to 33600 bps, auto-negotiating

RTU DTE Port Speed 300 – 115200 bps

Line Impedance 600 Ω

Approval International

Transmit level -10 dBm

Receive level -43 dBm to -9 dBm

Diall ing Pulse or Tone


Isolation Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 5 kV

Recommended Init ialization String

D Option: AT&FE0V0S0=2&W Original D Option: AT&FE0V0S0=2X0&W (ignores dial tone)




Alt itude 2000 m max

Compatibil ity





Option Board L: Line/Analogue Radio Interface

The line option board provides a Private Line or analogue radio interface and is software configurable for either of these modes.

The board is optically isolated, operates at 1200 bps and provides FSK CCITT V.23 modulation.

6.8.1 Line Board Connections

RJ45 Pin Direction Line / Radio Function

1 OUT Tx -

2 IN Rx -

3 OUT RTS/PTT

4 IN CD

5 IN GND (0 V)

6 IN 12 V

7 IN Rx +

8 OUT Tx +

Telecommunication Line Cord

To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger telecommunications line cord.




Ligne de Télécommunication Cordon

Pour réduire les risques d’incendie, utilisez seulement du câble d’une section minimale de 0.13 mm² (26 AWG) pour les connections de

télécommunications.

6.8.2 Connecting a Radio As the port is isolated it is necessary to use an external voltage source (normally from the RTU ‘radio’ connection +12 V) to power not only the radio but also the carrier detect circuit.

Some radios have a very low audio interface level (TX Audio), e.g. Maxon DM 0530, DM-2850, SD-125 and Tait T2010 / 2015. These radios will most likely require a resistor network external to the port to drop the TX Audio level.

Some radios (e.g. Maxon) have an internal pull up resistor to +5 V on the carrier detect line, if +12 V is used on the carrier detect optocoupler and then run to the carrier detect output on the radio, the optocoupler will always be driven. There are several ways to get around this:

1. Use a radio without an internal pull up to +5 V (Trio SR, possibly Tait).

2. Modify the radio by removing the internal pull up, as per manufacturer’s instructions.

3. Use +5 V to supply the carrier detect optoisolation circuit. (DO NOT USE +5 V FROM THE BACKPLANE CONNECTOR AS IT IS NOT ISOLATED).

Line / Radio Option Board Interface




6.8.3 2-Wire Line, point-to-point Either RTU can transmit/receive one at a time.

Note: line termination is required.

6.8.4 2-Wire Line, multi-drop Any RTU can transmit/receive one at a time.





6.8.5 4-Wire Line, point-to-point Either RTU can transmit/receive at any time.


6.8.6 4-Wire Line, multi-drop Master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to master RTU, one at a time.

Note that outstations cannot communicate to each other.




Line/Radio Option Board Specifications

Baud rate 1200 Baud

Modulation FSK, CCITT V.23

Carrier detect input Optical isolation Active low or high Min. input 2 mA (70 VDC maximum)

RTS/PTT output

Optical isolation Open collector output Active low 30 VDC maximum / 20 mA maximum Microwave networks typically use a negative supply rail for the carrier detect circuit. The more positive rail should be connected to pin #6 (RTS/PTT) and the difference between the rails must not exceed 30 VDC.

Output impedance 30 kΩ

Input impedance 30 kΩ

Line termination 600 Ω

Line configuration

2 or 4 wire The port is not full duplex and cannot use the full duplex functionality of a 4-wire configuration. 4-wire configurations eliminate the ability to communicate peer to peer but allow an increased number of drops on one link.

Line drive in multi-drop configuration

10 drops for 2 wire 20 drops for 4 wire

Transmit output level -6 dBm (LINE-2) -6 to -21 dBm software configurable (LINE-L)

Receive level -43 dBm to -9 dBm


Transmission Distance

Allowing 3dB for background noise and a 10dB fade margin, up to 24dB of cable loss can be tolerated. Therefore, transmission distance = 24 / cable loss per Km (dB). Note: if there are more than 2 RTUs (or other devices) on the line, reduce the allowable cable loss (24) by 1dB per additional RTU or device.

Isolation Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 3.88 kV

Operating Temperature -20 to +70 °C (v1.2 and below) -40 to +85 °C (v1.2.A and above) #



Alt itude 2000 m max




Compatibil ity


# Refer to the label on the PCB assembly of the Option Board L which indicates its hardware version. If there is no label then check the PCB silkscreen for the version number of the board.




Option Board H: HART Interface

The HART option board provides a Bell 202 interface to devices supporting the HART protocol. Each HART option board can communicate with up to 15 Hart devices. Two HART option boards can be installed on the one RTU allowing up to 2 point-to-point circuits or 2 multi-drop circuits.

In a point-to-point installation, the loop current can be measured using an RTU analogue input channel. If using two separate point to point circuits and reading the loop current in each, the RTU analogue input channels must be isolated from each other.

In a multi-drop installation, the loop current is not used or measured.

For more information regarding HART configurations please refer to the “HART Implementation Guide” available on Semaphore Helpdesk.

6.9.1 HART Board Connections RJ45 Pin HART Function

1 Line +

2 to 7 n/c

8 Line -



http://helpdesk.servelec-semaphore.com/semaphore/Knowledgebase/Article/View/83/


Point-to-point Wiring Configuration (Utilising Analogue Input)

Note: the resistor value can be from 50 to 500 Ohm. The 24 VDC field power output of the Analogue Input Module is used to power the current loop in this case. A generic power supply can be used instead.

Multi-drop Wiring Configuration

Note: the resistor value can be from 50 to 500 Ohm. The more HART devices connected, the closer the resistor value needs to be to 50 Ohm.

When using multiple HART networks on a single RTU, be sure to isolate the 24 V supplies.




HART Option Board Specifications

Baud-rate 1200 Baud, Half Duplex

Modulation Bell 202

Logical Frequencies 1 = 1200 Hz 0 = 2200 Hz


Maximum No. HART Devices 15 (multi-drop)

Data Available HART and loop current for point-to-point HART only for multi-drop

Isolation Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 3.88 kV




Compatibil ity Can be installed in any of the following ports:

CP-10/11/12/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3

# Refer to the label on the PCB assembly of the Option Board H which indicates its hardware version. If there is no label then check the PCB silkscreen for the version number of the board.




Option Boards T3 & T2: 10/100 Ethernet Controller The Ethernet Option Boards provide full duplex Ethernet connectivity over UTP cables. The option boards feature automatic speed and MDI/MDI-X negotiation. Technical specifications of the T3 (currently in production) and T2 (superseded product) Ethernet Option Boards are described below.

Ethernet Option Board T3 Ethernet Option Board T2

Ethernet Option Board Specifications

Parameter T3 Option Board T2 Option Board

Connection Speed 10/100 Mbps (auto negotiated)

Connection Durabil ity Approximately 750 cycles

Power Consumption 300 mA (from +5 VDC Bus on backplane)

310 mA (from +5 VDC Bus on backplane)




Compatibil ity

Can be installed in any of the following ports:

CP-11/12/30 Port 2 or Port 3 MC-11/12/31 Port 2 or Port 3 LP-2 Port 4 LP-3 Port 3 or Port 4

Can be installed in any of the following ports:

CP-30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3

Port 1 Pins Ethernet Function

1 Tx+ 2 Tx- 3 Rx+ 4 n/c 5 n/c 6 Rx- 7 n/c 8 n/c




Option Board A3: Fibre Optic Ethernet

Class I LED product

The A3 option board provides Ethernet connectivity via fibre optic cable. The A3 is functionally equivalent to a T3 Ethernet board, but fibre optical cabling is used in place of copper cabling allowing for excellent electrical isolation.

A3 Ethernet Option Board Specifications

Connection Speed 10/100 Mbps

Optical Compliance Full ATM 100 Mbps physical layer Full 100 Mbps-FX (IEEE802.3u)

Fiber Optic Transceiver AFBR-5903Z

Supported Fiber Optic Cables Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS

Option Board Connectors (use male connectors on cable)

MTRJ connector. Available from Semaphore are the MTRJ-SC and MTRJ-ST adaptors.




Compatibility

Can be installed in any of the following ports: CP-11/12/30 Port 2 or Port 3 MC-11/12/31 Port 2 or Port 3 LP-2 Port 4 LP-3 Port 3 or Port 4




Option Board R2: Australian Spread Spectrum Radio

The R2 Spread Spectrum radio option board uses the Digi 900 MHz RF module to provide a high speed data link in Australia. This radio uses the public frequency band and does not need to be licensed.

When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly.

During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage.

Warning: RF Exposure

900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station

transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all

persons and must not be co-located or operating in conjunction with any other antenna or transmitter.

Avertissement: l'Exposition aux RF

Radio 900 MHz à spectre étalé (Spread Spectrum)

Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les

antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne

doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur.




Modifications

Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could

void the user’s authority to operate this product.

Modifications

L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie

responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit.

R2 Spread Spectrum Radio Board Specifications

Countries Supported Australia

Frequency 915-928 MHz

Transmit Power 1-1000 mW configurable

Range Indoors 900 m

Range Outdoors 22 km

Range with Yagi Up to 32 km

Data rate — RTU to Radio 9600 bps

Data rate — Radio to Radio 115200 or 9600 bps

Power Consumption 3.7 W maximum

Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)

Encryption None

Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)

Receiver Sensitivity -110 dBm @ 9600 bps




Compatibility

Can be installed in any of the following ports: CP-10/11/12/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4

Please see http://www.digi.com for more information on XTend® 900MHz wireless module (P/N XTH9-MI-NA) specifications.



http://www.digi.com/products/wireless-wired-embedded-solutions/zigbee-rf-modules/point-multipoint-rfmodules/xtend-module%23specs


Option Board R3: International Spread Spectrum Radio

The R3 Spread Spectrum radio option board uses the 2.4 GHz RF module to provide a high speed data link anywhere in the world (international). This radio uses the public frequency band and does not need to be licensed.




2.4 GHz Spread Spectrum Radio This equipment is approved only for mobile and base station




Radio 2.4 GHz à spectre étalé (Spread Spectrum)




Modifications






Modifications




Countries Supported International

Frequency 2.4000-2.4835 GHz

Transmit Power 50 mW

Range Indoors 180 m

Range Outdoors 5 km



Data rate — Radio to Radio 9600 bps



Encryption None#


Receiver Sensitivity -105 dBm




Compatibility

Can be installed in any of the following ports: CP-10/11/12/30 Port 3 only MC-10/11/12/30/31 Port 3 only LP-2 Port4 LP-3 Port 3 or Port 4

# Encryption by special request in the USA only.

Please see http://www.digi.com/ for more information on XStream® 2.4GHz wireless module (P/N X24-019NMI) specifications.



http://www.digi.com/products/wireless-wired-embedded-solutions/zigbee-rf-modules/point-multipoint-rfmodules/xstream-module%23specs


Option Board R4: US/Canada Spread Spectrum Radio

The R4 Spread Spectrum radio option board uses the Digi 900 MHz RF module to provide a high speed data link in the US and Canada. This radio uses the public frequency band and does not need to be licensed.




