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Kingfisher Plus+ Hardware Manual KINGFISHER PLUS+ Modular RTU Hardware Reference Manual 7.16 Kingfisher Plus+ Hardware Manual Document Control Copyright Copyright 2000 - 2015 Semaphore Australia Pty Ltd. ABN 35 006 805 910 www.servelec-semaphore.com, [email protected] Kingfisher Plus+ Hardware Manual Revision History Version Number 7.0 7.1 7.12 7.13 7.14 7.15 Date 28/10/2011 3/9/2012 Summary 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 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 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. 18/11/2014 MC-10/11/30 modules added. PS-11 and PS-21 modules added. Option Board T2 added. Various corrections and updates. Kingfisher Plus+ Hardware Manual 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) 7.16 27/05/2015 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) Kingfisher Plus+ Hardware Manual 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............................................................................................... 39 3.2.4 Battery Charging ................................................................................................... 40 3.2.5 Module LEDs ........................................................................................................ 41 3.2.6 PS-x2 Specifications ............................................................................................. 44 3.2.7 PS-x1 Specifications ............................................................................................. 46 3.2.8 Wiring Diagrams ................................................................................................... 48 PSU-x AC Power Supply Unit ..................................................................................... 52 Calculating Power Requirements................................................................................ 56 3.4.1 Total Current Consumption ................................................................................... 56 3.4.2 5 V Rail Overload Check....................................................................................... 58 3.4.3 Total Power Load.................................................................................................. 60 3.4.4 Battery Backup ..................................................................................................... 60 4. PROCESSOR MODULES ........................................................................ 61 Overview .................................................................................................................... 61 PC-1: Power & Processor Module .............................................................................. 62 4.2.1 Overview .............................................................................................................. 62 4.2.2 Part Numbers ....................................................................................................... 63 4.2.3 PC-1 Module LEDs ............................................................................................... 64 4.2.4 PC-1 Specifications .............................................................................................. 65 4.2.5 PC-1 Pinout .......................................................................................................... 67 Kingfisher Plus+ Hardware Manual CP-12 Processor Module ........................................................................................... 68 4.3.1 Overview .............................................................................................................. 68 4.3.2 CP-12 Reset Procedures ...................................................................................... 68 4.3.3 CP-12 Module LEDs ............................................................................................. 69 4.3.4 CP-12 Specifications ............................................................................................ 70 4.3.5 CP-12 Ports .......................................................................................................... 71 CP-30: High Performance Processor Module ............................................................. 72 4.4.1 Overview .............................................................................................................. 72 4.4.2 CP-30 Options and Ordering Info.......................................................................... 72 4.4.3 Backup Battery / Reset to Factory Defaults........................................................... 73 4.4.4 CP-30 Module LEDs ............................................................................................. 76 4.4.5 CP-30 Specifications ............................................................................................ 79 4.4.6 CP-30 Ports .......................................................................................................... 80 5. COMMUNICATIONS MODULES ............................................................... 81 Overview .................................................................................................................... 81 MC-10/11/30 Communications Modules ..................................................................... 82 5.2.1 Overview .............................................................................................................. 82 5.2.2 MC-10/11/30 Module LEDs ................................................................................... 82 5.2.3 MC-10/11/30 Specifications .................................................................................. 83 5.2.4 MC-10/11/30 Block Diagram ................................................................................. 84 5.2.5 MC-10/11/30 Ports................................................................................................ 84 MC-12 Communications Module ................................................................................ 85 5.3.1 Overview .............................................................................................................. 85 5.3.2 MC-12 Module LEDs ............................................................................................ 86 5.3.3 MC-12 Specifications ............................................................................................ 87 5.3.4 MC-12 Ports ......................................................................................................... 88 MC-31 Communications Module ................................................................................ 89 5.4.1 Overview .............................................................................................................. 89 5.4.2 MC-31 Options and Ordering Info ......................................................................... 89 5.4.3 MC-31 Module LEDs ............................................................................................ 90 5.4.4 MC-31 Specifications ............................................................................................ 93 5.4.5 MC-31 Ports ......................................................................................................... 94 6. COMMUNICATIONS OPTION BOARDS .................................................... 95 Overview .................................................................................................................... 95 Compatibility ............................................................................................................... 95 Installing and removing Option Boards ....................................................................... 96 Option Board I: Isolated Serial .................................................................................... 99 6.4.1 Overview .............................................................................................................. 99 6.4.2 Serial Option Board Connections ........................................................................ 100 Option Board I2: Dual Isolated Serial........................................................................ 102 6.5.1 Overview ............................................................................................................ 102 6.5.2 Dual Serial Option Board Connections................................................................ 103 Option Board F: Fibre Optic Serial Board ................................................................. 104 Option Board D: 33.6 kbps Dial Option Board .......................................................... 105 Option Board L: Line/Analogue Radio Interface ........................................................ 107 Kingfisher Plus+ Hardware Manual 6.8.1 Line Board Connections...................................................................................... 107 6.8.2 Connecting a Radio ............................................................................................ 108 6.8.3 2-Wire Line, point-to-point................................................................................... 109 6.8.4 2-Wire Line, multi-drop........................................................................................ 109 6.8.5 4-Wire Line, point-to-point................................................................................... 110 6.8.6 4-Wire Line, multi-drop........................................................................................ 110 Option Board H: HART Interface .............................................................................. 113 6.9.1 HART Board Connections................................................................................... 113 Option Boards T3 & T2: 10/100 Ethernet Controller................................................ 116 Option Board A3: Fibre Optic Ethernet ................................................................... 117 Option Board R2: Australian Spread Spectrum Radio ............................................ 118 Option Board R3: International Spread Spectrum Radio ......................................... 120 Option Board R4: US/Canada Spread Spectrum Radio .......................................... 122 7. PC-1 OPTION BOARDS ........................................................................ 124 PC-1 Serial Option Board ......................................................................................... 124 PC-1 Modem Board PL: Two Wire Line .................................................................... 125 PC-1 Modem Board: Analogue Radio Interface ........................................................ 126 8. IO MODULES OVERVIEW ..................................................................... 127 9. ANALOGUE INPUT MODULES .............................................................. 131 AI-1: 8 Channel Analogue Current Input Module ...................................................... 131 9.1.1 Overview ............................................................................................................ 131 9.1.2 AI-1 Module LEDs............................................................................................... 133 9.1.3 AI-1 Specifications .............................................................................................. 134 9.1.4 AI-1 Wiring Diagram ........................................................................................... 135 AI-10: 8 Channel High Impedance Analogue Input Module ...................................... 137 9.2.1 Overview ............................................................................................................ 137 9.2.2 AI-10 Module LEDs............................................................................................. 140 9.2.3 AI-10 Specifications ............................................................................................ 141 9.2.4 AI-10 / AI-10-V Wiring Diagram........................................................................... 142 10. ANALOGUE OUTPUT MODULE ........................................................... 144 AO-3: Analogue Output Module .............................................................................. 144 10.1.1 Overview........................................................................................................... 144 10.1.2 AO-3 Module LEDs ........................................................................................... 146 10.1.3 AO-3 Specifications .......................................................................................... 147 10.1.4 AO-3 Wiring Diagram ........................................................................................ 148 11. DIGITAL INPUT MODULES ................................................................. 150 Overview ................................................................................................................ 150 DI-5: DC Input 16 Channel Digital Input Module ..................................................... 150 11.2.1 Overview........................................................................................................... 150 11.2.2 DI-5 Module LEDs ............................................................................................ 151 11.2.3 DI-5 Specifications ............................................................................................ 152 11.2.4 DI-5 Wiring Diagram ......................................................................................... 153 Kingfisher Plus+ Hardware Manual DI-10: AC or DC Input, 16 Channel ........................................................................ 155 11.3.1 Overview........................................................................................................... 155 11.3.2 DI-10 Options and Ordering Info ....................................................................... 156 11.3.3 Theory of operation ........................................................................................... 157 11.3.4 Configurable Functions ..................................................................................... 158 11.3.5 Sequence of Events Recording......................................................................... 159 11.3.6 GPS Time Synchronisation (Optional) .............................................................. 159 11.3.7 DI-10 Module LEDs .......................................................................................... 161 11.3.8 DI-10 Specifications .......................................................................................... 163 11.3.9 DI-10 Wiring Diagram ....................................................................................... 166 12. DIGITAL OUTPUT MODULES .............................................................. 168 Overview ................................................................................................................ 168 Switching Inductive Loads ...................................................................................... 