900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station




Radio 900 MHz à spectre étalé (Spread Spectrum)




Modifications






Modifications




Countries Supported US & Canada

Frequency 902-928 MHz

Transmit Power 1-1000 mW configurable

Range Indoors 900 m

Range Outdoors 22 km



Data rate — Radio to Radio 115200 or 9600 bps



Encryption None#


Receiver Sensitivity -110 dBm @ 9600 bps




Compatibility

Can be installed in any of the following ports: CP-10/11/12/30 Port 2 or Port 3 MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4

# Encryption by special request in the USA only.

Please see http://www.digi.com for more information on XTend® 900MHz wireless module (P/N XT09-MI-NA) specifications.



http://www.digi.com/products/wireless-wired-embedded-solutions/zigbee-rf-modules/point-multipoint-rfmodules/xtend-module%23specs


7. PC-1 OPTION BOARDS The PC-1 hybrid power supply and processor module has an accompanying range of communications option boards. These are not compatible with the CP series boards.

PC-1 Serial Option Board The serial option board provides a RS-232 or RS-485 interface. The port is software configurable for either of these modes. When RS-485 is used, a 120 Ω terminating resistor is required at each end of the transmission line.

PC-1 Serial Board Connections

RJ45 Pin Direction RS-232 RS-485

1 OUT DTR N/A

2 OUT +12 V low power N/A

3 OUT RTS LINE - *

4 IN DCD N/A

5 COM GND (0 V) GND (0 V)

6 IN CTS N/A

7 IN RXD N/A

8 OUT TXD LINE + *

* Polarity is opposite to CP-xx

For RS-485 wiring diagram please refer to CP-xx/MC-xx serial board RS-485 Diagrams




PC-1 Modem Board PL: Two Wire Line

The 2-wire (Private) line option board provides a 2-wire point-to-point connection to another RTU with a line option board.

The board is optically isolated, operates at 1200 bps and utilizes FSK CCITT V.23 modulation.

PC-1 Modem Board Connections

RJ45 Pin Direction Radio Function

1 OUT DTR


3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RXA

8 OUT TXA

PC-1 2 Wire Line Wiring Diagram (point-to-point)




PC-1 Modem Board: Analogue Radio Interface

The analogue radio option board provides an FSK interface to external analogue radios (typically Trio or Maxon).

Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait radios. Please indicate which Radio you are using when ordering a radio option card.

PC-1 Analogue Radio Board Connections

RJ12 Pin Direction Radio Function

1 OUT DTR


3 OUT RTS

4 IN DCD

5 COM GND (0 V)

6 IN CTS

7 IN RXA

8 OUT TXA




8. IO MODULES OVERVIEW This chapter contains general overview of and wiring guidelines applicable to IO modules in the Kingfisher Plus+ range. The types of available IO modules are listed in the table below.

Part Number Description of Module I/O Points Commons per Module

ANALOGUE MODULES

AI-1 Analogue Input Module 8 1

AI-10 Analogue Input Module (High Performance) 8 1

AO-3 Analogue Output Module 4 4

DIGITAL MODULES

DI-5 Digital DC Input Module 16 1

DI-10 Digital AC/DC Input Module 16 1

DO-1 Digital Relay Output Module (NO/NC) 8 4

DO-2 Digital Relay Output Module (NO) 16 2

DO-6 Digital Solid State Module 16 2

COMBINATIONAL I/O MODULES

IO-2 Combination Digital I/O Module 16 2

IO-3 Combination Analogue/Digital I/O Module 13 4



IO Modules Field Connector Each IO module has a removable 20-terminal I/O connector block mounted on the front of the module for connections from user devices. This allows the IO module to be swapped without having to detach the field wiring from the I/O connector. The I/O connector is secured to the module using two fastening screws as shown on the picture below.




Actual terminals used and their pin-outs are shown in the specifications for the individual modules.

Connecting an Analogue Input An analogue device (e.g. transducer) can be connected using loop power (power from the module) or it can be self-powered.

A loop-powered analogue device behaves like a variable load on the module. It is a two-wire device with the positive wire being connected to the module’s Field Power output and the negative wire being connected to the Analogue Input of the module as illustrated below.

Loop Powered Analogue Device Connected to Analogue Input

A self-powered analogue device behaves like a current source to the module. A self-powered device has at least three wires. One wire is connected to a positive terminal of an external supply or to the Field Power output of the module. The second wire is connected to




the Analogue Input of the module and the third wire is connected to the module Ground pin as illustrated below.

Self-Powered Analogue Device Connected to Analogue Input

Field Wiring It is impossible to provide a practical guide for installation of equipment that covers all possible real-world situations. However, some guidelines are suggested below.

To minimise capacitive loading and noise, all field connections to the module should be wired to the I/O terminal board using a good grade of twisted, shielded instrumentation cable.

Generally, the shield for inputs to a module should be grounded at the analogue source with one point on the shield tied to the module as shown in the following figure.

Shield Connections for Analogue Inputs

For Analogue Outputs, the shield is normally grounded only at the source end (the module). The shield connection provides access to the backplane (frame ground) resulting in superior rejection of noise caused by any shield drain currents. In extreme noise environments, a ground braid may be used to connect the frame ground on the base plate connector to earth ground. This additional connection will bypass noise around the module. An internal link is




factory fitted on each module for the GND connection and may be removed where high isolation for cabling is required.

Shield Connections for Analogue Outputs




9. ANALOGUE INPUT MODULES Analogue input modules provide analogue inputs to the Kingfisher Plus+ RTU.

Each module is equipped with a fully isolated 24 VDC power supply for energizing field equipment such as sensor loops.

AI-1: 8 Channel Analogue Current Input Module

9.1.1 Overview • 12 Bit resolution • 1.5 kV Field to Logic Isolation • 2 ms scan rate • 24 VDC isolated DC output • 0 – 20 mA or 4 – 20 mA current inputs • 0 – 5 VDC or 1 – 5 VDC Voltage Inputs (requires factory modification)

The analogue input module provides eight input channels, each capable of converting an analogue input signal to a digital variable for use as required by your application. A link on the rear of the module selects 4-20 mA or 0-20 mA for all 8 channels. The default range is 4 to 20 mA.

The module can also be factory modified to handle voltage inputs of 0-5 VDC or 1-5 VDC.

Conversion speed for each of the eight channels is 20 µs and this provides a total update rate of two milliseconds for the module. Resolution of the converted signal is 12 bits binary (1 part in 4096) over the range. The placement of the 12 bits from the A/D converter in the #AI data word is as follows:

MSB LSB

0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

If the current source is reversed into the input, or is less than the low end of the current range, then the module will output a data word corresponding to the low end of the current range (0000H in #AI). If an input that is out of range is entered (i.e. greater than 20 mA), the A/D converter will output up to full scale (corresponding to 7FF8H in #AI).




Scaling of the input is shown below:

Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.

To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to GND. The GND connection provides access to the backplane (frame ground).

This module can be installed in any I/O slot of a 4, 6 or 12-slot backplane.




Block-diagram of the AI-1 module is shown on the figure below.

AI-1 Block Diagram

9.1.2 AI-1 Module LEDs


OK OFF Module fault (no power)

ON Normal

FU OFF Fuse OK

ON Fuse fail

A1-A8 OFF Channel Input level < 1%

ON Channel Input level > 1%




9.1.3 AI-1 Specifications AI-1 Analogue Input Module Specifications

Input Current Ranges 4-20 mA and 0-20 mA

Input Voltage Ranges 1-5 V and 0-5 V *

Inputs per Module 8

Update Rate 2 ms (all eight channels)

Accuracy ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C

Resolution 12 bit (no sign bit)

Common Mode Voltage 1500 V

Linearity < 1 Least Significant Bit

Isolation 1.5 kV between field and logic

Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz

Cross-Channel Rejection > 80 dB from DC to 1 kHz

Input Impedance 250 Ω standard 11 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.

Input Filter Cutoff Frequency 2 kHz @ -3 dB

Output Power 24 VDC / 160 mA, Isolated




Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.

* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R9 to R16 (channels 1 to 8 correspondingly).




9.1.4 AI-1 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.




2 wire transmitter (powered by module)



2 wire transmitter (powered externally)






AI-10: 8 Channel High Impedance Analogue Input Module

9.2.1 Overview • 16 Bit resolution • 3 kV field to logic isolation • Bipolar differential channels • 24 VDC isolated DC output • AI-10: Current / Low Impedance Inputs • AI-10-V: High Impedance Voltage Inputs • 10 ms (1 ms*) scan rate • Mains noise rejection* * AI-10 hardware version 2.x only.

Unless explicitly noted, all hardware versions of AI-10 modules are described in this section. The newer AI-10 v2.x modules can be recognised by the label on the side which indicates the hardware version. If the version number is not printed on the label then the module is v1.6 or older.

The AI-10-V modules (v1.x only) are identical to the AI-10 modules but have the 250 Ω current sensing resistors disconnected. This increases the input impedance for each channel to more than 1 MΩ which is suitably high for voltage transducers. Each channel has its own current sensing resistor, so any combination of channels can be converted.

In order to modify AI-10 v1.x the current sensing resistors have to be physically disconnected (either by lifting one pin or by complete removal of the resistor). The circuit board resistors to change are: R64 to R71 (channels 1 to 8 correspondingly). It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients.

The AI-10 v2.x has internal jumpers (shorting links) that allow the input to be configured for either current or voltage measurement. If a jumper is installed (default) then the related input is configured to measure current. If a jumper is removed then the related input is configured to measure voltage. Note that the factory fitted jumpers are yellow in colour and of a higher grade than commonly found. Use of other jumpers may result in degradation of measurement accuracy and so should be avoided. Appropriate handling precautions have to be observed to avoid ESD and other damage when removing or installing shorting links.




All AI-10 modules provide: • 8 analogue inputs with high electrical isolation between the field terminals and the RTU

logic. • A 24 V isolated output that can be used to power field sensors / transducers • 16 bit input resolution • Full compatibility with the AI-1 and AI-4 analogue input modules but with enhanced

resolution. • Full compatibility between different hardware versions (i.e. AI-10 modules v1.x and

v2.x can be interchanged without any field wiring or software configuration modifications required).

The AI-10 supports various current input ranges as follows: • 0-20 mA • 4-20 mA • ±10 mA1 • ±20 mA1

1 For AI-10 v2.x only unipolar current ranges are recommended for use. Bipolar ranges are not calibrated for current measurement.

The AI-10-V supports various voltage input ranges as follows: • ±2.5 V • ±5 V • ±10 V

To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to ground.

This module consumes power from the +5 VDC and +12 VDC RTU rails. A built-in 24V DC-DC converter is used to provide isolated power to the analogue front-end and can also be utilised to power the field devices if required.




Block-diagrams of the AI-10 modules are shown on the figures below.