168 DO-1: 8 Channel Isolated Relay Output Module ..................................................... 170 12.3.1 Overview........................................................................................................... 170 12.3.2 DO-1 Module LEDs ........................................................................................... 171 12.3.3 DO-1 Specifications .......................................................................................... 172 12.3.4 DO-1 Wiring Diagram ....................................................................................... 173 DO-2: 16 Channel Relay Output Module ................................................................ 175 12.4.1 Overview........................................................................................................... 175 12.4.2 DO-2 Module LEDs ........................................................................................... 177 12.4.3 DO-2 Specifications .......................................................................................... 177 12.4.4 DO-2 Wiring Diagram ....................................................................................... 178 DO-6: 16 Channel Open Drain Output Module ....................................................... 180 12.5.1 Overview........................................................................................................... 180 12.5.2 DO-6 Module LEDs ........................................................................................... 181 12.5.3 DO-6 Specifications .......................................................................................... 181 12.5.4 DO-6 Wiring Diagram ....................................................................................... 182 13. RELAY EXPANSION BOARDS ............................................................ 184 Overview ................................................................................................................ 184 TEL REL 002: SPDT Relay Board .......................................................................... 186 13.2.1 Overview........................................................................................................... 186 13.2.2 TEL REL 002 Specifications ............................................................................. 186 13.2.3 TEL REL 002 Wiring Diagram ........................................................................... 188 TEL REL 003: SPST Relay Board .......................................................................... 190 13.3.1 Overview........................................................................................................... 190 13.3.2 TEL REL 003 Specifications ............................................................................. 190 13.3.3 TEL REL 003 Wiring Diagram ........................................................................... 191 TEL REL 004: DPDT Relay Board .......................................................................... 193 13.4.1 Overview........................................................................................................... 193 13.4.2 TEL REL 004 Specifications ............................................................................. 193 13.4.3 TEL REL 004 Wiring Diagram ........................................................................... 195 14. COMBINATION IO MODULES ............................................................. 197 IO-2: Combinational Digital IO Module ................................................................... 197 14.1.1 Overview........................................................................................................... 197 Kingfisher Plus+ Hardware Manual 14.1.2 IO-2 Module LEDs ............................................................................................ 199 14.1.3 IO-2 Specifications............................................................................................ 199 14.1.4 IO-2 Wiring Diagram ......................................................................................... 200 IO-3: Combinational Analogue/Digital IO Module .................................................... 202 14.2.1 Overview........................................................................................................... 202 14.2.2 IO-3 Module LEDs ............................................................................................ 204 14.2.3 IO-3 Specifications............................................................................................ 205 14.2.4 IO-3 Wiring Diagram ......................................................................................... 207 IO-4: Combinational Analogue / Digital IO Module .................................................. 210 14.3.1 Overview........................................................................................................... 210 14.3.2 IO-4 Module LEDs ............................................................................................ 212 14.3.3 IO-4 Specifications............................................................................................ 213 14.3.4 IO-4 Wiring Diagram ......................................................................................... 215 IO-5: Combinational Analogue / Digital IO Module .................................................. 217 14.4.1 Overview........................................................................................................... 217 14.4.2 IO-5 Module LEDs ............................................................................................ 220 14.4.3 IO-5 Specifications............................................................................................ 221 14.4.4 IO-5 Wiring Diagram ......................................................................................... 223 15. ADAPTORS AND CABLES .................................................................. 225 Overview ................................................................................................................ 225 RTU Test Cables .................................................................................................... 227 Device Cables and Adaptors .................................................................................. 228 16. ACCESSORIES .................................................................................. 239 MBR-3: 19” Rack Mounting for BA-12-PLUS .......................................................... 239 TEL-RAK-002: 19” Rack Mounting for BA-4/6/40.................................................... 240 Battery Bracket: 7 Ah Battery Mounting Bracket ..................................................... 241 17. GLOSSARY ........................................................................................ 242 18. APPENDIX A: SYSTEM INSTALLATION.......................................................... 244 Kingfisher Plus+ Hardware Manual 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 7.16 http://www.servelec-semaphore.com/ Page 10 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 11 Kingfisher Plus+ Hardware Manual BP-2-PLUS – based RTU BA-40-PLUS – based RTU BA-6-PLUS – based RTU Small RTUs examples Medium RTU example Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 12 Kingfisher Plus+ Hardware Manual Large RTU example (only one processor module is required for the entire RTU) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 13 Kingfisher Plus+ Hardware Manual 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 BA-6-PLUS Backplane, 6-slot BA-12-PLUS Backplane, 12-slot BP-2-PLUS Backplane with integrated 5 V power supply, 2-slot BP-4-PLUS Backplane with integrated 5 V power supply, 4-slot BP-6-PLUS Backplane with integrated 5 V power supply, 6-slot POWER SUPPLIES PS-12-0 PS-22-0 PS-12-C PS-22-C PSU-3 PSU-4 PSU-5 AC-DC Power Supply Module Input 100-240 VAC / 50-60 Hz DC-DC Power Supply Module Input 20-60 VDC AC-DC Power Supply Module Input 100-240 VAC / 50-60 Hz, additional 24 Volt Auxiliary Output DC-DC Power Supply Module Input 20-60 VDC, additional 24 Volt Auxiliary Output AC-DC Power Supply Unit Input 90-260 VAC / 50-60 Hz, 40 W AC-DC Power Supply Unit Input 90-260 VAC / 50-60 Hz, 60 W AC-DC Power Supply Unit Input 90-260 VAC / 50-60 Hz, 70 W PROCESSOR MODULES PC-1 CP-12 CP-30 Power and Processor Module Integrated Power Supply, 16 MHz 16-bit CPU, Fixed Serial Port + 1x Optional Port Processor Module 40 MHz 16-bit CPU, Fixed Serial Port + 2x Optional Ports Processor Module 166 MHz 32-bit CPU, Fixed Ethernet Port + 2x Optional Ports COMMUNICATIONS MODULES MC-12 MC-31 Communications Module up to 3 communications ports (incl. fixed serial port) Communications Module up to 3 communications ports (incl. fixed Ethernet port) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 14 Kingfisher Plus+ Hardware Manual Module Description ANALOGUE MODULES AI-1 AI-10 AO-3 Analogue Input Module 8 analogue current inputs, 1 common per module Analogue Input Module 8 analogue high impedance inputs, 1 common per module Analogue Output Module 4 analogue 0-20 mA / 4-20 mA outputs, 4 commons per module DIGITAL MODULES DI-5 DI-10 DO-1 DO-2 DO-6 Digital DC Input Module Bipolar dry contact inputs, 16 Points, 1 common per module Digital AC/DC Input Module Intelligent AC/DC inputs, 16 Points, 1 common per module Digital Relay Output Module NO/NC (SPDT), 8 Points, 4 commons per module Digital Relay Output Module NO (SPST), 16 Points, 2 commons per module 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 Combination Analogue/Digital I/O Module IO-3 IO-4 4 relay outputs / 4 analogue inputs / 4 digital inputs / 1 analogue output, 4 commons per module Combination Analogue/Digital I/O Module 2 relay outputs / 2 analogue inputs / 8 digital inputs, 3 commons per module Combination Analogue/Digital I/O Module IO-5 4 analogue inputs / 1 analogue output / 4 digital inputs / 4 sinking outputs, 4 common per module EXPANSION BOARDS TEL REL 002 TEL REL 003 TEL REL 004 SPDT Relay Expansion Board 16 SPDT relay outputs, 1 common per channel SPST Relay Expansion Board 16 SPST relay outputs, 1 common per channel DPDT Relay Expansion Board 16 DPDT relay outputs, 2 commons per channel Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 15 Kingfisher Plus+ Hardware Manual 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 lowcost RTUs. Seven versions of backplanes are available in total: BA-4 / BA-4-PLUS 4-slot backplane for use with PC-1 processor module BA-40 / BA-40-PLUS 4-slot backplane BA-6 / BA-6-PLUS 6-slot backplane BA-12 / BA-12-PLUS 12-slot backplane BP-2-PLUS 2-slot backplane with integrated 5 V power supply BP-4-PLUS 4-slot backplane with integrated 5 V power supply BP-6-PLUS 6-slot backplane with integrated 5 V power supply Note: Where the number of slots is not important, the backplanes will be referred to as ‘BA-x-PLUS’ (for all passive backplanes) and ‘BP-x-PLUS’ (for all backplanes with a built-in power supply) further in this document. The part numbers with the ‘-PLUS’ suffix use the green pluggable terminal blocks for the inter-rack data connectors, while the old (will be referred to as ‘BA-x’) backplanes use black crimp connectors (Harwin Datamate M80) for that purpose. All Kingfisher Plus+ backplanes are designed to be surface mounted. Mounting brackets (2 pieces) are supplied for user fitting. The backplanes can also be mounted in a 19" rack (see “Accessories” chapter for details). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 16 Kingfisher Plus+ Hardware Manual Module Dimensions Module mounted on a backplane Installing Modules onto a Backplane Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 17 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 18 Kingfisher Plus+ Hardware Manual 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 For information on the BA-40-PLUS backplane connectors please refer to the “Backplane Connectors” section below. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 19 Kingfisher Plus+ Hardware Manual 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 For information on the BA-6-PLUS backplane connectors please refer to the “Backplane Connectors” section below. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 20 Kingfisher Plus+ Hardware Manual 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 For information on the BA-12-PLUS backplane connectors please refer to the “Backplane Connectors” section below. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 21 Kingfisher Plus+ Hardware Manual BP-x-PLUS Backplanes BP-x-PLUS backplanes are available as two-, four- and six- slot versions (BP-2-PLUS, BP-4PLUS 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 22 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 23 Kingfisher Plus+ Hardware Manual 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 24 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 25 Kingfisher Plus+ Hardware Manual Specifications of the BP-x-PLUS backplanes are summarised in the table below. PARAMETER VALUE COMMENT Operating Temperature Range -40 to +85 °C Input Power Rating 10-16 VDC; 5 A Output Power Rating (5V output) 5 VDC ± 5%; 5 A max Derated at high temperatures, refer to the “BP-x-PLUS 5V Output Derating Curve” graph below for details. Output Power Rating (12V AUX output) 10-16 VDC; 2 A max Non-regulated. The output is ON by default but can be controlled by processor software. Rack Number 1 Slot Numbers Not configurable. 1-2 2-slot version (BP-2-PLUS). Not configurable. 1-4 4-slot version (BP-4-PLUS). Not configurable. 1-6 6-slot version (BP-6-PLUS). Not configurable. BP-x-PLUS 5V Output Derating Curve The BP-x-PLUS backplanes are fully compatible with all other Kingfisher Plus+ modules except Power Supply units (PS-xx). Although accidental installation of PS-xx module into a powered backplane will not cause any damage, this is not recommended as the BP-x-PLUS modules are intended to supply power independently and not designed to share power with other power sources. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 26 Kingfisher Plus+ Hardware Manual 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 6-pin 4.2 mm male header (white). J14 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 timesynchronisation between backplanes. 7-pin 3.5 mm male header (green). J13, J15* Phoenix P/N 1843651 (mating part P/N 1840418). 9-pin 5.08 mm male header (orange). J6 Weidmuller P/N 1520260000 (mating part P/N 1716390000). 4-pin 3.5 mm male header (green). J5 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 27 Kingfisher Plus+ Hardware Manual 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 BA12-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-xPLUS 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 28 Kingfisher Plus+ Hardware Manual 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 To be used with Backplanes (Connectors) Description POW ER CA B L E S 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) CO M M C A B L E S 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) S P EC I AL C A B L E S BPC-02-GPS BPC-SPLIT Interrack 2-way Cable, 1.1 m (24V / SYNC and GND pins only) To distribute GPS time-sync pulse across racks without power distribution BPC Splitter Cable, 6-way, 0.1 m Hardware Manual Version 7.16 All (J14 to J14) All (J14) to 2x BPC-0x / BPC-02-GPS cables http://www.servelec-semaphore.com/ Page 29 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 30 Kingfisher Plus+ Hardware Manual T o t al Nu m b e r o f R ac ks i n RT U Switch Settings 1 Rack 2 Racks 3 Racks 4 Racks 1st Rack 2nd Rack 3rd Rack 4th Rack Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 31 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 32 Kingfisher Plus+ Hardware 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-40PLUS 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 33 Kingfisher Plus+ Hardware Manual Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 34 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 35 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 36 Kingfisher Plus+ Hardware Manual Avertissement de Sécurité Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE. On ne peut pas compter sur lui pour assurer la sécurité. The PS-x2/PS-x1 modules provide AC-DC (PS-12 and PS-11 only) or DC-DC conversion from mains power into 12 VDC and 5 VDC for the backplane, as well as 12 VDC and optional 24 VDC auxiliary outputs. Both auxiliary outputs can be controlled by the RTU logic configuration. 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 Switchmode 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 37 Kingfisher Plus+ Hardware Manual 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 PS-12-0 PS-12-C PS-22-0 PS-22-C H/W version v1.31 v1.52 v1.31 v1.52 Mains Input Power 100–240 V, 50-60 Hz or 96-300 VDC 24V AUX power v1.31 3.0 5.0 3 -20 - +70 20-60 VDC -40 - +85 v1.52 Operating temperature, °C v1.31 v1.52 5 V max current, A 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 38 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 39 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 40 Kingfisher Plus+ Hardware Manual 3.2.5 Module LEDs PS-x2 LEDS PS-12-x LED OK PS-22-x State Description ON Module operating normally. 960 ms ON, 80 ms OFF No communications with RTU Processor Module. OFF Power off or Module fault. ON Mains present / SMPS running1,2. OFF Mains not present / SMPS not running. 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. ON The PS-x2 is sending data to Processor Module via Backplane. OFF No data being sent to Processor Module. ON Any RTU module sends data via Backplane. OFF No data being sent by other modules. VIN OVLD Tx Rx BATT (Battery) LEDs ON Battery or load or DC source connected to B terminals. OFF No battery nor load nor DC source connected to B terminals3. ON Battery is slow (float) charging. OFF Battery is not in Float Charge mode. 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. DET FLT BST Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 41 Kingfisher Plus+ Hardware Manual LED State Description ON Battery sources current of more than 0.1 A4 to the PS-x25. OFF Battery does not supply current to the PS-x2. 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. SUPP LOW OUT (Outputs) LEDs ON Backplane power is switched ON. OFF Backplane power is switched OFF (either start-up or shutdown). ON Backplane power is switched ON. OFF Backplane power is switched OFF (either start-up or shutdown). ON 12VAUX is switched ON. OFF 12VAUX is switched OFF. ON 24ViAUX is switched ON. OFF 24ViAUX is switched OFF. 12BP 5BP 12AUX 24AUX FAULT LEDs 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. 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. ON 12VAUX is switched ON and it is below 9 V5. OFF 12VAUX is switched OFF or it is ON and above 9 V5. 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. 12BP 5BP 12AUX 24AUX 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 42 Kingfisher Plus+ Hardware Manual PS-x1 LEDS PS-11-x LED OK1 Vsup1,2 PS-21-x State Description ON Module operating normally. 960 ms ON, 80 ms OFF No communications with RTU Processor Module. OFF Power OFF or Module fault. ON Mains present / SMPS running OFF Mains not present / SMPS not running. 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. ON Backplane power is switched ON. OFF Backplane power is switched OFF (either start-up or shutdown). 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 ON Battery is being charged (current into battery > 100 mA) OFF Battery is not being charged (current into battery < 100 mA or negative) ON Battery is in slow charging (Float Charge) mode. OFF Battery is not in Float Charge mode. ON Battery is fast (Boost Charge) charging mode. OFF Battery is not in Boost Charge mode. 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) Vb1 5V1 Vaux1 BATT CHG1 FL1 BO1 LO1 Notes: 1 ) Redundant Power Supply will have all LEDs turned ON when the Power Supply module is switched OFF. ) If the input supply source is disconnected from the redundant Power Supply, the Vsup LED will go OFF. 2 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 43 Kingfisher Plus+ Hardware Manual 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 - 340 VDC (1.5 A) 20 - 60 VDC (4.0 A) Power Inlet Connector PS-12-x PS-22-x Terminal Block Plug (7.62 mm) Phoenix PC 4/3-ST-7.62 Dinkle EC762V-03P Phoenix GMSTBA 2.5/3-G-7.62 Cable Housing (optional) Phoenix KGG-PC 4/3 Not available PCB Header (7.62 mm) Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P Phoenix GMVSTBR 2.5/3-ST-7.62 ‘B’ Input / Output DC Rated Voltage Range (Maximum Input Current) 12.0 – 16.0 VDC (4.5 A) Backup Battery Type Sealed Lead-Acid (SLA) 25 Ah1 Maximum Battery Capacity Output Power 60 W 2 Total Rated Output Power 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 aux 24 V ± 5% 0.25 A Polyfuse Yes Field Connector Terminal Block Plug (5.0 mm) WECO 120-M-111/07 Phoenix MSTB 2.5/7-G PCB Header (5.0 mm) WECO 120-A-111/07 Phoenix MSTB 2.5/7-ST Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 44 Kingfisher Plus+ Hardware Manual 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 Current5 ±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 Storage Temperature Operating Humidity -20 to +70 °C (v1.3) -40 to +85 °C (v1.5) -40 to +85 °C 5 to 95 % RH (non-condensing) Notes: 1 ) Batteries exceeding quoted maximum capacity can be used. However, full charging and estimated battery charge level cannot be guaranteed. 2 ) Linearly de-rated to 45 W from +70 °C to +85 °C (de-rating factor is 1 W / °C above +70 °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 ) Negative: current flows from the battery (battery supplies power) Positive: current flows to the battery (battery is charged). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 45 Kingfisher Plus+ Hardware Manual 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 DC Rated Voltage Range (Maximum Input Current) 96 - 340 VDC (1.5 A) 20 - 60 VDC (4.0 A) PS-11-x PS-21-x Phoenix PC 4/3-ST-7.62 Dinkle EC762V-03P JST VHR-3M (housing) JST SVH-41T-P1.1 (contact) Phoenix KGG-PC 4/3 Not available Phoenix PC 4/3-G-7.62 Dinkle ECH762R-03P JST S3P-VH Power Inlet Connector Mains Connector Plug Cable Housing (optional) Mains Connector PCB Header ‘B’ Input / Output DC Rated Voltage Range (Maximum Input Current) 12.0 – 15.0 VDC (4.5 A) Backup Battery Type Sealed Lead-Acid (SLA) 25 Ah1 Maximum Battery Capacity Output Power Total Rated Output Power 60 W 2 Maximum total current 4.5 A Output Voltage Range Maximum Current 12 V Backplane3 10.2 - 14.4 V 4.5 A 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 24 V Auxiliary Isolated 24 V ± 5% 0.25 A Protection PS-11 : Electronic PS-21 : No PS-11 : Electronic PS-21 : No Polyfuse Logic Control No Yes 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 46 Kingfisher Plus+ Hardware Manual 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 Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Notes: 1 ) Batteries exceeding quoted maximum capacity can be used. However, full charging and estimated battery charge level cannot be guaranteed. 2 ) For ambient temperatures for up to +50 °C. 3 ) Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and are controlled by the PS-x1 module when charging a battery. They will depend only on backup battery voltage when RTU runs from the battery (e.g. when there is a Mains outage). 4 ) In addition to polyfuse, the PS-11 module has a crowbar over-voltage and reverse polarity protection. The battery input of the PS-21 module does not have auto-resetting protection against reverse-polarity. Please ensure the battery is connected correctly. 5 ) Negative: current flows from the battery (battery supplies power) Positive: current flows to the battery (battery is charged). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 47 Kingfisher Plus+ Hardware Manual 3.2.8 Wiring Diagrams Safety Warning Ensure that the power cord is disconnected from the power source before uncoupling it from the PS-x2/PS-x1 mains power inlet. Disconnect power cord from the PS-x2/PS-x1 before wiring, removing or servicing the module. Connect PS-x2/PS-x1 to Mains supply in accordance with the relevant requirements of national wiring regulations. Mains connections of PS-x2/PS-x1 must comply with all installation requirements listed in this Manual. Avertissement de Sécurité Assurez-vous que le cordon d’alimentation est débranché de la source d’alimentation avant de le débrancher de l’entrée alimentation secteur du module PS-x2/PS-x1. Débranchez le cordon du module PS-x2/PS-x1 avant le câblage, le retrait ou la réparation du module. Connectez le module PS-x2/PS-x1 à l’alimentation secteur en respectant toutes les règles applicables des réglementations et normes électriques locales. L’alimentation secteur connexions du module PS-x2/PS-x1 doit se conformer à toutes les exigences d'installation répertoriées dans ce manuel. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 48 Kingfisher Plus+ Hardware Manual Power Supply with battery backup PS-x2/PS-11 Wiring Diagram PS-21 Wiring Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 49 Kingfisher Plus+ Hardware Manual Notes: 1. The PS-12 and PS-11 modules can be powered using either AC (100 – 240 VAC) or DC (96 – 340 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 50 Kingfisher Plus+ Hardware Manual Powered from 12 – 16 V D C Supply: PS-x2/PS-x1 Wiring Diagram Notes: 1. A battery, a solar system or any other low voltage DC supply can be connected to the ‘B’ terminals to power the PS-x2/PS-x1 module. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 51 Kingfisher Plus+ Hardware Manual PSU-x AC Power Supply Unit The PSU-x AC to DC power supply module is intended to be used as a standalone unit to provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-x units do not have any power monitoring functions. Power monitoring is performed by the PC-1 processor module. The range of supplied PSU-x modules consists of three unit types (PSU-3, PSU-4 and PSU-5), specifications of each are shown below. Fire Risks A supply voltage outside the specified limits may cause fire. Risques d'Incendie Une tension d’alimentation en dehors des limites spécifiées peut provoquer un incendie. Warning The Earth Terminal in the mains power inlet provides only FUNCTIONAL EARTH connection. It cannot be relied upon for safety purposes. Avertissement de Sécurité Le terminal de terre à l’entrée de l’alimentation secteur est uniquement une connexion de TERRE FONCTIONNELLE. On ne peut pas compter sur lui pour assurer la sécurité. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 52 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 53 Kingfisher Plus+ Hardware Manual Specifications PSU-x Power Supply Modules Specifications Parameter PSU-3 PSU-4 90 to 260 VAC 50/60 Hz, 125 to 370 VDC Input Supply Output Voltage Adj. Range 13.5 to 16.5 VDC Output Voltage +13.8 VDC (factory preset) Max Output Current* 2.8 A 4A 5A Load Capacity* 40 W 60 W 70 W Isolation 3 kVAC (AC input to DC output) Isolation (AC input to Functional Earth) 1.5 kVAC Connector Storage Temperature (at 10 – 95 % RH) Operating Humidity Weight (without mounting bracket) 2 kVAC 1.5 kVAC Screw Terminals Operating Temperature* *) PSU-5 -10 to +60 °C -25 to +70 °C -20 to +85 °C -40 to +85 °C 20 to 90 % RH (non-condensing) 440 g 510 g 410 g Refer to the “PSU-x Output Derating Curve” graph below. PSU-x Output Derating Curve Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 54 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 55 Kingfisher Plus+ Hardware Manual 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 Efficiency 100 V 170 V 240 V 85% 87% 88% Note: No DC-DC converter installed. Communications/Processor Modules current consumption (mA at 13.8 VDC) Item Basic Module, no options CP-12 / MC-12 CP-21 CP-30 / MC-31 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 56 Kingfisher Plus+ Hardware Manual IO Module typical current consumption (mA at 13.8 VDC) Extra current per Analogue Output ON Extra current per Digital Input ON Extra current per Digital Output ON Absolute maximum current draw Part number 24 V Converter OFF 24 V Converter ON Extra current per Analogue Input ON AI-1 11 80 +50 [+0] - - - 480 AI-10 v1.x 25 185 +62 [+3] - - - 681 AI-10 v2.x 15 50 +38 [+0] - - - 354 AO-3 5 180 - +50 - - 380 DI-5 23 - - - +7 [+2] - 135 DI-10 40 - - - +11 [+5] - 216 DO-1 7 - - - - +31 255 DO-2 7 - - - - +13 215 DO-5/6 3 - - - - +1 19 IO-2 5 - - - +7 [+3] +12 157 IO-3 10 53 +46 [-1] +42 +10 [+1] +12 367 IO-4 8 44 +44 [-2] - +9 [+1] +12 228 IO-5 13 97 +89 [0] +42 +14 [2] +12 389 Note: Values shown are for inputs powered by the IO module itself when power is available from the 13.8 VDC supply. Values in square brackets ‘[ ]’ denote current consumption when inputs are powered by an external supply. Relay Output Modules power consumption: Item Per Output Maximum Consumption TEL-REL 02 530 mW 8.5 Watts TEL-REL 03 800 mW 12.8 Watts TEL-REL 04 530 mW 8.5 Watts Superseded Communications Modules current consumption (mA at 13.8 VDC) Item CP-11 / MC-11 / MC-30 Basic Module, no options 165 Superseded IO Module typical current consumption (mA at 13.8 VDC) Part number 24 V Converter OFF 24 V Converter ON Extra current per Analogue Input ON Extra current per Analogue Output ON Extra current per Digital Input ON Extra current per Digital Output ON Absolute maximum current draw AO-2 11 115 - +55 - - 335 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 57 Kingfisher Plus+ Hardware Manual 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 R3 41 2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving 35 900 MHz (1 W) Spread Spectrum Radio: Transmitting R2 / R4 275 Receiving 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 58 Kingfisher Plus+ Hardware Manual CP-xx and MC-xx Option Boards typical 5 V Rail consumption (mA from 5 VDC) Option Board Type Port label Consumption 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 R3 100 ACTIVE 2.4 GHz (50 mW) Spread Spectrum Radio: Transmitting Receiving 85 900 MHz (1 W) Spread Spectrum Radio: Transmitting R2 / R4 670 Receiving T3 Ethernet 100 T3 300 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 SER-S 5 L(1) 120 J 1000 SUPERSEDED Serial (RS-232) Line (original version) Image Capture Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 59 Kingfisher Plus+ Hardware Manual 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 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 𝐼𝐼𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝑀𝑀𝑀𝑀−𝑥𝑥𝑥𝑥 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 Total Power load is therefore: 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 [𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊] = 13.8 [𝑉𝑉] × 𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 [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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 60 Kingfisher Plus+ Hardware Manual 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 - - 32 MB NV RAM 256 KB 512 KB 512 KB1 Port 1 (resident) RS-232 RS-232 10BASE-T / 100BASE-TX Ethernet Optional Ports 12 23 23 Programming Languages Ladder Logic Ladder Logic Structured Text, Ladder Diagram, Function Block Diagram, Instruction List, Sequential Function Chart and Flow Chart Notes: 1) 128 KB for CP-30 v1.x. 2) See PC-1 Option Boards for available options. 