AI-10 v1.x Block Diagram

AI-10 v2.x Block Diagram




9.2.2 AI-10 Module LEDs

AI-10 LEDs State Description

OK

OFF Module Fault (no power)

ON Module OK

1 s ON, 1 s OFF Module Fault

LED B (unlabelled)

1 s ON, 1 s OFF

Processor module has not communicated with the module for more than 15 seconds (e.g. no processor module is present in rack)

0.1 s ON, 1.9 s OFF1

Module Fault (Module running on internal clock source as the external crystal is faulty – module needs repair)

OFF Normal operation

LED C (unlabelled)

ON1 Module Fault (firmware not loaded – module needs repair)

OFF Normal operation

DC OK OFF AI-10 loop power OFF

ON AI-10 loop power ON

1-8 (left side)

OFF Channel Input level < 1%

ON Channel Input level > 1%

1-8 (right side)

OFF Channel Normal

ON Channel Fault (under/over range, data invalid) 1) On AI-10 v2.x only

Note: On power up some LEDs may come ON for a short time.




9.2.3 AI-10 Specifications AI-10 / AI-10-V Analogue Input Module Specifications

Parameter Hardware v1.x Hardware v2.x

Input Current ranges1,2 4-20, 0-20, ±20, ±10 mA (software selectable)

Input Voltage ranges3,4 ±2.5, ±5, ±10 VDC (software selectable)

Inputs per Module 8

Sub System Isolation The analogue subsystem of the AI-10 is fully isolated from the RTU’s digital system.

Isolation 3 kV Transient

Input impedance AI-10 : 250 Ω standard, > 1 MΩ optional4 AI-10-V : > 1 MΩ

Input Filter Cutoff Frequency 1.5 kHz @ -3 dB 9 Hz @ -3 dB

Common Mode Rejection 80 dB minimum 66 dB minimum

Mains Rejection None 42dB minimum @ 50Hz 45dB minimum @ 60Hz

Maximum Input Voltage ±12 V to GND ±12 V differential

±12 V to GND ±24 V differential

Accuracy ± 0.1% @ +25 °C ± 0.25% @ -20 to +70 °C

± 0.1% @ 0 to +50 °C2 ± 0.2% @ -40 to +85 °C2

Resolution 16 bit (15 data bits and 1 sign bit)

Output Power Isolated 24 VDC, 160 mA maximum





Compatibility

One range setting for all channels when used with a PC-1 or CP-11/12/21 processor. Individual range setting for each channel when used with a CP-30 processor.

1) AI-10 only. 2) For AI-10 V2.x only unipolar current ranges are recommended for use. Bipolar ranges are not

calibrated for current measurement and their accuracy can reach 1.4% of full scale when used to measure current.

3) Analogue Input channels can be modified from low impedance to high impedance by disconnecting the 250 Ω channel resistor.

4) The ±10 V input range can only be used on an AI-10 input channel if the current sensing resistor has been disconnected. Resistors have already been disconnected in an AI-10-V.




9.2.4 AI-10 / AI-10-V Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.










Loop

* When using the +24 V output to power a transducer, the negative input terminal of the analogue input channel (2, 4, 6, 8, 12, 14, 16 or 18) must be wired to the 0 V terminal (10 or 20). This will complete the current loop due to electrical isolation between the input channel and the module +24 V Output. Note: Any channels sharing the same power source (e.g. +24 V from module or a field power supply) are no longer isolated from one other.




10. ANALOGUE OUTPUT MODULE The AO-3 analogue output module provides four 12-bit current loop outputs allowing a Kingfisher Plus+ RTU to drive analogue loads.

AO-3: Analogue Output Module

10.1.1 Overview • 12 bit resolution • 3 kV field to logic isolation • Open loop detection • 0 – 20 or 4 – 20 mA outputs • 3 kV channel group to channel group isolation

The AO-3 provides four current output channels that use 12-bit digital to analogue converters (DAC). The AO-3 also provides open loop detection.

The sign bit is not used in the digital to analogue conversion process. The placement of the 12 bits within the data word is as follows:

MSB LSB

0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

This module provides two output ranges. The default range is 4 to 20 mA with user data scaled so that a count of 0 corresponds to 4 mA and a count of 32760 corresponds to 20 mA. A range link (on the rear of the module) selects either 4-20 mA or 0-20 mA for all four channels. The default condition is 4-20 mA with the link on. The module provides 12 bits of resolution in either range.

Scaling of the output is shown below.




Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups that are isolated from each other and from the backplane logic. Each group is powered by a separate DC-DC converter module that produces an isolated voltage of +24 V to drive the current loop outputs and analogue front-end.

The current loop drivers on the module are source type drivers. To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields should be connected to E (Shield) on the user terminal connector block. The E connection provides path to the backplane (frame Earth / Ground) resulting in attenuation of noise caused by the shield drain currents. To further improve noise immunity, direct connection of the analogue cable shields to the Earth / Ground rails with metal clamps or similar method is recommended, especially in environments with high electromagnetic noise levels.

This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane in a system. Up to 10 Analogue output modules can be installed on a single 12-slot backplane.

AO-3 configuration link location




Block-diagram of the AO-3 module is shown on the figure below.

AO-3 Block Diagram

10.1.2 AO-3 Module LEDs

AO-3 LEDs State Description

OK OFF Module fault / no power

ON Normal

RST OFF Module running

ON Module in Reset (power-on or watchdog)

ANALOGUE OUT 1-4 OFF Channel output set to 0%

ON Channel output greater than 0%

OPEN LOOP 1-4 OFF Closed Loop (load detected)

ON Open Loop (no load)




10.1.3 AO-3 Specifications

AO-3 Analogue Output Module Specifications

Output Current Range 4 to 20 mA [default] or 0 to 20 mA (loop current is supplied by module)

Outputs per Module 4

Output Power Isolated 24 VDC / 40 mA for outputs 1 & 2 Isolated 24 VDC / 40 mA for outputs 3 & 4

Supply Voltage (nominal) +5 VDC and +12 VDC from backplane

Update Rate 250 ms (all channels) Determined by I/O scan time and is application dependent


Accuracy ± 0.2% @ 25 °C ± 0.5% @ -20 to +70 °C

Load Resistance 0 to 850 Ω

Load Capacitance 2000 pF maximum

Load Inductance 1 H maximum

Isolation

Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups. Each group is isolated from the other group and from the backplane logic. There is no isolation between outputs 1 & 2 and no isolation between outputs 3 & 4. Transient voltage (Group to Group and Group to Logic): 5 kV. Maximum working voltage in respect to system earth/ground must not exceed SELV limits (42.4 VPEAK / 60 VDC).




Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.

Open Loop Detection

Yes. Monitors output circuit for failure (e.g. cable breakage) or if the load is disconnected. Note: when using the 0-20 mA range, Open Loop Detection cannot be guaranteed on an output when set below 160 / 0.1 mA / 0.5%.




10.1.4 AO-3 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.




0 – 20 / 4 – 20 mA Current Loop Receiver




11. DIGITAL INPUT MODULES

Overview The Digital Input Modules allow various level digital signals to be interpreted by your RTU.

All modules provide a minimum of 1 kV field isolation, 16 input channels and can be configured to use counters and input buffers to count incoming pulses.

Summary:

Module Maximum input Voltage

Channel group 1 maximum capture speed

Channel group 2 maximum capture speed

DI-5-1 28 VDC Channels 1 and 2 10 kHz

Channels 3 and 4 255 Hz

DI-5-1-48 60 VDC Channels 1 and 2 10 kHz

Channels 3 and 4 255 Hz

DI-10-1 DI-10-1-48

+130 VDC 125 VAC

Channels 1 to 4 10 kHz


DI-10(-GPS) DI-10-48(GPS)

+130 VDC 250 VAC


DI-5: DC Input 16 Channel Digital Input Module

11.2.1 Overview • Pulse counting on channels 1 to 4 (up to 10 kHz) • Positive or Negative Polarity Inputs • Isolated DC Outputs for powering inputs

The DI-5 provides 16 input channels with one common. As a wide input voltage is accepted a wide range of input devices can be used such as buttons, reed switches, line switches, PIR sensors, and proximity sensors. Any combination of inputs powered externally or by the modules own isolated DC supply (+12 V) can be used.

Applying a high input voltage results in logic 1 in the module’s status register. Low (or not present) input voltages result in logic 0.

The DI-5 counter can also count pulses in the first 4 digital inputs. It is able to count up to 10 kHz on inputs 1 and 2 and can count up to 255 Hz on inputs 3 and 4. The pulse total and the frequency for each of the first 4 digital inputs are stored.

This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane system.




Block-diagram of the DI-5 module is shown on the figure below.

DI-5 Block Diagram

11.2.2 DI-5 Module LEDs



ON Normal

1 - 16 OFF Digital Input OFF

ON Digital Input ON




11.2.3 DI-5 Specifications DI-5 Input Module Specifications

Rated Voltage + 12 to 24 VDC nominal (supports reverse polarity) Note: The DI-5-1-48 High Input Voltage module in the Custom Products chapter supports higher DC input voltages (48 VDC nominal)

Inputs per Module 16

Input Characteristics

Impedance 2.7 kΩ

ON-state Voltage Channels 1 and 2 : 10 to 28 VDC maximum Channels 3 to 16 : 7.5 to 28 VDC maximum

OFF-state Voltage Channels 1 and 2 : 0 to 3.5 VDC Channels 3 to 16 : 0 to 3.0 VDC

ON-state Current 4.3 mA minimum

OFF-state Current 1 mA maximum

ON Response Time Channels 1 and 2 : 50 µs maximum Channels 3 and 4 : 500 µs maximum Channels 5 to 16 : 10 ms maximum

OFF Response Time Channels 1 and 2 : 50 µs maximum Channels 3 and 4 : 500 µs maximum Channels 5 to 16 : 17 ms maximum


Output Power 12 VDC / 250 mA (3 W) isolated, supplied by module




Pulse Totalisation Channels 1 to 4 : 0-65535 Pulses

Pulse Rates / Frequency

Channels 1 and 2 : 10 kHz maximum Channels 3 and 4 : 255 Hz maximum





11.2.4 DI-5 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.




Powered by Module:

External positive supply:

External negative supply:

Combined positive and negative power supplies:




DI-10: AC or DC Input, 16 Channel

11.3.1 Overview • Frequency/Pulse/Quadrature counters on up to 7 inputs or input pairs • Isolated DC Field Power Output • Software Debounce • AC or DC Inputs • Sequence of events recording (with optional GPS time synchronisation) • Hot Swappable

The DI-10 provides 16 AC or DC input channels allowing it to interface a wide range of input devices to your RTU. Inputs can be powered by the module’s own +12 VDC Field Output Power or from external AC or DC power sources.

Applying a high positive or AC input voltage results in a logical ‘1’ in the status register, no or low input voltage results in a logical ‘0’. Negative DC input voltages cannot be used with DI-10 modules.

The DI-10 features software configurable pre-conditioning of inputs such as debounce filters, channel inversion and sequence-of-event recording selectable on any channel(s).

The DI-10 can also perform frequency, pulse or quadrature counting for up to 7 input channels (or pairs of input channels for quadrature counters).

DI-10 modules can be swapped while RTU is running without causing RTU restart. Inputs are cleared in RTU memory while module is removed.

Electrical Hazards


Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system

earth and/or ground) before performing any operation on this product, including field wiring.







Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou

AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le

câblage.

Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel.

11.3.2 DI-10 Options and Ordering Info Unless explicitly noted, all hardware versions of DI-10 modules are described in this manual. Comparing with its predecessor (v3.2), the newer DI-10 version (v4.3) has some differences in the module features and specifications and also has a new optional GPS time synchronisation of the sequence of event recording.

The DI-10 modules without “-48” suffix in their Order Code have Digital Inputs compatible with 12 V and 24 V control systems. The modules with the “-48” suffix in the Order Code have elevated change-over thresholds of Digital Inputs designed for use in 48 V and higher control systems.

Any DI-10 v4.3 module can be a GPS Slave, having its events timing synchronised to an accurate timing signal generated by a DI-10-[48]GPS v4.3 module (GPS Master) that has an additional interface for connection to an external 3rd party GPS device. Any number of GPS Slaves and GPS Masters can be installed in the RTU. With more than one GPS Master installed in the system, each of them will generate time synchronisation signal for the GPS Slaves in parallel, providing system redundancy if it is required.




DI-10 options, ordering info, the main features and / or main specification differences are summarised in the table below:

Order Code

H/W version

Target System Voltage IEC 61131

types I & III compliant

High-speed inputs4

GPS

v3.21 v4.32 12 V & 24 V3 ≥48 V Slave Master

DI-10-1 4

DI-10-1-48 5 4

DI-10 16

DI-10-48 5 16

DI-10-GPS 6 16

DI-10-48GPS 5,6 16

Notes: 1) And earlier versions (here and further in this Manual). 2) And later versions (here and further in this Manual). 3) Will also work with higher input voltages within the specified input range. 4) Up to 7 counters in total is currently supported by firmware. 5) DI-10-48 refers also to DI-10-1-48 and to DI-10-48GPS models further in this

document. 6) DI-10-GPS refers also to DI-10-48GPS model further in this document.

11.3.3 Theory of operation Block-diagram of DI-10 v3.2 module is shown on the figure below.

DI-10 v3.2 Block Diagram




Digital Inputs are connected to the input optocouplers via series diodes, resistors and 3.6 mA current limiters. Optocouplers with integrated Schmitt triggers are installed on first four (high-speed) channels. When input voltage and, consequently, input current of an optocoupler exceeds its threshold, microcontroller (MCU) reads this input as ‘1’, otherwise it is ‘0’.

Block-diagram of DI-10 v4.3 module is shown on the picture below.

DI-10 v4.3 Block Diagram

Digital Inputs are connected to a digital serialiser via series diodes and over-voltage protection circuits. The digital serialiser has its threshold input current set (and limited) to 2.51 mA. External signal sources should be able to supply 2.51 mA current to the DI-10 v4.3 module. When the input voltage exceeds its threshold, the microcontroller (MCU) reads this input as ‘1’, otherwise it is ‘0’.

11.3.4 Configurable Functions The first 4 channels of the DI-10 v3.2 and all channels of the DI-10 v4.3 are high speed and capable of counting up to 10kHz, while channels 5 to 16 of the DI-10 v3.2 can count up to 1 kHz.

Seven user-configurable counters are available which appear as 16-bit unsigned integer values in the analogue input register. Each of these counters can be configured either to measure frequency, to count pulses or to decode quadrature signals. Any channel from 1 to 16 can be assigned as an input to any frequency or pulse counter. Any pair of eight channel pairs (1-2, 3-4, etc.) can be assigned as inputs to any quadrature counter.

Channel inversion can be configured on any input channel. Normally a high voltage level results in a logical HIGH state (1) to be set in the digital input register with the corresponding LED illuminating on the front panel. By enabling channel inversion, a low voltage level applied to an input will result in a logical HIGH (1).

Software debounce can be activated on any input channel. The time constant can be configured from 1 ms to 250 ms. When AC inputs are used, the input channel must be configured with the debounce filter set to ‘AC Filter’ as shown below.




A 1 ms debouncing is automatically enforced when ‘AC Filter’ is chosen.

11.3.5 Sequence of Events Recording Sequence-of-Event (SoE) recording can be configured for any input channel. When enabled, any change of state (event) on the input is logged to 1 millisecond resolution. These events are automatically included in the Event Log of the RTU. The DI-10 module has an internal timer that is synchronised with the Real Time Clock of the processor.

Timestamps of the DI-10 v4.3 are guaranteed to be within ±2 ms of UTC time when optional GPS synchronisation feature is used in the RTU system.

The DI-10 module has a buffer capable of storing 1000 events. This means bursts of up to one thousand events can be recorded at a time. Events are uploaded into the processor module at a maximum rate of 100 events per second allowing the DI-10 module to cope with events at a sustained rate of 100 events per second.

Please note that SoE recording is not supported when using a PC-1 processor.

11.3.6 GPS Time Synchronisation (Optional) When a GPS device is attached to the DI-10-GPS module, it will synchronise the time on the CP-30 processor and all other DI-10 modules (GPS Slaves) in the RTU via signalling on the backplane. SoE timestamps on all DI-10 v4.3 modules will then be synchronised to the GPS time within 2 ms.

This feature does NOT work with other Kingfisher Plus+ processor modules (such as CP-12, CP-11, CP-21 and PC-1) nor with DI-10 v3.2 modules.

The GPS time synchronisation feature requires at least one DI-10-GPS module (GPS Master) per RTU. More than one GPS Master can be used to provide redundancy.

One of the unused backplane connections (24V power rail) is used to carry the time synchronisation signal between DI-10 modules.

WARNING. Installing DI-10 v4.3 modules on 24V backplanes (that are used in some old Kingfisher Plus+ installations) will damage DI-10 modules and void their warranty.

To support time synchronisation of the DI-10 modules across multiple backplanes, the time synchronisation signal must be connected between them. This signal is available on backplane power connector J14:




Backplane Power Header J14

Only two rails (24V and 0V) are required to be connected for time synchronisation between backplanes to work.

The following cables can be ordered from Semaphore to provide required connections:

• BPC-01 or BPC-02 Backplane Power Cables. WARNING. All power rails of the connected backplanes will be connected as well.

• BPC-02-GPS time synchronisation cable. • BPC-SPLIT splitter cable if more than two backplanes need to be connected.

The DI-10-GPS has an RJ-45 jack for direct connection of a Garmin GPS16x-HVS device. It is located directly underneath the LED display of the DI-10-GPS module.

The Garmin GPS16x-HVS can be ordered from Semaphore directly or via many commercial outlets.

RJ45 Jack for GPS device

RJ-45 pin-out and wire colours of the Garmin GPS16x-HVS are shown on the DI-10 v4.3 block-diagram. If a different model of GPS device is to be used, an adapter should be constructed using signal information in the table below.




RJ45 Pin

DI-10-GPS Signal

Direction (DI-10-GPS)

Direction (GPS Device) Signal Level Note

1 +12V OUT IN +12 V Power for GPS (100 mA max)

2 GND - - - Power & Signal Ground

3 PWR_ONn OUT IN Open Drain to GND

Pulled to GND: GPS ON Floating: GPS OFF

4 Din OUT IN RS-232 Serial Data to GPS

5 Dout IN OUT RS-232 Serial Data from GPS

6 PPS IN OUT 5 V TTL Pulse Per Second

7 nc Not connected

8 nc Not connected

11.3.7 DI-10 Module LEDs

DI-10-1 [-48] (v3.2) DI-10 [-48] (v4.3) DI-10-[48]GPS (v4.3)





OK

ON Module operating normally

0.5 s ON, 0.5 s OFF Internal Fault: (module needs repair)1

OFF Power off

ERR1

1 s ON, 1 s OFF

Backplane communications time-out (15 s) expired (no polling received from the RTU processor module)

0.1 s ON, 1.9 s OFF Module faulty and needs repair.

OFF Normal

GPS1,2

ON GPS serial port data detected and GPS is synchronised to the GPS network.

1 s ON, 1 s OFF

GPS serial port data detected but the GPS is not synchronised to the GPS network.

1.8 s ON, 0.2 s OFF

Time Synchronized to another DI-10-[48]GPS (master). This implies that no GPS is connected to this module so it acts as a DI-10 (slave).

0.2 s ON, 0.2 s OFF

Timing error in GPS slave synchronisation signal. This stays active until the next properly timed synchronisation signal, which could be a few minutes. This implies that no GPS is connected to this module so it acts as a DI-10 (slave).

OFF No GPS detected.

SYNC1

1.8 s ON, 0.2 s OFF Time Synchronised to a DI-10-[48]GPS (master).

0.2 s ON, 0.2 s OFF

Timing error in GPS slave synchronisation signal. This stays active until the next properly timed synchronisation signal, which could be a few minutes.

OFF No time synchronisation signal detected.

PCON ON +12V DC-DC converter on

OFF +12V DC-DC converter off. No digital input sampling occurs.

1-16 ON Digital Input ON

(channel input level is above low-to-high threshold)

OFF Digital Input OFF (channel input level is below high-to-low threshold)

Notes: 1) Only hardware v4.3 or later. 2) Only on DI-10-GPS modules (GPS Master).




11.3.8 DI-10 Specifications

DI-10 Digital Input Module Specifications

Parameter v3.2 v4.3

Digital Inputs per Module 16

Maximum Input Voltage 130 VDC / 125 VAC 130 VDC / 250 VAC

Maximum Current per Input1 3.7 mA 2.6 mA

Digital Input Levels

ON-state Voltage @ Input Current

Standard modules

≥7.5 VDC @ 1.0 mA (Ch. 1-4) ≥7.5 VDC @ 0.5 mA (Ch. 5-16) ≥20.0 VAC @ 1.0 mA (Ch. 1-4)

≥20.0 VDC @ 0.5 mA (Ch. 5-16)

≥7.5 VDC @ 2.5 mA

≥20.0 VAC @ 1.2 mA

-48 modules

≥35.0 VDC @ 1.0 mA (Ch. 1-4) ≥35.0 VDC @ 0.5 mA (Ch. 5-16) ≥27.0 VAC @ 1.0 mA (Ch. 1-4)

≥27.0 VDC @ 0.5 mA (Ch. 5-16)

≥35.0 VDC @ 2.5 mA

≥27.0 VAC @ 1.2 mA

OFF-state Voltage

Standard modules ≤3.0 VDC ≤3.0 VAC

≤3.0 VDC ≤3.0 VAC

-48 modules ≤24.0 VDC ≤15.0 VAC

≤24.0 VDC ≤15.0 VAC

Digital Input Thresholds2

Low-to-High Transition

Standard modules 5.4 VDC / 3.8 VAC (Ch. 1-4) 5.3 VDC / 4.0 VAC (Ch. 5-16) 7.2 VDC / 5.1 VAC

-48 modules 36.2 VDC / 27.6 VAC (Ch. 1-4) 34.7 VDC / 24.9 VAC (Ch. 5-16) 26.4 VDC / 19.1 VAC

High-to-Low Transition

Standard modules 5.1 VDC / 3.7 VAC (Ch. 1-4) 5.1 VDC / 3.7 VAC (Ch. 5-16) 6.3 VDC / 4.4 VAC

-48 modules 36.0 VDC / 25.5 VAC (Ch. 1-4) 34.5 VDC / 24.3 VAC (Ch. 5-16) 25.5 VDC / 18.4 VAC





Parameter v3.2 v4.3

Digital Input Timing

ON Response Time (max) 50 µs (DC, Ch. 1-4)

500 µs (DC, Ch. 5-16) 30 ms (AC)

50 µs (DC)

30 ms (AC)

OFF Response Time (max) 50 µs (DC, Ch. 1-4)

500 µs (DC, Ch. 5-16) 30 ms (AC)

50 µs (DC)

30 ms (AC)

Filtering None,1, 3, 10, 30, 100, 250 ms or AC Filter

Frequency, Pulse and Quadrature Counters

Total number of Counters 7 maximum

Maximum Frequency 10 kHz (Ch. 1-4) 1 kHz (Ch. 5-16) 10 kHz

Frequency Counting 1 Hz resolution on any input(s)

Pulse Counting 0-65535 Pulses on any input(s)

Quadrature Counting 0-65535 Pulses on any of the inputs pair(s) 1-2, 3-4, etc.





Parameter v3.2 v4.3

Sequence of Events

Time Stamp Resolution 1 ms

Events Time Stamp Accuracy

with GPS synchronisation3 n/a ±2 ms to UTC time

Events Buffer Size 1000 events

Events Transfer Rate (via backplane to a Processor Module)

100 events/s maximum

Output Power

To Field Devices Isolated 12 V 80 mA maximum

To GPS Device4 n/a Isolated 12 V 100 mA maximum

Isolation

Maximum Working Voltage (in respect to system

earth / ground) 130 VDC / 125 VAC 130 VDC / 264 VAC

Transient Voltage 3 kV

Environment




Notes: 1) Limited by internal circuitry of a DI-10 module. 2) Approximate values for information only (not factory tested) 3) For systems without GPS, the time-stamping accuracy depends on the accuracy of the Real

Time Clock in the RTU Processor module, the SCADA / Network time management protocol used, the Backplane time synchronisation latency (that is influenced by the type of the Processor module used and by its loading with the RTU logic and communications), by the number of installed DI-10 modules and by other system-dependent parameters.

4) Only on DI-10-GPS modules (GPS Master)




11.3.9 DI-10 Wiring Diagram An edge-pluggable terminal block Fujicon F5021 is used for wiring of Digital Inputs and power outputs to the DI-10 module PCB. It can be un-coupled from the DI-10 board for wiring convenience if required.

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.

Note 1. Pins 9 and 19 (+12V) are connected together internally.

Note 2. Pins 10 and 20 (0V) are connected together internally.

Powered by Module

External DC Power Supply

Note: DC voltage applied to any input channel must be positive in respect to 0V.




External AC Power Supply

Note: AC filter must be enabled in the DI-10 configuration for this channel.

DC and AC powered inputs can be used simultaneously on the same module. Care should be taken to ensure that the negative rail of each external power supply is connected to the Common (0V) terminal.




12. DIGITAL OUTPUT MODULES

Overview The digital output modules provide relay and transistor outputs to the Kingfisher Plus+ series of RTUs.

The DO-1 and DO-2 offer relay outputs, eight and sixteen respectively, while the DO-6 is transistor based.

The DO-6 is compatible with the TEL-REL-00x series of relay output boards to allow for higher current and voltage switching.

Switching Inductive Loads When switching inductive loads, users should be mindful of possible reduced relay service life due to back-EMF. To mitigate this negative effect, suppression circuits should be used when switching inductive loads.

Switching DC Supplied inductive loads (high switching relay output)

Switching DC Supplied inductive loads (ground switching relay output)



http://en.wikipedia.org/wiki/Counter-electromotive_force


Switching AC supplied inductive loads (*MOV = Metal Oxide Varistor)



http://en.wikipedia.org/wiki/Varistor


DO-1: 8 Channel Isolated Relay Output Module

12.3.1 Overview • 8 SPDT isolated relay outputs • One common per channel pair • Can switch AC or DC voltages • 500 V channel pair isolation • 3 kV coil to contact isolation

The DO-1 provides 8 normally open or normally closed relay circuits for controlling output loads. All output channels are isolated from each other and arranged into pairs. Each channel pair shares a separate common terminal (please see the “DO-1 Wiring Diagram” section for more details).

The relay outputs can control a wide range of user supplied load devices such as motors, starters, solenoids, and indicators. The user is required to supply the AC or DC power to operate the field devices connected to this module. Internal fuses offer protection to the relay contacts should their maximum load be exceeded.

This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.




Electrical Hazards









câblage.


Electrical Hazards

If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all commons must be connected to a single

power source and no other power sources are allowed to be connected to this module.


Si l’on prévoit que la tension d’entrée dépasse les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60V ou AC 42 Vcrête par rapport à la terre du système et/ou au sol) alors les connexions

communes doivent être connectées à une seule source d’alimentation et aucune autre source ne peut-être connectée au

module.




Block-diagram of the DO-1 module is shown on the figure below.

DO-1 Block Diagram

12.3.2 DO-1 Module LEDs



ON Normal

FU OFF Fuse OK

ON Fuse fail

A1, A2 B3, B4 C5, C6 D7, D8

OFF Digital output OFF (open)

ON Digital output ON (closed)




12.3.3 DO-1 Specifications DO-1 Isolated Relay Output Module Specifications


Commons 4 (each common supplies 2 outputs)

Relay Type SPDT (Single Pole, Double Throw)

Rated Load (per common) 5 A at 250 VAC Resistive 5 A at 30 VDC Resistive (20 A maximum per DO-1 module)

Maximum Operating Voltage 250 VAC, 125 VDC

Maximum Switching Power - Resistive 1250 VA, 150 W

Maximum Switching Power - Inductive 375 VA, 80 W

Minimum Load 10 mA at 5 VDC

Relay Operations 100,000 minimum at 1800 operations per hour at rated load




Altitude 2000 m max

Isolation 3 kV coil to contacts 500 V between channel groups

Relay Part Number Omron G6B-2114P-US (G6B datasheet is available from http://components.omron.eu/)


CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing.

# Refer to the label on the side of the module which indicates the hardware version. If the version number is not printed on the label then the module is v2.2 or older.



http://components.omron.eu/Product-details/G6B


12.3.4 DO-1 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.




Wiring Example

Notes: 1. Polarity can be reversed. 2. For safety reasons, do not connect more than one power source to a Digital Out Common

terminal. 3. If power supply voltage exceeds SELV levels (DC 60 V or AC 42 VPEAK relative to system earth

and/or ground) then all Common Terminals of the module must be connected to a single power source and no other power sources can be connected to the same module.

LOAD Y

LOAD X

Channel Y

Channel X

Common

PowerSupply

+

_




DO-2: 16 Channel Relay Output Module

12.4.1 Overview • 16 SPST relay outputs • One common per 8 channels • 3 kV coil to contact isolation • Can switch AC or DC voltages

The DO-2 provides 16 normally-open relay circuits for controlling output loads provided by the user. The output points are arranged in two groups of eight. Each group shares a common terminal. The relay outputs can be used to control a wide range of devices such as motor starters, solenoids, and indicators.

Internal fuses protect the DO-2 relay contacts should ratings be exceeded.



DO-2 Block Diagram




Electrical Hazards









câblage.


Electrical Hazards

If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all commons must be connected to a single

power source and no other power sources are allowed to be connected to this module.


Si l’on prévoit que la tension d’entrée dépasse les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60V ou AC 42 Vcrête par rapport à la terre du système et/ou au sol) alors les connexions

communes doivent être connectées à une seule source d’alimentation et aucune autre source ne peut-être connectée au

module.







ON Normal

FU OFF Fuse OK

ON Fuse fail

1-16 OFF Digital output OFF (open)


12.4.3 DO-2 Specifications DO-2 16 Channel Digital Output Module Specifications


Commons 2 (each common supplies 8 outputs)

Relay Type SPST (Single Pole Single Throw, Normally Open)

Maximum Switched Voltage 30 VDC, 250 VAC

Maximum Switched Current 5 A per common

Minimum Load 10 mA @ 5 VDC (wetting current)

Contact Resistance 100 mΩ maximum




Altitude 2000 m max

Isolation Maximum working voltage in respect to system earth/ground must not exceed 250 VAC / 130 VDC Transient voltage: 3 kV


Fuse Monitor LED Enabled when the common is wired to pins 10 and 20. CAUTION! When wired, a maximum voltage of 30 V AC or DC can be used to power the common.

Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/)






http://components.omron.eu/Product-details/G6D


Note: Link terminals can be optionally connected to the adjacent Common terminals to enable the Fuse Monitor LED (FU).

Caution: A maximum of 30 V (AC or DC) can be used to power the common if the link is installed.

Wiring Example

Notes: 1. Polarity can be reversed. 2. For safety reasons, do not connect more than one power source to a Digital Out Common

terminal. 3. If power supply voltage exceeds SELV levels (DC 60 V or AC 42 VPEAK relative to

system earth and/or ground) then both Common Terminals of the module must be connected to a single power source and no other power sources can be connected to the same module.

LOAD Z

LOAD Y

Channel Z

Channel Y

Common

PowerSupply

+

_

LOAD XChannel X




DO-6: 16 Channel Open Drain Output Module

12.5.1 Overview • 16 Open-drain outputs • Designed to operate TEL REL 00x relay board • DC Field Output (non-isolated)

The DO-6 provides 16 open drain N-FET outputs for controlling various loads including the TELREL series of relay boards. Power for external loads can be provided from the modules +12 VDC which is sourced from the backplane rail.

The DO-6 output channels are current limited and are protected from high levels of EMI that may trigger false outputs.



DO-6 Block Diagram







ON Normal

A1-A16 OFF Digital output OFF (open)


12.5.3 DO-6 Specifications DO-6 Channel Open Drain Output Module Specifications


Commons 1

Rated Voltage 30 VDC maximum.

Output Type N-FET, Open Drain

Rated Load 70 mA per channel

Current Limit 90 mA per channel

Output Power 12 VDC non-regulated, non-isolated (supplied by module directly from backplane), 1.6 A maximum

ON Response Time 15 ms maximum

OFF Response Time 15 ms maximum





Compatibility The DO-6 is functionally equivalent and pin compatible with the superseded DO-5.





Note: The +12 V Output is sourced from the backplane power rail and is not isolated. Users should exercise caution to avoid shorting or overloading this output.

External DC power supply:

Load powered by module:




13. RELAY EXPANSION BOARDS

Overview The Kingfisher Plus+ Relay Expansion Boards are designed to be used in conjunction to the DO-6 module. The relay boards allow much more flexible use of the DO-6 module due to the wide range of relay types available.

Each relay board has unique internal wiring. Users should be mindful that they are not completely pin-compatible. Please refer to individual wiring diagrams for details.