3) See 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 retournezla au fournisseur. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 61 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 62 Kingfisher Plus+ Hardware Manual 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 Device: Part Number: A P 24 V 10 W Auxiliary Supply Converter Port 2 0 = Not Fitted C = Fitted M Memory Option Board Type 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 63 Kingfisher Plus+ Hardware Manual 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 OK DC +5V +12V T1 +Vs Description ON when module is functioning OK ON when the internal 5 V supply is OK. This LED should always be on ON when the internal 12 V supply is OK. This LED should always be on (software controlled) Test LED 1. Flashes during Power Down mode. 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 64 Kingfisher Plus+ Hardware Manual 4.2.4 PC-1 Specifications PROCESSOR SPECIFICATIONS Processor Type W ord Size Clock Speed BIOS Flash Memory SRAM Real-time Clock Accuracy Intel 80C188 16 Bit internal data bus 8 Bit external data bus 16 MHz Yes 128 KB Total. 28 KB for firmware drivers. 256 KB 1 minute per month (± 20 ppm) W atchdog Timer Yes Status Indication Yes Batter y Type Batter y Life (module unpowered) Communications Ports Port 1 (RS-232) Port 2 (Optional) Lithium. Not rechargeable. 7 years @ 25°C 2 Serial, 300 to 115200 Baud 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 Basic Configuration RTU Address Range Communications Protocol Yes Auto on power-up 1 – 249 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 Redundanc y Operating Temperature Hardware Manual Version 7.16 Port 1 and 2 -20 to +70 °C http://www.servelec-semaphore.com/ Page 65 Kingfisher Plus+ Hardware Manual Storage Temperature Operating Humidity Hot Swap -40 to +85 °C 5 to 95 % RH (non-condensing) 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 +5 VDC / 1 A maximum (5 W) to Backplane +12 VDC / 4 A maximum to Backplane* Outputs From PC-1 +12 VDC / 2 A maximum to Vr* +24 VDC / 400 mA (10 W) Optional Auxiliary Output (3 kV Isolation)# Backup Batter y Deep Discharge Protection 12 V RTU Shutdown at 10.6 V RTU Start-up at 11.8 V Supply Fuse 7 A (Maximum Current into the PC-1) Batter y Fuse 7 A (Maximum Current into or out of battery) Combined Vr and 24 V D C Fuse 3 A Polyfuse Parameter Monitoring Battery Current PC-1 Supply Voltage PC-1 Supply Current PC-1 Temperature Accuracy ± 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 66 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 67 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 68 Kingfisher Plus+ Hardware Manual 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 OK Description ON when Processor is functioning correctly MON ON when Processor is in Monitor mode W DT ON when Processor watchdog timer overflows, such as in the event of a software crash. RST ON when in reset. Will be lit for 200 ms when cold starting. TxD ON when transmitting data on corresponding Port RxD ON when receiving data on corresponding Port RTS ON when asserting Request To Send on corresponding Port DCD ON when Data Carrier Detect affirmed on corresponding Port 10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port 100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port LINK ON when Ethernet Link is established COL ON when Ethernet Collision is detected IOTX IORX Intensity is proportional to load on backplane IO Bus (this bus is used to poll all IO modules) CMTX CMRX Intensity is proportional to load on load on backplane Communications Bus (this bus is used for communications modules data transmission) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 69 Kingfisher Plus+ Hardware Manual 4.3.4 CP-12 Specifications PROCESSOR SPECIFICATIONS Processor 40 MHz x86 W ord Size 16 bit data bus BIOS Yes Flash Memory 512 KB SRAM 512 KB Batter y Type Batter y Life (module unpowered) Real-time Clock Accuracy Lithium Primary (not rechargeable) 7 years @ 25°C 1 minute per month (+/- 20 ppm) W atchdog timer Yes Status Indication Yes Communications Ports Port 1 (RS-232) Ports 2 and 3 (Optional) Configuration Software RTU Address Range Communications Protocol Default Data Format 1-3 (1 fixed, 2 option ports) 300 to 115200 Baud (factory default 9600 8-N-1) For supported port types, please see the Option Boards chapter Toolbox 32 1 – 249 (expandable to 2000 by using multiple masters) Kingfisher, Modbus + many more 8 data bits, no parity, 1 stop (8, N, 1) Analogue Block Processing Yes PID Block Processing Yes Redundancy Internal Power Consumption (without Option Boards) 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. 150 mA from +5 VDC bus on backplane I/O Bus Data Rate 250 kbps CM Bus Data Rate 83 kbps Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Hot Swap 5 to 95 % RH (non-condensing) 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 70 Kingfisher Plus+ Hardware 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. Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 71 Kingfisher Plus+ Hardware Manual 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 nonvolatile data such as retained variables and system log. The module is powered from the +5 VDC rail on the backplane. 4.4.2 CP-30 Options and Ordering Info Unless explicitly noted, all hardware versions of CP-30 modules are described in this manual. The newer CP-30 version (v2.3) has some differences in the module features and specifications comparing with its predecessor (v1.6); in particular the amount of battery backed SRAM has increased from 128 KB to 512 KB, a quick reset to factory defaults has been added, the backup battery has been made user replaceable, and the operating temperature range has been extended to -40 °C to +85 °C. CP-30 options, ordering info and main specification differences are summarised in the table below: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 72 Kingfisher Plus+ Hardware Manual Order Code H/W version Item v1.6 1 V2.3 2 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 CP-30-x3y4 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 L Private Line 2/4 Wire, FSK, 1200 Baud 0 No Option Board installed 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 73 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 74 Kingfisher Plus+ Hardware Manual 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 75 Kingfisher Plus+ Hardware Manual 4.4.4 CP-30 Module LEDs CP-30-xy (v1.x) LED OK1,2 F11,2 F21,2 State Description ON Normal operation. 0.5 s ON, 0.5 s OFF Firmware/configuration update in progress. OFF Power off or module faulty. 0.25 s ON, 0.25 s OFF Port 2 configuration error. OFF Normal operation. 0.25 s ON, 0.25 s OFF Port 3 configuration error. OFF Normal operation. ON Normal operation (active CP-30). 1 s ON, 1 s OFF Normal operation (standby CP-30). One of the following may be indicated: F31,2 OFF F4 – F73 CP-30-xy (v2.x) n/a • • • • 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). Reserved for future use. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 76 Kingfisher Plus+ Hardware Manual LED State Description P1 (Port 1) LEDs 10 100 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. ON Linked at 100 Mbps (no data activity). Flashing Data activity (transmit or receive) at 100 Mbps. OFF Port not connected or no link at 100 Mbps. ON Linked at either 10 or 100 Mbps. OFF Port not connected or no Ethernet link established. ON Ethernet collision(s) detected. OFF No collisions detected. LNK4 COL4 P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options Tx4 TxD / 10ACT3 Rx4 RxD / 100ACT3 RTS4 RTS / LINK3 CD4 DCD / COL3 Flashing Port is transmitting serial data. OFF Port is not transmitting. Flashing Port is receiving serial data. OFF Port is not receiving. 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. ON Carrier Detect input is asserted by a connected serial device. OFF Carrier Detect input is not asserted. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 77 Kingfisher Plus+ Hardware Manual LED State Description P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options Tx4 TxD / 10ACT3 Rx4 RxD / 100ACT3 RTS4 RTS / LINK3 CD4 DCD / COL3 Flashing Data activity (transmit or receive) at 10 Mbps. OFF No data activity at 10 Mbps. Flashing Data activity (transmit or receive) at 100 Mbps. OFF No data activity at 100 Mbps. ON Linked at either 10 or 100 Mbps. OFF Port not connected or no Ethernet link established. ON Ethernet collision(s) detected. OFF No collisions detected. Notes: 1 ) Progressively set ON during booting sequence. After a successful start-up: OK is ON; F1 and F2 are OFF; F3 is ON (for active processor) or flashing (for standby processor). 2 ) Flash rapidly to indicate firmware upgrade error. 3 ) CP-30 v2.x only. 4 ) CP-30 v1.x only. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 78 Kingfisher Plus+ Hardware Manual 4.4.5 CP-30 Specifications CP-30 Processor Module Specifications Parameter v1.x Processor v2.x Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus SRAM (Battery Backed) 128 KB 512 KB Flash Memory 16 MB SDRAM 32 MB Real-time Clock Accuracy ±1 min / month (± 20 ppm) max Backup Battery Battery type CR2470 with tabs (solder type) Battery Life (module unpowered) CR2450 (coin, user replaceable) 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) Voltage 5 V ± 5% Input Power Current1 290 mA 200 mA Isolation Port 1 Transient Voltage 1 kV Environment Operating Temperature Storage Temperature Operating Humidity -20 to +70 °C -40 to +85 °C -40 to +85 °C 5 to 95 % RH (non-condensing) Notes: 1 ) No communications option cards installed on Ports 2 and 3. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 79 Kingfisher Plus+ Hardware Manual 4.4.6 CP-30 Ports Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 80 Kingfisher Plus+ Hardware Manual 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 retournezla au fournisseur. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 81 Kingfisher Plus+ Hardware Manual 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 CD L1, L2 Request to send. Set ON when transmitting Carrier Detect. ON while a communications signal is detected Not used Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 82 Kingfisher Plus+ Hardware Manual 5.2.3 MC-10/11/30 Specifications MC-10/11/30 Communications Module Specifications Processor Intel 80C386EX W ord Size 32 bit internal data bus 16 bit external data bus Clock Speed BIOS 25 MHz Yes Flash Memory 1 MB Static CMOS RAM 1 MB RTC (Real-Time Clock) Yes W DT (W atchdog Timer) Yes Status Indication Yes Communications Ports Port 1 (RS-232) 1-3 (1 fixed, 2 option ports) 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 Internal Power Consumption (without Option Boards) Maximum of 16 ports per RTU For example, can use 5 MCs if each has 3 ports 310 mA from +5 VDC bus on backplane Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Hot Swap Hardware Manual Version 7.16 5 to 95 % RH (non-condensing) 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. http://www.servelec-semaphore.com/ Page 83 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 84 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 85 Kingfisher Plus+ Hardware Manual 5.3.2 MC-12 Module LEDs MC-12 LED OK Description ON when Module is functioning correctly MON ON when Module is in Monitor mode W DT ON when Module watchdog timer is overflows, such as in the event of a software crash. RST ON when in reset. Will be lit for 200 ms when cold starting. TxD ON when transmitting data on corresponding Port RxD ON when receiving data on corresponding Port RTS ON when Request To Send on corresponding Port is asserted DCD ON when Data Carrier Detect affirmed on corresponding Port 10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port 100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port LINK ON when Ethernet Link is established COL ON when Ethernet Collision is detected IOTX IORX Brightness of each indicates load on backplane IO Bus (this bus is used to poll all IO modules) CMTX CMRX Brightness of each indicates load on backplane Communications Bus (this bus is used for communications modules data transmission) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 86 Kingfisher Plus+ Hardware Manual 5.3.3 MC-12 Specifications MC-12 Communications Module Specifications Processor 40 MHz x86 W ord Size 16 bit data bus BIOS Flash Memory Yes 512 KB W atchdog timer Yes Status Indication Yes Communications Ports Port 1 (RS-232) Default Data Format Ports 2 and 3 (Optional) Configuration Software RTU Address Range Communications Protocol Analogue Block Processing Internal Power Consumption (without Option Boards) 1-3 (1 fixed, 2 option ports) 300 to 115200 Baud (factory default = 9600 bps) 8 data bits, no parity, 1 stop (8, N, 1) For supported port types, please see the Communications Option Boards chapter Toolbox 32 1 – 249 (expandable to 2000 by using multiple masters) Kingfisher, Modbus + many more Yes 150 mA from +5 VDC bus on backplane I/O Bus Data Rate 250 kbps CM Bus Data Rate 83 kbps Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Hardware Manual Version 7.16 5 to 95 % RH (non-condensing) http://www.servelec-semaphore.com/ Page 87 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 88 Kingfisher Plus+ Hardware Manual 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: H/W version Order Code Item MC-31-x3y4 Operating Temperature Range v1.6 1 V2.3 2 -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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 89 Kingfisher Plus+ Hardware Manual Communications Option Boards codes: Code Short Description Code Short Description L Private Line 2/4 Wire, FSK, 1200 Baud 0 No Option Board installed 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) LED OK1,2 F11,2 F21,2 MC-31-xy (v2.x) State Description ON Normal operation. 