TEL REL 002

• 16 Channel Isolated Relay SPDT for DO-6-x complete with 1.5m cable • Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel) • Max Current 16 A @ 250 VAC resistive, 16 A @ 30 VDC resistive, 0.45 A @

125 VDC Inductive. • 5 kV isolation (Coil to Contact) • Omron G2R-1-E 12 VDC Relay

TEL REL 003

• Relay Board - 16 Channel Isolated Relay SPST for DO-6-x complete with 1.5m cable

• Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel) • Max Current 8 A @ 250 VAC resistive, 8 A @ 30 VDC resistive, 1 A @ 125 VDC

Inductive • 5 kV isolation (Coil to Contact) • Omron G2RG-2A4 12 VDC Relay

TEL REL 004

• Relay Board - 16 Channel Isolated Relay DPDT for DO-6-x complete with 1.5m cable

• Max Voltage 380 VAC, 125 VDC, 32 commons (2 common per channel) • Max Current 5 A @ 250 VAC resistive, 5 A @ 30 VDC resistive • 5 kV isolation (Coil to Contact) • Omron G2R-2 12 VDC Relay

Electrical Hazards












câblage.





TEL REL 002: SPDT Relay Board

13.2.1 Overview • 16 SPDT Relay Outputs • Common for each channel • 5 kV coil to contact isolation • Can switch AC or DC voltages

The TEL REL 002 is designed to accompany the DO-6 to provide 16 SPDT voltage free output contacts.

Each relay consumes 43 mA @ +12 VDC from the backplane power supply. An external supply can be connected to a screw terminal on the PCV is available (this is not the case if the standard cable supplied with the DO-6 modules is utilized).

LED indicators are provided for each relay on the relay board. LED ON = relay active.

13.2.2 TEL REL 002 Specifications TEL REL 002 SPDT Relay Boards Specifications

Outputs per Terminal Board 16

Commons 16# (1 common per channel)

Relay Type (per channel) SPDT (Single Pole, Double Throw)

Rated Load (per contact) 16 A @ 250 VAC Resistive 16 A @ 30 VDC Resistive


Maximum Switching Power - Resistive

16 A @ 30 VDC 5 A @ 48 VDC 0.6 A @ 125 VDC

Maximum Switching Power - Inductive

16 A @ 12 VDC 8 A @ 30 VDC 0.7 A @ 48 VDC 0.45 A @ 125 VDC




Operating Temperature -20 to +70 °C (no icing)


Humidity 5 to 95 % RH (non-condensing)

Isolation 5 kV coil to contacts

Coil Rated Voltage 12 VDC @ 43 mA

Coil Resistance 275 Ω @ 12 VDC




Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)

Mounting 35 mm DIN rail

Interface Cable Length 1500 mm (for connection to the DO-6 module)

Connection Terminals Phoenix double height PCB terminal unit arranged in a dual three way terminal (please see wiring diagram). These terminals can take wire sizes up to 4 mm2.

Relay Part Number Omron G2R-1-E 12 VDC (datasheet is available from http://components.omron.eu/)

CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing. #) CAUTION! If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons must be connected to a single power source and no other power sources are allowed to be connected to this module.



http://components.omron.eu/Product-details/G2R


13.2.3 TEL REL 002 Wiring Diagram

DO-6 to TEL REL 00x Interface Cable




Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Colour Panduit 20 way header pins

1 Channel 1 Black 1

2 Channel 2 White 2

4 Channel 3 Red 4

4 Channel 4 Green 4

5 Channel 5 Orange 5

6 Channel 6 Blue 6

7 Channel 7 White/Black 7

8 Channel 8 Red/Black 8

9 0 V Green/Black 9

10 0 V Orange/Black 10

11 Channel 9 Blue/Black 11

12 Channel 10 Black/White 12

13 Channel 11 Red/White 13

14 Channel 12 Green/White 14

15 Channel 13 Blue/White 15

16 Channel 14 Black/Red 16

17 Channel 15 White/Red 17

18 Channel 16 Orange/Red 18

19 + 12 VDC Blue/Red 19

20 + 12 VDC Green/Red 20




TEL REL 003: SPST Relay Board

13.3.1 Overview • 16 SPST Relay Outputs • Common for each channel • 5 kV coil to contact isolation • Can switch AC or DC voltages • Higher inductive rating than other TEL REL 002

(1 A @ 125 V as opposed to 0.4 A @ 125 V)

The TEL REL 003 board is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides superior inductive load rating than the TEL REL 002.


13.3.2 TEL REL 003 Specifications TEL REL 003 SPST Relay Board Specifications


Commons 16# (1 common per channel)

Relay Type (per channel) SPST (Single Pole, Single Throw)

Rated Load (per contact) 8 A at 250 VAC Resistive 8 A at 30 VDC Resistive 1 A at 125 VDC Inductive


Maximum Switching Power - Resistive 2000 VA, 240 W


Relay Operations 100,000 minimum at 1800 operations per hour at rated resistive load 50,000 minimum at 360 operations per hour at rated inductive load




Coil Rated Voltage 12 VDC @ 66 mA




Interface Cable Length 1.5 m (for connection to the DO-6 module)

Connection Terminals Weidmuller single height PCB 3-way terminal unit (please see wiring diagram). These terminals can take wire sizes up to 4 mm2.




Relay Part Number Omron G2RG-2A4 12 VDC (datasheet is available from http://components.omron.eu/)


#) CAUTION! If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons must be connected to a single power source and no other power sources are allowed to be connected to this module.




http://components.omron.eu/Product-details/G2RG



Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins

1 Channel 1 Black 1

2 Channel 2 White 2

4 Channel 3 Red 4

4 Channel 4 Green 4


6 Channel 6 Blue 6



9 0 V Green/Black 9















TEL REL 004: DPDT Relay Board

13.4.1 Overview • 16 DPDT relay outputs • 2 commons per channel • 5 kV coil to contact isolation • Can switch AC or DC voltages

The TEL REL 004 is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides Double Pole Double Throw (DPDT) relays. This allows the user to utilize both normally open and normally closed relay operation.


13.4.2 TEL REL 004 Specifications TEL REL 004 DPDT Relay Board Specifications


Commons 32# (2 commons per channel)

Relay Type (per channel) DPDT (Double Pole, Double Throw)

Rated Load (per contact) 5 A at 250 VAC Resistive 5 A at 30 VDC Resistive

Maximum Current 5 A

Maximum Operating Voltage 380 VAC, 125 VDC (2 A maximum)

Maximum Switching Power 750 VA, 90 W Resistive



Relay Operations >10,000,000




Coil Rated Voltage 12 VDC @ 44 mA per coil




Interface Cable Length 1.5 m (for connection to the DO-5/6 module)

Relay Part Number Omron G2R-2 12 VDC (datasheet is available from http://components.omron.eu/ )



http://components.omron.eu/Product-details/G2R


CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing. #) CAUTION! If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons must be connected to a single power source and no other power sources are allowed to be connected to this module.




Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins

1 Channel 1 Black 1

2 Channel 2 White 2

4 Channel 3 Red 4

4 Channel 4 Green 4


6 Channel 6 Blue 6



9 0 V Green/Black 9















14. COMBINATION IO MODULES Combinational IO modules provide digital and analogue IO in a single module. They can be installed in any 4, 6, or 12 slot backplane.

IO-2: Combinational Digital IO Module

14.1.1 Overview • 8 SPST relay outputs • Digital inputs

This module can be installed in any slot of a 4, 6 or 12 slot backplane.

Digital Inputs The digital inputs are designed to be powered using an external power supply. A wide range of digital input devices can be used such as push buttons, limit switches and electronic proximity switches. Current through an input (in either direction) results in a logic 1 in the status register. Power to operate the field devices must also be supplied by the user.

Digital Outputs The output points are arranged in one group of eight points with one common. The output switching capacity of each output is 2 amps. The relay outputs can control a wide range of load devices such as motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate the field devices. An internal fuse protects the relay contacts should ratings be exceeded.




Block-diagram of the IO-2 module is shown on the figure below.

IO-2 Block Diagram




14.1.2 IO-2 Module LEDs



ON Normal

FU OFF Fuse OK

ON Fuse fail

A1-A8 OFF Digital input OFF

ON Digital input ON

B1-B8 OFF Digital output OFF (open)


14.1.3 IO-2 Specifications IO-2 Combinational IO Module Specifications




Hot Swap

Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.

DIGITAL INPUTS

Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)

Inputs per Module 8


ON-state Voltage 11.5 to 30 VDC maximum

OFF-state Voltage 0 to 4 VDC



ON Response Time 10 ms typical

OFF Response Time 17 ms typical

Input Current 4 mA (typical) at rated voltage

Isolation 3 kV between field and logic




DIGITAL OUTPUTS


Commons 1 (common supplies all 8 outputs)

Relay Type SPST (Single Pole Single Throw)




Minimum Load 10 mA @ 5 VDC





14.1.4 IO-2 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert.





Digital Input Example: (Note polarity can be

reversed on power supply)

Digital Output Example:

* Optional link for DC Supply only. Enables fuse fail LED ‘FU’ on module.

CAUTION: when the link is installed a maximum of 30 V (AC or DC) can be used to power the common.

Note: DC powered inputs and low voltage AC inputs can both be used on the same module.




IO-3: Combinational Analogue/Digital IO Module

14.2.1 Overview • 4 SPST relay outputs • 4 analogue inputs • 4 digital inputs • 1 analogue output

This module can be installed in any slot of a 4, 6 or 12 slot backplane.

Analogue IO The IO-3 provides two signal ranges: 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.

Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. All channels are updated four times per second (250 ms refresh time). The placement of the bits within the data word is shown below.

MSB LSB

0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0


All inputs share a single common and all outputs share a separate common at the zero volt rail.


To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).




Digital IO Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.





IO-3 Block Diagram




ON Normal

FU OFF Fuse OK

ON Fuse fail

A1-A4 - Not used

B1 - Not used

C1-C4 OFF Digital input OFF

ON Digital input ON

D1-D4 OFF Digital output OFF (open)





14.2.3 IO-3 Specifications IO-3 Analogue/Digital Combinational IO Module Specifications

Supply Voltage (nominal) +5 VDC and +12 VDC from backplane


Output Power 24 VDC / 100 mA max, Isolated




Hot Swap


ANALOGUE INPUTS

Input Current Ranges 4 to 20 mA or 0 to 20 mA

Input Voltage Ranges * 1 to 5 V and 0 to 5 V *

Inputs per Module 4

Update Rate 2 ms (all four channels)

Accuracy ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C


Linearity < 1 Least Significant Bit

Isolation Transient voltage: 1 kV

Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz



Input Filter Cutoff Frequency 325 Hz @ -3 dB

ANALOGUE OUTPUT

Output Current Range 4 to 20 mA or 0 to 20 mA


Update Rate 250 ms (all channels) Determined by I/O scan time and is application dependent

Accuracy ± 0.25% @ 25 °C


User Load 0 to 850 Ω

Output Load Capacitance 2000 pF




Output Load Inductance 1 H

DIGITAL INPUTS


Inputs per Module 4









DIGITAL OUTPUTS


Commons 1 (common supplies all 4 outputs)

Relay Type SPNO (Single Pole, Normally Open)


Maximum Switched Current

4 A per channel 5 A per common

Minimum Load 10 mA @ 5 VDC (wetting current)






* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R39, R41, R43 and R45 (channels 1 to 4 correspondingly).






Note: Link terminal can be optionally connected to the Digital OUT Common terminal to enable the Fuse Monitor LED (FU).

CAUTION: when the link is installed a maximum of 30 V (AC or DC) can be used to power the common.




Note: DC powered inputs and low voltage AC inputs can both be used on the same module.

Analogue Input Examples







Analogue Output Example

Analogue load

Digital Input Example

Sensing the output form a field contact




Digital Output Example

Driving external load(s) from digital output(s)

Notes:

1. Polarity can be reversed. 2. For safety reasons, do not connect more than one power source to a Digital Out Common

terminal.

LOAD Z

LOAD Y

Channel Z

Channel Y

Common

PowerSupply

+

_

LOAD XChannel X




IO-4: Combinational Analogue / Digital IO Module

14.3.1 Overview • 2 SPST relay outputs • 2 analogue inputs • 8 digital inputs


Analogue IO The IO-4 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.

Channel 1 can be utilized for a strain gauge input of range approximately 50 mV. 5 V excitation voltage is supplied from this module (please refer to the wiring diagram for further information).

Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.

MSB LSB

0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0







Digital IO Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.


IO-4 Block Diagram




ON Normal

FU OFF Fuse OK

ON Fuse fail

A1-A8 OFF Digital input OFF

ON Digital input ON

B1-B2 OFF Digital output OFF (open)





14.3.3 IO-4 Specifications IO-4 Analogue / Digital Combinational Module Specifications





Hot Swap


ANALOGUE INPUTS

Input Current Ranges 4-20 mA and 0-20 mA

Input Voltage Ranges * 1-5 V and 0-5 V *

Inputs per Module 2

Update Rate 2 ms (all four channels)

Accuracy ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C


Common Mode Voltage 1500 V

Linearity <1 Least Significant Bit

Isolation 1000 VRMS between field and logic

Common Mode Rejection >70 dB at DC; >70 dB at 60 Hz

Cross-Channel Rejection >80 dB from DC to 1 kHz






DIGITAL INPUTS


Inputs per Module 8









Isolation 1000 VRMS between field and logic

DIGITAL OUTPUTS


Commons 1 (common supplies both outputs)

Relay Type SPST (Single Pole Single Throw)




Minimum Load 10 mA @ 5 VDC




CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the “Switching Inductive Loads” section for more details). Contacts should also be protected with external fusing.

* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R85 and R41 (channels 1 and 2 correspondingly).






* Optional link for DC Supply only. Enables fuse fail LED ‘FU’ on module. CAUTION! When the link is installed, a maximum voltage of 30 V (AC or DC) can be used to power the common.




Strain gauge input (4 wire Wheatstone bridge)




2 wire transmitter (externally powered)



Field contact input (externally powered)

Driving digital load (externally powered)

Passive field contact (powered by module)




IO-5: Combinational Analogue / Digital IO Module

14.4.1 Overview • 4 analogue inputs • 1 analogue output with open line detection • 4 digital inputs • 4 sinking solid state outputs


Analogue IO Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.


Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.

MSB LSB

0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0



For analogue outputs, an Open Line Detection circuit will indicate whether current loop is open or closed. Please note that open line detection circuit performance cannot be guaranteed when AO value is set to less than 1% (328 decimal) of full scale in the 0-20 mA range.




The IO-5 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.

Digital Inputs For high speed isolated digital inputs are provided on the module. All four digital inputs share on one common rail.

All channels can be configured as pulse counters that appear 16 bit unsigned integer values in the analogue input registers of the RTU processor module. Because of processor module limitations, only channels 1 and 2 can be configured as pulse counters when used with the CP-11/12/21 and PC-1 processors (Toolbox 32). All four channels can be used as pulse counters when used with CP-30 processor module (Toolbox PLUS).

Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches, Hall sensors, proximity switches, etc.

Digital Outputs The IO-5 provides 4 open-drain (sinking) outputs for controlling various loads. Power for the loads can be provided from the on-board isolated +24 VDC power supply or from an external power source.

The IO-5 output channels provide continuous protection from overloads.





IO-5 Block Diagram







ON Normal

RST OFF Normal

ON Module Reset in progress

24Va OFF Field Power disabled

ON Field Power enabled

AI 1-4 OFF Analogue input is less or equal to 1% of range

ON Analogue input is greater than 1% of range

AO1 OFF Analogue output is set to less or equal to 1% of range

ON Analogue output is set to greater than 1% of range

OL OFF Analogue output line is closed (loaded)

ON Analogue output line is open / loop current equal to zero

DI 1-4 OFF Digital input OFF

ON Digital input ON

DO 1-4 OFF Digital output OFF (Output switch does not conduct)

ON Digital output ON (Output switch conducts)




14.4.3 IO-5 Specifications IO-5 Analogue / Digital Combinational Module Specifications





Maximum Working Voltage on any contact of

the f ield connector 42.4 VPEAK / 60 VDC relative to system (backplane) ground

Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start.

ANALOGUE INPUTS

Input Current Ranges 4 - 20 mA or 0 - 20 mA

Input Voltage Ranges * 1 - 5 V or 0 - 5 V *

Inputs per Module 4

Resolution Unsigned 12 bit

Accuracy (includes Gain, Linearity

and Offset errors)

± 0.25% @ 25 °C ± 0.50% @ -40 to +85 °C

Update Rate 120 ms


Input Impedance 250 Ω standard 1 MΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.


AC noise attenuation 16 dB @ 50 Hz 18 dB @ 60 Hz

Output Field Power 24 VDC / 80 mA Isolated





ANALOGUE OUTPUT

Output Current Range 4 - 20 mA or 0 - 20 mA


Output Type Isolated, Sourcing

Resolution Unsigned 12 bit

Update Rate 250 ms Determined by I/O scan time and is application dependent

Accuracy ( includes Gain, Linearity and Offset errors)

± 0.25% @ 25°C ± 0.50% @ -40 to +85 °C

User Load 0 to 850 Ω


DIGITAL INPUTS

Inputs per Module 4 with one common

Input Type Optically isolated, Sinking

Maximum Input Voltage 30 VDC

Guaranteed ON-state Voltage 10 VDC minimum

Guaranteed OFF-state Voltage 4.0 VDC maximum

Counters Type Pulse, Unsigned 16-bit (all channels)

Maximum Counters Speed 10 kHz

Input Current Approx. (VIN / 4.7) mA:

2 mA @ 9.4 VIN; 6.4 mA @ 30 VIN


DIGITAL OUTPUTS

Outputs per Module 4 with one common

Output Type Optically isolated, Solid State, Sinking

Maximum Switched Voltage 30 VDC

Maximum Switched Current 2 A per channel


* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are:

• Ch.1: R81 (or R85+R86); • Ch.2: R82 (or R87+R88); • Ch.3: R83 (or R89+R90); • Ch.4: R84 (or R91+R92).




Analogue Input Examples







Analogue Output Example

Analogue load

Digital Input Example

Sensing the output form a field contact

Digital Output Example

Driving external load from digital output




15. ADAPTORS AND CABLES

Overview A range of adaptor and cable accessories are available for the Kingfisher Plus+ range to allow for communications interfacing. The adaptor plugs universally adapt to RJ45 to allow standard CAT5/6 cabling to be used between RTUs, PLCs and communications devices.

Connectivity Example

Reference:




Summary of available adaptors and cables Part Number Description

ADP-04 Maxon and Tait radios (DB9F to RJ45 Adaptor) for 'R' option

ADP-05 PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options

ADP-N DB9 port saver. Used with ADP-05 for concealed PC serial ports (e.g. Current HP Notebooks)

ADP-05-N PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver.

ADP-07 PSTN modem external 25 pin (DB25M to RJ45 Adaptor) for 'S' options, confirm PSTN pin-outs

ADP-08 RJ45 to DB9 Female Converter (Straight Connect)

ADP-08 M RJ45 to DB9 Male Converter (Straight Connect) for Serial Port to MaxStream External Spread Spectrum Radio

ADP-16 Trio "D" and "E" Series Radio (DB9M to RJ45 Adapter) for 'S' options

ADP-25 Uni-Op Display Model - MD02R-04-00A5 (DB15M to RJ45 Adapter) for 'S' options

ADP-28 Trio "H" series Spread Spectrum Radio (DB9M to RJ45 Adapter) for 'S' options

ADP-29 Trio "M" series Radio (Modem fitted) (DB9M to RJ45 Adapter) for 'S' options

ADP-31 Trio "M" series Radio (DB9M to RJ45 Adapter) for PC-1 'R' option

RJC-05 Cable RJ45 Plug both ends "1:1" - 0.5 meters

RJC-10 Cable RJ45 Plug both ends "1:1" - 1.0 meter





RJC-ADP-22B Wavecom GSM Cable (RJ45 to HD15) for 'S' options, to suit Fastrack Xtend FXT009, and superseded 1205-1306, Supreme 10

RJC-ADP-26 Maxon MM-6280IND 3G Cable (RJ45 to DB15) for 'S' options

RJC-ADP-27 Motorola Satellite Series 9522 L-Band Cable (RJ45 to DB25) for 'S' options

RJC-ADP-30 Trio "M" series radio Cable (RJ45 to DB15) for 'L' option

RJC-45/12 RJ45 to RJ12 Phone Lead - 2.0meters

RJC-X-OVER Serial RJ45 to RJ45 cross over cable - 1.5 meters

RJC-ETHER-X-OVER Ethernet RJ45 to RJ45 cross over cable - 2.0 meters

CAB-OPTION-J Image Capture Option cable - SMB to BNC female - 2.5m

CAB-IO-1 External I/O cable - 1m



CAB-FO-PATCH-1 Patch Cable for A3 Ethernet Option Board (MTRJ to ST)

CAB-FO-PATCH-2 Patch Cable for A3 Ethernet Option Board (MTRJ to SC)




RTU Test Cables RJC-X-OVER: Kingfisher Plus+ RJ45 to RJ45 RS-232 Null Modem Cable (serial crossover)

RJ45 to Kingfisher RTU Serial Port RJ45 to Kingfisher RTU Serial Port

RJC-ETHER-X-OVER: Kingfisher Plus+ RJ45 to RJ45 Ethernet Crossover Cable

RJ45 to Kingfisher RTU Ethernet Port RJ45 to Kingfisher RTU Ethernet Port




Device Cables and Adaptors ADP-04: PC-1/MC-1 Radio Port to Tait T2010 or Maxon RDM-01 Radio (SD125)

RJ45 to Kingfisher RTU Radio Port To Tait 2010 or Maxon RDM-01 radio

ADP-05: RTU Serial Port to PC Serial Port (creates a null modem cable)

To Kingfisher Serial Port To PC Serial Port




ADP-07: RTU Serial Port to External PSTN Modem

To Kingfisher Serial Port To PSTN Modem

ADP-08: RJ45 to DB9 Female Converter (Straight Connect)

(Note: when coupled with an ADP-05 forms a null modem cable DB9 female to DB9 female)

To Kingfisher Serial Port To External Device




ADP-08-M: Serial Port to Digi External Spread Spectrum Radio

For Digi XTend-PKG or XStream-PKG, and other 3rd party radios.