0.5 s ON, 0.5 s OFF Firmware/configuration update in progress. OFF Power off or module faulty. 0.25 s ON, 0.25 s OFF Port 2 configuration error. OFF Normal operation. 0.25 s ON, 0.25 s OFF Port 3 configuration error. OFF Normal operation. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 90 Kingfisher Plus+ Hardware Manual LED F31,2 F4 – F73 State Description OFF Normal operation. n/a Reserved for future use. P1 (Port 1) LEDs 10 100 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. ON Linked at 100 Mbps (no data activity). Flashing Data activity (transmit or receive) at 100 Mbps. OFF Port not connected or no link at 100 Mbps. ON Linked at either 10 or 100 Mbps. OFF Port not connected or no Ethernet link established. ON Ethernet collision(s) detected. OFF No collisions detected. LNK4 COL4 P2 (Port 2) and P3 (Port 3) LEDs: I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options Tx4 TxD / 10ACT3 Rx4 RxD / 100ACT3 RTS4 RTS / LINK3 CD4 DCD / COL3 Flashing Port is transmitting serial data. OFF Port is not transmitting. Flashing Port is receiving serial data. OFF Port is not receiving. 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. ON Carrier Detect input is asserted by a connected serial device. OFF Carrier Detect input is not asserted. P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options Tx4 TxD / 10ACT3 Flashing Data activity (transmit or receive) at 10 Mbps. OFF No data activity at 10 Mbps. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 91 Kingfisher Plus+ Hardware Manual LED Rx4 RxD / 100ACT3 RTS4 RTS / LINK3 CD4 DCD / COL3 State Description Flashing Data activity (transmit or receive) at 100 Mbps. OFF No data activity at 100 Mbps. ON Linked at either 10 or 100 Mbps. OFF Port not connected or no Ethernet link established. ON Ethernet collision(s) detected. OFF No collisions detected. Notes: 1 ) Progressively set ON during booting sequence. After a successful start-up: OK is ON; F1, F2 and F3 are OFF. 2 ) Flash rapidly to indicate firmware upgrade error. 3 ) MC-31 v2.x only. 4 ) MC-31 v1.x only. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 92 Kingfisher Plus+ Hardware Manual 5.4.4 MC-31 Specifications MC-31 Communications Module Specifications Parameter v1.x Processor v2.x Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus SRAM (Battery Backed) 128 KB 512 KB Flash Memory 16 MB SDRAM 32 MB Communications Ports Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation) Optional 2 (for supported port types, please see the Option Boards chapter) Input Power Voltage 5 V ± 5% Current1 290 mA 200 mA Isolation Port 1 Transient Voltage 1 kV Environment Operating Temperature Storage Temperature Operating Humidity -20 to +70 °C -40 to +85 °C -40 to +85 °C 5 to 95 % RH (non-condensing) Notes: 1 ) No communications option cards installed on Ports 2 and 3. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 93 Kingfisher Plus+ Hardware Manual 5.4.5 MC-31 Ports Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 94 Kingfisher Plus+ Hardware Manual 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 I Option Board Description 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 95 Kingfisher Plus+ Hardware Manual 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 firmware v1.45a or earlier CP-12 CP-21 MC-10/11 CP-10/11 firmware v159 or earlier firmware v160 or later MC-12 PC-1 with MC-10/11 PC-1 with MC-12 MC-11 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 Warning: Follow anti-static procedures Electronic components can be damaged by even small amounts of static discharge. It is highly recommend that antistatic procedures be used. Avoid touching any components and metal parts. Do not store cards near strong electrostatic, electromagnetic, or radioactive fields. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 96 Kingfisher Plus+ 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 97 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 98 Kingfisher Plus+ Hardware Manual 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 Internal Power Consumption Output Power 300 – 115200 bps 70 mA from +5 VDC Bus on backplane +4.3 V / 100 mA maximum RS-422 Line drive 10 Receivers RS-485 Line drive 32 Receivers Communications Isolation 8 data bits, no parity, 1 stop (8, N, 1) Transient voltage: 2.5 kV Operating Temperature -40 to +85 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: RTU Hardware Required Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 99 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 100 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 101 Kingfisher Plus+ Hardware Manual 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 Internal Power Consumption 300 – 115200 bps 95 mA from +5 VDC Bus on backplane RS-422 Line drive 10 Receivers RS-485 Line drive 32 Receivers Isolation (Field to Backplane) Transient voltage: 2.5 kV Operating Temperature -40 to +85 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: RTU Hardware Required 1 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 102 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 103 Kingfisher Plus+ Hardware Manual 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 Communications Maximum Fiber Optic Cable Length Supported Fiber Optic Cables Option Board Connectors (use male connectors on cable) Power Consumption (Tx) Line drive Electrical Isolation 115.2 kbps (equivalent to RS-232 port) 8 data bits, no parity, 1 stop (8, N, 1) Approx. 4 km (depends on cable and other factors) Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS Tx: ST female (light grey port) Rx: ST female (dark grey port) 50 mA maximum from +5 VDC Bus on backplane 1 Receiver (point to point) 15 kV Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 RTU Hardware Required MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 104 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 105 Kingfisher Plus+ Hardware Manual Dial Option Board Specifications PSTN Modem / Data Rate RTU DTE Port Speed Line Impedance Approval Transmit level Receive level Dialling Internal Power Consumption Isolation V.34, 300 to 33600 bps, auto-negotiating 300 – 115200 bps 600 Ω International -10 dBm -43 dBm to -9 dBm Pulse or Tone 165 mA from +5 VDC Bus on backplane Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 5 kV Recommended Initialization String D Option: AT&FE0V0S0=2&W Original D Option: AT&FE0V0S0=2X0&W (ignores dial tone) Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: Compatibility Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 106 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 107 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 108 Kingfisher Plus+ Hardware Manual 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. Note: line termination is required. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 109 Kingfisher Plus+ Hardware Manual 6.8.5 4-Wire Line, point-to-point Either RTU can transmit/receive at any time. Note: line termination is required. 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 110 Kingfisher Plus+ Hardware Manual Line/Radio Option Board Specifications Baud rate Modulation Carrier detect input RTS/PTT output 1200 Baud FSK, CCITT V.23 Optical isolation Active low or high Min. input 2 mA (70 VDC maximum) 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 Line drive in multi-drop configuration Transmit output level Receive level Internal Power Consumption Transmission Distance Isolation 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. 10 drops for 2 wire 20 drops for 4 wire -6 dBm (LINE-2) -6 to -21 dBm software configurable (LINE-L) -43 dBm to -9 dBm 20 mA from +5 VDC Bus on backplane 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. 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 Storage Temperature -40 to +85 °C Operating Humidity Hardware Manual Version 7.16 5 to 95 % RH (non-condensing) http://www.servelec-semaphore.com/ Page 111 Kingfisher Plus+ Hardware Manual Can be installed in any of the following ports: CP-10/11/12/21/30 Port 2 or Port 3 Compatibility MC-10/11/12/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 112 Kingfisher Plus+ Hardware Manual 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 - Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 113 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 114 Kingfisher Plus+ Hardware Manual HART Option Board Specifications Baud-rate Modulation Logical Frequencies Internal Power Consumption Maximum No. HART Devices Data Available Isolation 1200 Baud, Half Duplex Bell 202 1 = 1200 Hz 0 = 2200 Hz 20 mA from +5 VDC Bus on backplane 15 (multi-drop) HART and loop current for point-to-point HART only for multi-drop 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 Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: Compatibility CP-10/11/12/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 115 Kingfisher Plus+ Hardware Manual 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 T3 Option Board Parameter 10/100 Mbps (auto negotiated) Connection Speed Approximately 750 cycles Connection Durability Power Consumption 300 mA 310 mA (from +5 VDC Bus on backplane) (from +5 VDC Bus on backplane) -40 to +85 °C -20 to +70 °C Operating Temperature 5 to 95 % RH (non-condensing) Operating Humidity -40 to +85 °C Storage Temperature Compatibility Port 1 Pins 1 2 3 4 5 6 7 8 T2 Option Board 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 Ethernet Function Tx+ TxRx+ n/c n/c Rxn/c n/c Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 116 Kingfisher Plus+ Hardware Manual Option Board A3: Fibre Optic Ethernet The A3 option board provides Ethernet connectivity via fibre optic cable. The A3 is functionally equivalent to a T3 Ethernet board, but fibre optical cabling is used in place of copper cabling allowing for excellent electrical isolation. A3 Ethernet Option Board Specifications Connection Speed Optical Compliance Fiber Optic Transceiver Supported Fiber Optic Cables Option Board Connectors (use male connectors on cable) Internal Power Consumption 10/100 Mbps Full ATM 100 Mbps physical layer Full 100 Mbps-FX (IEEE802.3u) AFBR-5903Z Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS MTRJ connector. Available from Semaphore are the MTRJ-SC and MTRJ-ST adaptors. 600 mA from +5 VDC Bus on backplane Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Can be installed in any of the following ports: Compatibility Hardware Manual Version 7.16 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 http://www.servelec-semaphore.com/ Page 117 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 118 Kingfisher Plus+ Hardware Manual 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 Frequency Transmit Power Australia 915-928 MHz 1-1000 mW configurable Range Indoors 900 m Range Outdoors 22 km Range with Yagi Up to 32 km Data rate — RTU to Radio Data rate — Radio to Radio Power Consumption Spread Spectrum Type Encryption 9600 bps 115200 or 9600 bps 3.7 W maximum FHSS (Frequency Hopping Spread Spectrum) None Antenna Connector RPSMA (reverse polarity SMA) Male (on radio) Receiver Sensitivity -110 dBm @ 9600 bps Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: Compatibility 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 119 Kingfisher Plus+ Hardware Manual Option Board R3: International Spread Spectrum Radio The R3 Spread Spectrum radio option board uses the 2.4 GHz RF module to provide a high speed data link anywhere in the world (international). This radio uses the public frequency band and does not need to be licensed. When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly. During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage. Warning: RF Exposure 2.4 GHz Spread Spectrum Radio This equipment is approved only for mobile and base station transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all persons and must not be co-located or operating in conjunction with any other antenna or transmitter. Avertissement: l'Exposition aux RF Radio 2.4 GHz à spectre étalé (Spread Spectrum) Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur. Modifications Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate this product. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 120 Kingfisher Plus+ Hardware Manual Modifications L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit. R3 Spread Spectrum Radio Board Specifications Countries Supported Frequency International 2.4000-2.4835 GHz Transmit Power 50 mW Range Indoors 180 m Range Outdoors 5 km Range with Yagi Up to 8 km Data rate — RTU to Radio 19200 bps Data rate — Radio to Radio 9600 bps Power Consumption Spread Spectrum Type Encryption 0.75 W maximum FHSS (Frequency Hopping Spread Spectrum) None# Antenna Connector RPSMA (reverse polarity SMA) Male (on radio) Receiver Sensitivity -105 dBm Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: Compatibility # 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 121 Kingfisher Plus+ Hardware Manual Option Board R4: US/Canada Spread Spectrum Radio The R4 Spread Spectrum radio option board uses the Digi 900 MHz RF module to provide a high speed data link in the US and Canada. This radio uses the public frequency band and does not need to be licensed. When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly. During testing units should have a minimum separation of 60 cm, and an antenna should always be fitted to avoid damage. Warning: RF Exposure 900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all persons and must not be co-located or operating in conjunction with any other antenna or transmitter. Avertissement: l'Exposition aux RF Radio 900 MHz à spectre étalé (Spread Spectrum) Cet équipement est approuvé uniquement pour les appareils mobiles de transmission et pour la station de base. La ou les antennes utilisées pour cet émetteur doivent être installées pour garantir une distance d’au moins 30 cm de toutes personnes et ne doivent pas être proche ou en opération en conjonction avec n’importe quel autre antenne ou émetteur. Modifications Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate this product. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 122 Kingfisher Plus+ Hardware Manual Modifications L’utilisation d’antennes non autorisées ou d’autres changements ou modifications non explicitement approuvées par la partie responsable de la conformité pourrait annuler l’autorisation pour l’utilisateur de faire fonctionner ce produit. R4 Spread Spectrum Radio Board Specifications Countries Supported US & Canada Frequency 902-928 MHz Transmit Power 1-1000 mW configurable Range Indoors 900 m Range Outdoors 22 km Range with Yagi Up to 32 km Data rate — RTU to Radio Data rate — Radio to Radio Power Consumption Spread Spectrum Type Encryption 9600 bps 115200 or 9600 bps 3.7 W maximum FHSS (Frequency Hopping Spread Spectrum) None# Antenna Connector RPSMA (reverse polarity SMA) Male (on radio) Receiver Sensitivity -110 dBm @ 9600 bps Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Can be installed in any of the following ports: Compatibility # 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 123 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 124 Kingfisher Plus+ Hardware Manual PC-1 Modem Board PL: Two Wire Line The 2-wire (Private) line option board provides a 2-wire point-to-point connection to another RTU with a line option board. The board is optically isolated, operates at 1200 bps and utilizes FSK CCITT V.23 modulation. PC-1 Modem Board Connections RJ45 Pin Direction Radio Function 1 OUT DTR 2 OUT +12 V low power 3 OUT RTS 4 IN DCD 5 COM GND (0 V) 6 IN CTS 7 IN RXA 8 OUT TXA PC-1 2 Wire Line Wiring Diagram (point-to-point) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 125 Kingfisher Plus+ Hardware Manual PC-1 Modem Board: Analogue Radio Interface The analogue radio option board provides an FSK interface to external analogue radios (typically Trio or Maxon). Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait radios. Please indicate which Radio you are using when ordering a radio option card. PC-1 Analogue Radio Board Connections RJ12 Pin Direction Radio Function 1 OUT DTR 2 OUT +12 V low power 3 OUT RTS 4 IN DCD 5 COM GND (0 V) 6 IN CTS 7 IN RXA 8 OUT TXA Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 126 Kingfisher Plus+ Hardware Manual 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-4 Combination Analogue/Digital I/O Module 12 3 IO-5 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 127 Kingfisher Plus+ Hardware Manual 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 selfpowered 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 128 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 129 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 130 Kingfisher Plus+ Hardware Manual 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 0 LSB 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 131 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 132 Kingfisher Plus+ Hardware Manual Block-diagram of the AI-1 module is shown on the figure below. AI-1 Block Diagram 9.1.2 AI-1 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail OFF Channel Input level < 1% ON Channel Input level > 1% OK FU A1-A8 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 133 Kingfisher Plus+ Hardware Manual 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 Update Rate Accuracy Resolution Common Mode Voltage 8 2 ms (all eight channels) ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C 12 bit (no sign bit) 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 Input Filter Cutoff Frequenc y Output Power 250 Ω standard 11 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required. 2 kHz @ -3 dB 24 VDC / 160 mA, Isolated Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Hot Swap 5 to 95 % RH (non-condensing) 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 134 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 135 Kingfisher Plus+ Hardware Manual 2 wire transmitter (powered by module) 3 wire transmitter (powered by module) 4 wire transmitter (powered by module) 2 wire transmitter (powered externally) 3 wire transmitter (powered externally) 4 wire transmitter (powered externally) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 136 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 137 Kingfisher Plus+ Hardware Manual All AI-10 modules provide: • 8 analogue inputs with high electrical isolation between the field terminals and the RTU logic. • A 24 V isolated output that can be used to power field sensors / transducers • 16 bit input resolution • Full compatibility with the AI-1 and AI-4 analogue input modules but with enhanced resolution. The AI-10 supports various current input ranges as follows: • 0-20 mA • 4-20 mA • ±10 mA1 • ±20 mA1 1 For AI-10 v2.x only unipolar current ranges are recommended for use. Bipolar ranges are not calibrated for current measurement. The AI-10-V supports various voltage input ranges as follows: • 0-5 V1 • 1-5 V1 • ±2.5 V • ±5 V • ±10 V 1 For AI-10 v2.x only bipolar voltage ranges are recommended for use. Unipolar ranges are not calibrated for voltage measurement. To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to ground. This module consumes power from the +5 VDC and +12 VDC RTU rails. A built-in 24V DC-DC converter is used to provide isolated power to the analogue front-end and can also be utilised to power the field devices if required. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 138 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 139 Kingfisher Plus+ Hardware Manual 9.2.2 AI-10 Module LEDs AI-10 LEDs State Description OFF Module Fault (no power) ON Module OK 1 s ON, 1 s OFF Module Fault 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 ON1 Module Fault (firmware not loaded – module needs repair) (unlabelled) OFF Normal operation 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) OK1 LED B (unlabelled) DC OK 1 ) On AI-10 v2.x only Note: On power up some LEDs may come ON for a short time. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 140 Kingfisher Plus+ Hardware Manual 9.2.3 AI-10 Specifications AI-10 / AI-10-V Analogue Input Module Specifications Hardware v1.x Parameter Input Current ranges1,2 Input Voltage 4-20, 0-20, ±20, ±10 mA (software selectable) ranges3,4,5 1-5, 0-5, ±2.5, ±5, ±10 VDC (software selectable) Inputs per Module Sub System Isolation Isolation Input impedance Hardware v2.x 8 The analogue subsystem of the AI-10 is fully isolated from the RTU’s digital system. 3 kV Transient AI-10 : AI-10-V : 250 Ω standard, > 1 MΩ optional5 > 1 MΩ Input Filter Cutoff Frequenc y 1.5 kHz @ -3 dB 9 Hz @ -3 dB Common Mode Rejection 80 dB minimum 66 dB minimum None 42dB minimum @ 50Hz 45dB minimum @ 60Hz Mains Rejection ±12 V to GND ±12 V differential Maximum Input Voltage Accuracy ± 0.1% @ +25 °C ± 0.25% @ -20 to +70 °C Resolution ±12 V to GND ±24 V differential ± 0.1% @ 0 to +50 °C2,3 ± 0.2% @ -40 to +85 °C2,3 16 bit (15 data bits and 1 sign bit) Output Power Isolated 24 VDC, 160 mA maximum Operating Temperature -30 to +80 °C Storage Temperature -40 to +85 °C -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed. Compatibility One range setting for all channels when used with a PC-1 or CP-11/12/21 processor. Individual range setting for each channel when used with a CP-30 processor. 1) AI-10 only. For AI-10 V2.x only unipolar current ranges are recommended for use. Bipolar ranges are not calibrated for current measurement and their accuracy can reach 1.4% of full scale when used to measure current. 3) For AI-10 V2.x only bipolar voltage ranges are recommended for use. Unipolar ranges are not calibrated for voltage measurement and their accuracy can reach 1.4% of full scale when used to measure voltage. 4) Analogue Input channels can be modified from low impedance to high impedance by disconnecting the 250 Ω channel resistor. 5) The ±10 V input range can only be used on an AI-10 input channel if the current sensing resistor has been disconnected. Resistors have already been disconnected in an AI-10-V. 2) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 141 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 142 Kingfisher Plus+ Hardware Manual 2 wire transmitter (powered by module) 3 wire transmitter (powered by module) 4 wire transmitter (powered by module) 2 wire transmitter (powered externally) 3 wire transmitter (powered externally) 4 wire transmitter (powered externally) Loop * When using the +24 V output to power a transducer, the negative input terminal of the analogue input channel (2, 4, 6, 8, 12, 14, 16 or 18) must be wired to the 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 143 Kingfisher Plus+ Hardware Manual 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 0 LSB 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 144 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 145 Kingfisher Plus+ Hardware Manual 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 OFF Module fault / no power ON Normal OFF Module running ON Module in Reset (power-on or watchdog) OFF Channel output set to 0% ON Channel output greater than 0% OFF Closed Loop (load detected) ON Open Loop (no load) OK RST ANALOGUE OUT 1-4 OPEN LOOP 1-4 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 146 Kingfisher Plus+ Hardware Manual 10.1.3 AO-3 Specifications AO-3 Analogue Output Module Specifications Output Current Range Outputs per Module Output Power Supply Voltage (nominal) Update Rate Resolution Accuracy Load Resistance Load Capacitance Load Inductance Isolation 4 to 20 mA [default] or 0 to 20 mA (loop current is supplied by module) 4 Isolated 24 VDC / 40 mA for outputs 1 & 2 Isolated 24 VDC / 40 mA for outputs 3 & 4 +5 VDC and +12 VDC from backplane 250 ms (all channels) Determined by I/O scan time and is application dependent 12 bit (no sign bit) ± 0.2% @ 25 °C ± 0.5% @ -20 to +70 °C 0 to 850 Ω 2000 pF maximum 1 H maximum Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups. Each group is isolated from the other group and from the backplane logic. There is no isolation between outputs 1 & 2 and no isolation between outputs 3 & 4. Transient voltage (Group to Group and Group to Logic): 5 kV. Maximum working voltage in respect to system earth/ground must not exceed SELV limits (42.4 VPEAK / 60 VDC). Operating Temperature -40 to +85 °C Storage Temperature -40 to +85 °C Operating Humidity Hot Swap Open Loop Detection 5 to 90 % RH (non-condensing) 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. 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%. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 147 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 148 Kingfisher Plus+ Hardware Manual 0 – 20 / 4 – 20 mA Current Loop Receiver Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 149 Kingfisher Plus+ Hardware Manual 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 Channel group 2 maximum capture speed maximum capture speed DI-5-1 28 VDC Channels 1 and 2 10 kHz Channels 3 and 4 255 Hz DI-5-1-48 60 VDC Channels 1 and 2 10 kHz Channels 3 and 4 255 Hz DI-10-1 DI-10-1-48 +130 VDC 125 VAC Channels 1 to 4 10 kHz Channels 5 to 16 1 kHz DI-10(-GPS) DI-10-48(GPS) +130 VDC 250 VAC Channels 1 to 16 10 kHz 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 150 Kingfisher Plus+ Hardware Manual Block-diagram of the DI-5 module is shown on the figure below. DI-5 Block Diagram 11.2.2 DI-5 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Digital Input OFF ON Digital Input ON OK 1 - 16 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 151 Kingfisher Plus+ Hardware Manual 11.2.3 DI-5 Specifications DI-5 Input Module Specifications + 12 to 24 VDC nominal (supports reverse polarity) Rated Voltage Inputs per Module Input Characteristics Isolation Output Power Note: The DI-5-1-48 High Input Voltage module in the Custom Products chapter supports higher DC input voltages (48 VDC nominal) 16 Impedance 2.7 kΩ ON-state Voltage Channels 1 and 2 : Channels 3 to 16 : 10 to 28 VDC maximum 7.5 to 28 VDC maximum OFF-state Voltage Channels 1 and 2 : Channels 3 to 16 : 0 to 3.5 VDC 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 : Channels 3 and 4 : Channels 5 to 16 : 50 µs maximum 500 µs maximum 10 ms maximum OFF Response Time Channels 1 and 2 : Channels 3 and 4 : Channels 5 to 16 : 50 µs maximum 500 µs maximum 17 ms maximum 5 kV Transient 12 VDC / 250 mA (3 W) isolated, supplied by module Operating Temperature -40 to +85 °C Storage Temperature -40 to +85 °C Operating Humidity Pulse Totalisation Pulse Rates / Frequency Hot Swap 5 to 95 % RH (non-condensing) Channels 1 to 4 : Channels 1 and 2 : Channels 3 and 4 : 0-65535 Pulses 10 kHz maximum 255 Hz maximum 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 152 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 153 Kingfisher Plus+ Hardware Manual Powered by Module: External positive supply: External negative supply: Combined positive and negative power supplies: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 154 Kingfisher Plus+ Hardware Manual 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 Only appropriately qualified and trained personnel can install and service this equipment. Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) before performing any operation on this product, including field wiring. Failure to do so may cause fire and may result in a serious personnel injury or even death. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 155 Kingfisher Plus+ Hardware Manual Risques Électriques Seul le personnel qualifié et formé peut installer et entretenir cet équipement. Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le câblage. Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel. 11.3.2 DI-10 Options and Ordering Info Unless explicitly noted, all hardware versions of DI-10 modules are described in this manual. Comparing with its predecessor (v3.2), the newer DI-10 version (v4.3) has some differences in the module features and specifications and also has a new optional GPS time synchronisation of the sequence of event recording. The DI-10 modules without “-48” suffix in their Order Code have Digital Inputs compatible with 12 V and 24 V control systems. The modules with the “-48” suffix in the Order Code have elevated change-over thresholds of Digital Inputs designed for use in 48 V and higher control systems. Any DI-10 v4.3 module can be a GPS Slave, having its events timing synchronised to an accurate timing signal generated by a DI-10-[48]GPS v4.3 module (GPS Master) that has an additional interface for connection to an external 3rd party GPS device. Any number of GPS Slaves and GPS Masters can be installed in the RTU. With more than one GPS Master installed in the system, each of them will generate time synchronisation signal for the GPS Slaves in parallel, providing system redundancy if it is required. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 156 Kingfisher Plus+ Hardware Manual DI-10 options, ordering info, the main features and / or main specification differences are summarised in the table below: H/W version Target System Voltage Order Code v3.21 v4.32 DI-10-1 DI-10-1-48 5 DI-10-GPS 6 DI-10-48GPS 5,6 GPS Slave Master 4 DI-10-48 5 ≥48 V Highspeed inputs4 DI-10 12 V & 24 V3 IEC 61131 types I & III compliant 4 16 16 16 16 Notes: 1 ) And earlier versions (here and further in this Manual). ) 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. 