To Kingfisher Serial Port To External Radio

ADP-09: Serial Port to HITECH or Nematron Display Panel

To Kingfisher Serial Port To Operators Panel




ADP-16: Serial Port to Trio D-Series Radio or Trio E/K/M Series Radio

Hardware flow control supported.

To Kingfisher Serial Port To Trio Radio

RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio

For TC-450SR, TC-900SR or RTU Serial Port to Trio S-Series Radio with 24/48SR modem.





RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125)

To Kingfisher Serial Port To Maxon Radio




RJC-ADP-20: CP-xx Line Option Board to Trio S Series Analogue Radio

For use with TC-450SR or TC-900SR.

To Kingfisher Serial Port To Maxon Radio

RJC-ADP-21: CP-xx Line Option Board to Tait T2010 Analogue Radio

To Kingfisher Serial Port To Tait Radio




RJC-ADP-22B: Serial Port to Wavecom GSM

For use with the WM02-G900, Fastrack, Fastrack Supreme, or Fastrack Xtend.

Note: Adds a RTS/DTR link to the previous RJC-ADP-22 cable. Link required for Fastrack Supreme. Link will also work with the older WM02-G900 and Fastrack modems.

To Kingfisher Serial Port To GSM or GPRS Modem

RJC-ADP-23: PC-1/MC-1 Radio Port/Serial Port to Trio S- Series (SB) Repeater

To Kingfisher Serial Port To GSM or GPRS Modem




RJC-ADP-26: Serial Port to Maxon MM-6280IND 3G Data Modem (previously used for the Maxon MM-5100 CDMA Modem)

To Kingfisher Serial Port To 3G Data Modem

RJC-ADP-27: RTU Serial Port to Motorola 9522 Satellite Transceiver

To Kingfisher Serial Port To Satellite Transceiver




ADP-28: RTU Serial Port to Trio H–Series Spread Spectrum Radio


ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR450

For hardware flow control see the ADP-16.





RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio (no modem fitted) E.g. MR450


ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g. MR450





CAB-FO-PATCH-1: A3 Ethernet MTRJ Fibre Optic to 2 × ST adaptor cable

To Kingfisher A3 Option Board To external Device

CAB-FO-PATCH-2: A3 Ethernet MTRJ Fibre Optic to 2 × SC adaptor cable

To Kingfisher A3 Option Board To external Device

Maxon Intermax: Serial Modem to Kingfisher Serial Port




16. ACCESSORIES Accessories are available that can ease the installation of your RTU. These include rack mounting hardware and battery carrier mounts.

MBR-3: 19” Rack Mounting for BA-12-PLUS

A 12 slot backplane (BA-12-PLUS) is mounted in a 19 inch rack using two MBR-3 mounting brackets. The MBR-3 brackets replace the surface mount brackets supplied with BA-12-PLUS backplanes. Each pair of MBR-3 brackets is supplied with four M4 x 6 mm pan head screws.

Installation Note The holes in the MBR-3 brackets that are used to attach the brackets to the back of the backplane are drilled oversize to accommodate slight variances in racking equipment. By loosening these screws, pushing the brackets toward the centre of the backplane and then re-tightening the screws, the unit will fit freely into any correctly sized 19-inch rack.




TEL-RAK-002: 19” Rack Mounting for BA-4/6/40 A four slot backplane (BA-4 or BA-40) or a six slot backplane (BA-6-PLUS) is mounted in a 19 inch rack using a TEL-RAK-002 mounting bracket. One BA-6-PLUS or two BA-4/BA-40 backplanes can be attached to the TEL-RAK-002 using the surface mount brackets supplied with each backplane. The TEL-RAK-002 is supplied with eight M3 x 5 mm screws for attaching the backplane(s).




Battery Bracket: 7 Ah Battery Mounting Bracket When using a 7 Ah backup battery, a standard battery holder is available for mounting on an enclosure gear plate. The bracket supports the battery and allows a General Power Outlet (GPO) to be mounted on the front using M3 x 10 mm pan head screws. The battery holder also allows an ISB50LN lightning arrester to be mounted underneath.




17. GLOSSARY Terms and Abbreviations

AI, AO, DI, DO Analogue Input, Analogue Output, Digital Input and Digital Output respectively

Byte A group of 8 bits. Each bit can be a 0 (off) or a 1 (on) allowing up to 256 combinations.

Comms Communications

Current Sinking Current is supplied into the RTU’s IO terminal.

EMI Electro-magnetic interference

Functional Earthing

Earthing of a point in a system, which is necessary for a purpose other than safety.

IO Input / Output

LED Light-emitting diode

N-FET N-channel Field Effect Transistor

Port A physical connection or socket on an RTU used for communications

Processor Module Processor module containing a CPU (Central Processing Unit)

Protocol

Refers to the format of messages that may be passed to, from and through an RTU in communication with local and remote devices. Communications may use one or more RTU ports. Examples of protocols used within telemetry include Kingfisher, Modbus and DNP3.

RTU Remote Terminal Unit. Describes a group of processor, communications and IO modules that comprise a device for monitoring and control of equipment in remote locations.

TCP/IP Transfer Control Protocol / Internet Protocol. Commonly used for Ethernet communications.




Symbols

The module can only be used in not-tropical climate regions.

The module can only be used at altitude not exceeding 2000 metres above sea level.

This point can be used for Functional Earthing connection.

The module is Class II Equipment

The module is Class II Equipment with Functional Earthing

DANGER. Failure to follow these instructions could result in death or serious injury.

WARNING. Failure to follow these instructions could potentially result in personal injury or death.

CAUTION. Failure to follow these instructions could potentially result in product damage.




18. APPENDIX A: SYSTEM INSTALLATION Superseded items are not present in this hardware manual.

For information regarding any modules not present in this document please refer to the Superseded Products Manual available on Semaphore Helpdesk.

To avoid fire hazards and exposure to electrical shock and other safety hazards, all instructions listed below must be followed.

Enclosure Requirements All components of a Kingfisher Plus+ RTU shall be installed inside of an enclosure providing safety and environmental protection as required. The enclosure shall be made from metal or other material with a flammability rating of V-0 or better in accordance with the requirements of the IEC 60950-1 standard for a fire enclosure. An enclosure not required to prevent a fire hazard if the RTU is installed above concrete or another non-combustible surface.

An RTU shall be mounted with all modules in a vertical position as illustrated below. The enclosure must provide sufficient clearances for conventional air cooling, with a minimum clearance of 100 mm between the RTU modules and the top and bottom of the enclosure:



http://helpdesk.servelec-semaphore.com/semaphore/Knowledgebase/Article/View/144/0/hardware-manual


RTU Installation Example

1. Vent must be installed if enclosure has a battery. Install a second vent in lower right corner if battery capacity exceeds 26 Ah or if environmental conditions require greater airflow.

2. Install Backplane low enough to allow for airflow through modules. 3. Radio or Modem.

Note: Radio or Modem can be mounted on rear of door by using DIN rail. Ensure that the radio is mounted on the top left corner of the door to allow radio to clear the RTU modules when the door is closed.

4. Gear plate. 5. PSU-x AC Power Supply Unit. 6. Power cable strain relief.

Note: Kingfisher Plus+ modules do not specifically allow for wire strain relief, however, cable ties can be attached to the enclosures of the modules via the venting slots, or a self-adhesive cable tie mount can be affixed onto the housing frame.

7. Slotted duct (20 × 60 mm). 8. IO wiring terminal. 9. Double GPO.

One outlet for the RTU and a spare for a laptop. When 7 Ah battery is used, DGPO is mounted on side of battery bracket (available from your supplier).

10. Lightning arrester. Install high enough to allow easy access for antenna lead connection. 11. Battery bracket. Can rest on front lip of enclosure. 12. Earthing stud. Ensure GPO, Backplane and lightning arrester are connected to this point

using appropriate earthing methods.




13. Leave at least 30 mm clearance to allow room for glands and cables. 14. Cable glands mounted through gland plate. 15. Enclosure must not contain openings in this area to avoid fire risk to external

environment.

Mains Power Connection Only appropriately qualified and trained personnel can install and service this equipment. Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide appropriate short-circuit backup protection rated not higher than 20 A and with a breaking capacity of at least 1500 A.

Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit breaker, depending on installation) before performing any operation on this product. Failure to do so may cause fire and may result in a serious personnel injury or even death.

Disconnect power cord from the Power Supply Module and wait for its LEDs on the front panel to go OFF before wiring, removing or servicing.

Warning

For PERMANENTLY CONNECTED EQUIPMENT, a readily accessible disconnect device shall be incorporated in the building installation wiring.

For PLUGGABLE EQUIPMENT, the socket-outlet shall be installed near the equipment and shall be easily accessible.

Earth / Ground Conductors Earth / Ground conductors should be connected in a tree fashion with branches routed to a central earth ground point. This ensures that no ground conductor carries current from any other branch. This method is shown in the following figure.

PROGRAMMING DEVICE

RTU CABINET MOTOR DRIVES AND OTHER ELECTRICAL

CONTROL EQUIPMENT

MACHINERY

CENTRAL GROUND POINT EARTH GROUND

NOTE: SIGNAL AND POWER CONNECTIONS NOT SHOWN

BACKPLANE BACKPLANE

Recommended System Grounding

Earth / Ground conductors should be as short and as large in size as possible. Braided straps or ground cables (typically green insulation with a yellow tracer - AWG #12 / 5 mm2 or larger) can be used to minimise resistance. Conductors must always be large enough to carry the maximum short circuit current of the path being considered.




Protective Earth / Ground Although safety of the Power Supply Module and other modules with the potentially hazardous voltage levels have been assessed and found to be in compliance with the appropriate requirements, an additional level of protection from a potential electrical shock can be provided by connecting the RTU backplane to the Protective Earth / Ground.

The Earth / Ground rail of the backplane PCB can be grounded by mounting screws to the metal back-plate of the backplane when properly installed. Additional grounding wire straps should be used in case reliable screw connections cannot be assured. Earth / Ground connections should be made from one of the PCB mounting tabs to a system earth / ground terminal (usually a threaded stud) using a minimum AWG#12 wire and ring terminals. Use of a nut and star washer for each wire on the ground connection lug is recommended to ensure adequate grounding. Ensure the paint coating is removed under the lug to make good electrical contact.

All backplanes grouped together in a RTU system must have a common ground connection. This is especially important for backplanes that are not mounted in the same enclosure.

The best way to provide proper ground connections is to ensure that the RTU backplane metal frame is directly connected to the mounting panel (or rear plate) by connecting a ground strap from one of the ground lugs on either side of the backplane to the mounting panel or cabinet in accordance with local safety requirements.

Functional Earth / Ground Yellow / Green wire in the mains power cord provides only Functional (NOT Protective) Earth / Ground connection and cannot be relied upon for safety purposes.



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