2 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 157 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 158 Kingfisher Plus+ Hardware Manual 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: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 159 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 160 Kingfisher Plus+ Hardware Manual 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) Hardware Manual Version 7.16 DI-10 [-48] (v4.3) DI-10-[48]GPS (v4.3) http://www.servelec-semaphore.com/ Page 161 Kingfisher Plus+ Hardware Manual LED OK ERR1 State Description ON Module operating normally 0.5 s ON, 0.5 s OFF Internal Fault: (module needs repair)1 OFF Power off 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 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, GPS1,2 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. 1.8 s ON, 0.2 s OFF Time Synchronised to a DI-10-[48]GPS (master). SYNC1 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. ON +12V DC-DC converter on OFF +12V DC-DC converter off. No digital input sampling occurs. 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) PCON 1-16 Notes: 1 ) Only hardware v4.3 or later. 2 ) Only on DI-10-GPS modules (GPS Master). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 162 Kingfisher Plus+ Hardware Manual 11.3.8 DI-10 Specifications DI-10 Digital Input Module Specifications Parameter v3.2 Digital Inputs per Module v4.3 16 Maximum Input Voltage Maximum Current per Input1 130 VDC / 125 VAC 130 VDC / 250 VAC 3.7 mA 2.6 mA Digital Input Levels ON-state Voltage @ Input Current Standard modules -48 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) ≥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) ≥7.5 VDC @ 2.5 mA ≥20.0 VAC @ 1.2 mA ≥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 5.4 VDC / 3.8 VAC (Ch. 1-4) 5.3 VDC / 4.0 VAC (Ch. 5-16) 7.2 VDC / 5.1 VAC 36.2 VDC / 27.6 VAC (Ch. 1-4) 34.7 VDC / 24.9 VAC (Ch. 5-16) 26.4 VDC / 19.1 VAC 5.1 VDC / 3.7 VAC (Ch. 1-4) 5.1 VDC / 3.7 VAC (Ch. 5-16) 6.3 VDC / 4.4 VAC 36.0 VDC / 25.5 VAC (Ch. 1-4) 34.5 VDC / 24.3 VAC (Ch. 5-16) 25.5 VDC / 18.4 VAC Digital Input Thresholds2 Low-to-High Transition Standard modules -48 modules High-to-Low Transition Standard modules -48 modules Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 163 Kingfisher Plus+ Hardware Manual DI-10 Digital Input Module Specifications Parameter v3.2 v4.3 50 µs (DC, Ch. 1-4) 500 µs (DC, Ch. 5-16) 30 ms (AC) 50 µs (DC) Digital Input Timing ON Response Time (max) OFF Response Time (max) Filtering 30 ms (AC) 50 µs (DC, Ch. 1-4) 500 µs (DC, Ch. 5-16) 30 ms (AC) 50 µs (DC) 30 ms (AC) None,1, 3, 10, 30, 100, 250 ms or AC Filter Frequency, Pulse and Quadrature Counters Total number of Counters Maximum Frequency 7 maximum 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 Hardware Manual Version 7.16 0-65535 Pulses on any of the inputs pair(s) 1-2, 3-4, etc. http://www.servelec-semaphore.com/ Page 164 Kingfisher Plus+ Hardware Manual DI-10 Digital Input Module Specifications Parameter v3.2 v4.3 Sequence of Events Time Stamp Resolution 1 ms Events Time Stamp Accuracy with GPS synchronisation3 n/a ±2 ms to UTC time Events Buffer Size 1000 events Events Transfer Rate (via backplane to a Processor Module) 100 events/s maximum Output Power To Field Devices Isolated 12 V 80 mA maximum n/a Isolated 12 V 100 mA maximum 130 VDC / 125 VAC 130 VDC / 264 VAC To GPS Device4 Isolation Maximum Working Voltage (in respect to system earth / ground) Transient Voltage 3 kV Environment Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C -40 to +85 °C Operating Humidity 5 to 95 % RH (non-condensing) Notes: 1) Limited by internal circuitry of a DI-10 module. 2) Approximate values for information only (not factory tested) 3) For systems without GPS, the time-stamping accuracy depends on the accuracy of the Real Time Clock in the RTU Processor module, the SCADA / Network time management protocol used, the Backplane time synchronisation latency (that is influenced by the type of the Processor module used and by its loading with the RTU logic and communications), by the number of installed DI-10 modules and by other system-dependent parameters. 4) Only on DI-10-GPS modules (GPS Master) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 165 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 166 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 167 Kingfisher Plus+ Hardware Manual 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) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 168 Kingfisher Plus+ Hardware Manual Switching AC supplied inductive loads (*MOV = Metal Oxide Varistor) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 169 Kingfisher Plus+ Hardware Manual 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 Only appropriately qualified and trained personnel can install and service this equipment. Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) before performing any operation on this product, including field wiring. Failure to do so may cause fire and may result in a serious personnel injury or even death. Risques Électriques Seul le personnel qualifié et formé peut installer et entretenir cet équipement. Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le câblage. Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 170 Kingfisher Plus+ Hardware Manual Block-diagram of the DO-1 module is shown on the figure below. DO-1 Block Diagram 12.3.2 DO-1 Module LEDs LED OK FU A1, A2 B3, B4 C5, C6 D7, D8 Hardware Manual Version 7.16 State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail OFF Digital output OFF (open) ON Digital output ON (closed) http://www.servelec-semaphore.com/ Page 171 Kingfisher Plus+ Hardware Manual 12.3.3 DO-1 Specifications DO-1 Isolated Relay Output Module Specifications Outputs per Module Commons 8 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 Relay Operations 10 mA at 5 VDC 100,000 minimum at 1800 operations per hour at rated load Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Altitude Isolation Relay Part Number Hot Swap 5 to 95 % RH (non-condensing) 2000 m max 3 kV coil to contacts 500 V between channel groups Omron G6B-2114P-US (G6B datasheet is available from http://components.omron.eu/) 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. 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. #) CAUTION! 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 172 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 173 Kingfisher Plus+ Hardware Manual Channel X LOAD X Channel Y LOAD Y _ Power Supply + Common 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 174 Kingfisher Plus+ Hardware Manual DO-2: 16 Channel Relay Output Module 12.4.1 Overview • • • • 16 SPST relay outputs One common per 8 channels 3 kV coil to contact isolation Can switch AC or DC voltages The DO-2 provides 16 normally-open relay circuits for controlling output loads provided by the user. The output points are arranged in two groups of eight. Each group shares a common terminal. The relay outputs can be used to control a wide range of devices such as motor starters, solenoids, and indicators. Internal fuses protect the DO-2 relay contacts should ratings be exceeded. This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Block-diagram of the DO-2 module is shown on the figure below. DO-2 Block Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 175 Kingfisher Plus+ Hardware Manual Electrical Hazards Only appropriately qualified and trained personnel can install and service this equipment. Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) before performing any operation on this product, including field wiring. Failure to do so may cause fire and may result in a serious personnel injury or even death. Risques Électriques Seul le personnel qualifié et formé peut installer et entretenir cet équipement. Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le câblage. Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 176 Kingfisher Plus+ Hardware Manual 12.4.2 DO-2 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail OFF Digital output OFF (open) ON Digital output ON (closed) OK FU 1-16 12.4.3 DO-2 Specifications DO-2 16 Channel Digital Output Module Specifications Outputs per Module Commons Relay Type 16 2# (each common supplies 8 outputs) SPST (Single Pole Single Throw, Normally Open) Maximum Switched Voltage 30 VDC, 250 VAC# Maximum Switched Current 5 A per common Minimum Load Contact Resistance 10 mA @ 5 VDC (wetting current) 100 mΩ maximum Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Altitude Isolation Relay Operations 5 to 95 % RH (non-condensing) 2000 m max Maximum working voltage in respect to system earth/ground must not exceed 250 VAC / 130 VDC Transient voltage: 3 kV 70,000 minimum at 1800 operations per hour at rated load Fuse Monitor LED Enabled when the common is wired to pins 10 and 20. CAUTION! When wired, a maximum voltage of 30 V AC or DC can be used to power the common. Relay Part Number Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/) Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. 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 both commons must be connected to a single power source and no other power sources are allowed to be connected to this module. #) CAUTION! Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 177 Kingfisher Plus+ Hardware Manual 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. 12.4.4 DO-2 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 178 Kingfisher Plus+ Hardware Manual 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. Channel X LOAD X Channel Y LOAD Y Channel Z LOAD Z _ Power Supply + Common 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 179 Kingfisher Plus+ Hardware Manual 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. This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Block-diagram of the DO-6 module is shown on the figure below. DO-6 Block Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 180 Kingfisher Plus+ Hardware Manual 12.5.2 DO-6 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Digital output OFF (open) ON Digital output ON (closed) OK A1-A16 12.5.3 DO-6 Specifications DO-6 Channel Open Drain Output Module Specifications Outputs per Module Commons Rated Voltage 16 1 30 VDC maximum. Output Type N-FET, Open Drain Rated Load 70 mA per channel Current Limit 90 mA per channel Output Power 12 VDC non-regulated, non-isolated (supplied by module directly from backplane), 1.6 A maximum ON Response Time 15 ms maximum OFF Response Time 15 ms maximum Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Operating Humidity Hot Swap Compatibility 5 to 95 % RH (non-condensing) 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. The DO-6 is functionally equivalent and pin compatible with the superseded DO-5. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 181 Kingfisher Plus+ Hardware Manual 12.5.4 DO-6 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 182 Kingfisher Plus+ Hardware Manual 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: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 183 Kingfisher Plus+ Hardware Manual 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 Only appropriately qualified and trained personnel can install and service this equipment. Always power down input voltages exceeding Safety Extra Low Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth and/or ground) before performing any operation on this product, including field wiring. Failure to do so may cause fire and may result in a serious personnel injury or even death. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 184 Kingfisher Plus+ Hardware Manual Risques Électriques Seul le personnel qualifié et formé peut installer et entretenir cet équipement. Toujours mettre hors tension les tensions d’entrées dépassant les limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou AC 42 VPOINTE par rapport à la terre du système et/ou du sol) avant d’effectuer toute opération sur ce produit, y compris le câblage. Ne pas le faire peut provoquer un incendie et peut entrainer des blessures graves ou même la mort du personnel. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 185 Kingfisher Plus+ Hardware Manual 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 Commons 16 16# (1 common per channel) Relay Type (per channel) SPDT (Single Pole, Double Throw) Rated Load (per contact) 16 A @ 250 VAC Resistive 16 A @ 30 VDC Resistive Maximum Operating Voltage 380 VAC, 125 VDC Maximum Switching Power Resistive 16 A @ 30 VDC 5 A @ 48 VDC 0.6 A @ 125 VDC Maximum Switching Power Inductive 16 A @ 12 VDC 8 A @ 30 VDC 0.7 A @ 48 VDC 0.45 A @ 125 VDC Minimum Load Contact Resistance Relay Operations Operating Temperature Storage Temperature 100 mA at 5 VDC 100 mΩ maximum 100,000 minimum at 1800 operations per hour at rated load -20 to +70 °C (no icing) -40 to +85 °C Humidity 5 to 95 % RH (non-condensing) Isolation 5 kV coil to contacts Coil Rated Voltage 12 VDC @ 43 mA Coil Resistance 275 Ω @ 12 VDC Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 186 Kingfisher Plus+ Hardware Manual Dimensions Mounting Interface Cable Length Connection Terminals Relay Part Number 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps) 35 mm DIN rail 1500 mm (for connection to the DO-6 module) 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. 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 187 Kingfisher Plus+ Hardware Manual 13.2.3 TEL REL 002 Wiring Diagram DO-6 to TEL REL 00x Interface Cable Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 188 Kingfisher Plus+ Hardware Manual 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 V D C Blue/Red 19 20 + 12 V D C Green/Red 20 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 189 Kingfisher Plus+ Hardware Manual TEL REL 003: SPST Relay Board 13.3.1 Overview • • • • • 16 SPST Relay Outputs Common for each channel 5 kV coil to contact isolation Can switch AC or DC voltages Higher inductive rating than other TEL REL 002 (1 A @ 125 V as opposed to 0.4 A @ 125 V) The TEL REL 003 board is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides superior inductive load rating than the TEL REL 002. LED indicators are provided for each relay on the relay board. LED ON = relay active. 13.3.2 TEL REL 003 Specifications TEL REL 003 SPST Relay Board Specifications Outputs per Terminal Board Commons 16 16# (1 common per channel) Relay Type (per channel) SPST (Single Pole, Single Throw) Rated Load (per contact) 8 A at 250 VAC Resistive 8 A at 30 VDC Resistive 1 A at 125 VDC Inductive Maximum Operating Voltage 380 VAC, 125 VDC Maximum Switching Power Resistive 2000 VA, 240 W Contact Resistance Relay Operations Operating Temperature 100 mΩ maximum 100,000 minimum at 1800 operations per hour at rated resistive load 50,000 minimum at 360 operations per hour at rated inductive load -20 to +70 °C (no icing) Humidity 5 to 95 % RH (non-condensing) Isolation 5 kV coil to contacts Coil Rated Voltage 12 VDC @ 66 mA Coil Resistance 180 Ω @ 12 VDC Dimensions Mounting Interface Cable Length Connection Terminals 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps) 35 mm DIN rail 1.5 m (for connection to the DO-6 module) Weidmuller single height PCB 3-way terminal unit (please see wiring diagram). These terminals can take wire sizes up to 4 mm2. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 190 Kingfisher Plus+ Hardware Manual Relay Part Number Omron G2RG-2A4 12 VDC (datasheet is available from http://components.omron.eu/) CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing. 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. #) CAUTION! 13.3.3 TEL REL 003 Wiring Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 191 Kingfisher Plus+ Hardware Manual DO-6 to TEL REL 00x Interface Cable Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins 1 Channel 1 Black 1 2 Channel 2 White 2 4 Channel 3 Red 4 4 Channel 4 Green 4 5 Channel 5 Orange 5 6 Channel 6 Blue 6 7 Channel 7 White/Black 7 8 Channel 8 Red/Black 8 9 0 V Green/Black 9 10 0 V Orange/Black 10 11 Channel 9 Blue/Black 11 12 Channel 10 Black/White 12 13 Channel 11 Red/White 13 14 Channel 12 Green/White 14 15 Channel 13 Blue/White 15 16 Channel 14 Black/Red 16 17 Channel 15 White/Red 17 18 Channel 16 Orange/Red 18 19 + 12 V D C Blue/Red 19 20 + 12 V D C Green/Red 20 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 192 Kingfisher Plus+ Hardware Manual TEL REL 004: DPDT Relay Board 13.4.1 Overview • • • • 16 DPDT relay outputs 2 commons per channel 5 kV coil to contact isolation Can switch AC or DC voltages The TEL REL 004 is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides Double Pole Double Throw (DPDT) relays. This allows the user to utilize both normally open and normally closed relay operation. LED indicators are provided for each relay on the relay board. LED ON = relay active. 13.4.2 TEL REL 004 Specifications TEL REL 004 DPDT Relay Board Specifications Outputs per Terminal Board Commons 16 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 Maximum Operating Voltage Maximum Switching Power Minimum Load Contact Resistance Relay Operations Operating Temperature 5A 380 VAC, 125 VDC (2 A maximum) 750 VA, 90 W Resistive 10 mA at 5 VDC 50 mΩ maximum >10,000,000 -20 to +70 °C (no icing) Humidity 5 to 95 % RH (non-condensing) Isolation 5 kV coil to contacts Coil Rated Voltage Coil Resistance Dimensions Mounting Interface Cable Length Relay Part Number Hardware Manual Version 7.16 12 VDC @ 44 mA per coil 275 Ω @ 12 VDC 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps) 35 mm DIN rail 1.5 m (for connection to the DO-5/6 module) Omron G2R-2 12 VDC (datasheet is available from http://components.omron.eu/ ) http://www.servelec-semaphore.com/ Page 193 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 194 Kingfisher Plus+ Hardware Manual 13.4.3 TEL REL 004 Wiring Diagram DO-6 to TEL REL 00x Interface Cable Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 195 Kingfisher Plus+ Hardware Manual Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins 1 Channel 1 Black 1 2 Channel 2 White 2 4 Channel 3 Red 4 4 Channel 4 Green 4 5 Channel 5 Orange 5 6 Channel 6 Blue 6 7 Channel 7 White/Black 7 8 Channel 8 Red/Black 8 9 0 V Green/Black 9 10 0 V Orange/Black 10 11 Channel 9 Blue/Black 11 12 Channel 10 Black/White 12 13 Channel 11 Red/White 13 14 Channel 12 Green/White 14 15 Channel 13 Blue/White 15 16 Channel 14 Black/Red 16 17 Channel 15 White/Red 17 18 Channel 16 Orange/Red 18 19 + 12 V D C Blue/Red 19 20 + 12 V D C Green/Red 20 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 196 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 197 Kingfisher Plus+ Hardware Manual Block-diagram of the IO-2 module is shown on the figure below. IO-2 Block Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 198 Kingfisher Plus+ Hardware Manual 14.1.2 IO-2 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail OFF Digital input OFF ON Digital input ON OFF Digital output OFF (open) ON Digital output ON (closed) OK FU A1-A8 B1-B8 14.1.3 IO-2 Specifications IO-2 Combinational IO Module Specifications Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Humidity Hot Swap 5 to 95 % RH (non-condensing) 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 Inputs per Module 12 to 24 VAC/DC (can use reverse polarity) 8 ON-state Voltage 11.5 to 30 VDC maximum OFF-state Voltage 0 to 4 VDC ON-state Current 3.2 mA minimum OFF-state Current 1 mA maximum ON Response Time 10 ms typical OFF Response Time 17 ms typical Input Characteristics Input Current Isolation Hardware Manual Version 7.16 4 mA (typical) at rated voltage 3 kV between field and logic http://www.servelec-semaphore.com/ Page 199 Kingfisher Plus+ Hardware Manual DIGITAL OUTPUTS Outputs per Module 8 Commons 1 (common supplies all 8 outputs) Relay T ype SPST (Single Pole Single Throw) Maximum Switched Voltage 30 VDC, 42 VAC Maximum Switched Current 5 A per common Isolation Minimum Load Contact Resistance Relay Operations Relay Part Number 3 kV coil to contacts 10 mA @ 5 VDC 100 mΩ maximum 70,000 minimum at 1800 operations per hour at rated load Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/) CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing. 14.1.4 IO-2 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 200 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 201 Kingfisher Plus+ Hardware Manual 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 0 LSB D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0 Scaling of the input is shown below: All inputs share a single common and all outputs share a separate common at the zero volt rail. Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 202 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 203 Kingfisher Plus+ Hardware Manual Block-diagram of the IO-3 module is shown on the figure below. IO-3 Block Diagram 14.2.2 IO-3 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail A1-A4 - Not used B1 - Not used OFF Digital input OFF ON Digital input ON OFF Digital output OFF (open) ON Digital output ON (closed) OK FU C1-C4 D1-D4 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 204 Kingfisher Plus+ Hardware Manual 14.2.3 IO-3 Specifications IO-3 Analogue/Digital Combinational IO Module Specifications Supply Voltage (nominal) Isolation Output Power +5 VDC and +12 VDC from backplane 5 kV Transient 24 VDC / 100 mA max, Isolated Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Humidity Hot Swap 5 to 95 % RH (non-condensing) Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed. ANALOGUE INPUTS Input Current Ranges Input Voltage Ranges * Inputs per Module Update Rate Accurac y Resolution 4 to 20 mA or 0 to 20 mA 1 to 5 V and 0 to 5 V * 4 2 ms (all four channels) ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C 12 bit (no sign bit) Linearity < 1 Least Significant Bit Isolation Transient voltage: 1 kV Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz Cross-Channel Rejection > 80 dB from DC to 1 kHz Input Impedance Input Filter Cutoff Frequency 250 Ω standard 15 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required. 325 Hz @ -3 dB ANALOGUE OUTPUT Output Current Range Outputs per Module Update Rate 4 to 20 mA or 0 to 20 mA 1 250 ms (all channels) Determined by I/O scan time and is application dependent Accurac y ± 0.25% @ 25 °C Resolution 12 bit (no sign bit) User Load 0 to 850 Ω Output Load Capacitance Output Load Inductance Hardware Manual Version 7.16 2000 pF 1H http://www.servelec-semaphore.com/ Page 205 Kingfisher Plus+ Hardware Manual DIGITAL INPUTS Rated Voltage Inputs per Module Input Characteristics Input Current 12 to 24 VAC/DC (can use reverse polarity) 4 ON-state Voltage 11.5 to 30 VDC maximum OFF-state Voltage 0 to 4 VDC ON-state Current 3.2 mA minimum OFF-state Current 1 mA maximum ON Response Time 10 ms typical OFF Response Time 17 ms typical 4 mA (typical) at rated voltage DIGITAL OUTPUTS Outputs per Module Commons Relay T ype 4 1 (common supplies all 4 outputs) SPNO (Single Pole, Normally Open) Maximum Switched Voltage 30 VDC, 42 VAC Maximum Switched Current 4 A per channel 5 A per common Minimum Load Contact Resistance Relay Operations Relay Part Number 10 mA @ 5 VDC (wetting current) 100 mΩ maximum 70,000 minimum at 1800 operations per hour at rated load Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/) CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the "Switching Inductive Loads" section for more details). Contacts should also be protected with external fusing. * Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R39, R41, R43 and R45 (channels 1 to 4 correspondingly). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 206 Kingfisher Plus+ Hardware Manual 14.2.4 IO-3 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 207 Kingfisher Plus+ Hardware Manual Note: DC powered inputs and low voltage AC inputs can both be used on the same module. Analogue Input Examples 2 wire transmitter (powered by module) 3 wire transmitter (powered by module) 4 wire transmitter (powered by module) 2 wire transmitter (powered externally) 3 wire transmitter (powered externally) 4 wire transmitter (powered externally) Analogue Output Example Analogue load Digital Input Example Sensing the output form a field contact Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 208 Kingfisher Plus+ Hardware Manual Digital Output Example Driving external load(s) from digital output(s) Channel X LOAD X Channel Y LOAD Y Channel Z LOAD Z _ Power Supply Common + Notes: 1. Polarity can be reversed. 2. For safety reasons, do not connect more than one power source to a Digital Out Common terminal. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 209 Kingfisher Plus+ Hardware Manual IO-4: Combinational Analogue / Digital IO Module 14.3.1 Overview • 2 SPST relay outputs • 2 analogue inputs • 8 digital inputs This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. 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 0 LSB D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0 Scaling of the input is shown below: All inputs share a single common and all outputs share a separate common at the zero volt rail. Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 210 Kingfisher Plus+ Hardware Manual 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 211 Kingfisher Plus+ Hardware Manual Digital IO Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded. Block-diagram of the IO-4 module is shown on the figure below. IO-4 Block Diagram 14.3.2 IO-4 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Fuse OK ON Fuse fail OFF Digital input OFF ON Digital input ON OFF Digital output OFF (open) ON Digital output ON (closed) OK FU A1-A8 B1-B2 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 212 Kingfisher Plus+ Hardware Manual 14.3.3 IO-4 Specifications IO-4 Analogue / Digital Combinational Module Specifications Operating Temperature -20 to +70 °C Storage Temperature -40 to +85 °C Humidity Output Power Hot Swap 5 to 95 % RH (non-condensing) 24 VDC / 100 mA max, Isolated Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed. ANALOGUE INPUTS Input Current Ranges Input Voltage Ranges * Inputs per Module Update Rate Accuracy Resolution Common Mode Voltage 4-20 mA and 0-20 mA 1-5 V and 0-5 V * 2 2 ms (all four channels) ± 0.25% @ 25 °C ± 0.50% @ -20 to +70 °C 12 bit (no sign bit) 1500 V Linearity <1 Least Significant Bit Isolation 1000 VRMS between field and logic Common Mode Rejection >70 dB at DC; >70 dB at 60 Hz Cross-Channel Rejection >80 dB from DC to 1 kHz Input Impedance Input Filter Cutoff Frequenc y 250 Ω standard 15 kΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required. 325 Hz @ -3 dB Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 213 Kingfisher Plus+ Hardware Manual DIGITAL INPUTS Rated Voltage Inputs per Module 12 to 24 VAC/DC (can use reverse polarity) 8 ON-state Voltage 11.5 to 30 VDC maximum OFF-state Voltage 0 to 4 VDC ON-state Current 3.2 mA minimum OFF-state Current 1 mA maximum ON Response Time 10 ms typical OFF Response Time 17 ms typical Input Characteristics Input Current Isolation 4 mA (typical) at rated voltage 1000 VRMS between field and logic DIGITAL OUTPUTS Outputs per Module 2 Commons 1 (common supplies both outputs) Relay Type SPST (Single Pole Single Throw) Maximum Switched Voltage 30 VDC, 42 VAC Maximum Switched Current 5 A per common Isolation Minimum Load Contact Resistance Relay Operations Relay Part Number 3 kV coil to contacts 10 mA @ 5 VDC 100 mΩ maximum 70,000 minimum at 1800 operations per hour at rated load Omron G6D-1A 12 VDC (G6D datasheet is available from http://components.omron.eu/) CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase the service life of relays (please see the “Switching Inductive Loads” section for more details). Contacts should also be protected with external fusing. * Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: R85 and R41 (channels 1 and 2 correspondingly). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 214 Kingfisher Plus+ Hardware Manual 14.3.4 IO-4 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. * Optional link for DC Supply only. Enables fuse fail LED ‘FU’ on module. CAUTION! When the link is installed, a maximum voltage of 30 V (AC or DC) can be used to power the common. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 215 Kingfisher Plus+ Hardware Manual Strain gauge input (4 wire Wheatstone bridge) 2 wire transmitter (powered by module) 3 wire transmitter (powered by module) 4 wire transmitter (powered by module) 2 wire transmitter (externally powered) 3 wire transmitter (externally powered) 4 wire transmitter (externally powered) Field contact input (externally powered) Driving digital load (externally powered) Passive field contact (powered by module) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 216 Kingfisher Plus+ Hardware Manual IO-5: Combinational Analogue / Digital IO Module 14.4.1 Overview • • • • 4 analogue inputs 1 analogue output with open line detection 4 digital inputs 4 sinking solid state outputs This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Analogue IO Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground). Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below. MSB 0 LSB D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0 Scaling of the input is shown below: All inputs share a single common and all outputs share a separate common at the zero volt rail. For analogue outputs, an Open Line Detection circuit will indicate whether current loop is open or closed. Please note that open line detection circuit performance cannot be guaranteed when AO value is set to less than 1% (328 decimal) of full scale in the 0-20 mA range. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 217 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 218 Kingfisher Plus+ Hardware Manual Block-diagram of the IO-5 module is shown on the figure below. IO-5 Block Diagram Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 219 Kingfisher Plus+ Hardware Manual 14.4.2 IO-5 Module LEDs LED State Description OFF Module fault (no power) ON Normal OFF Normal ON Module Reset in progress OFF Field Power disabled ON Field Power enabled OFF Analogue input is less or equal to 1% of range ON Analogue input is greater than 1% of range OFF Analogue output is set to less or equal to 1% of range ON Analogue output is set to greater than 1% of range OFF Analogue output line is closed (loaded) ON Analogue output line is open / loop current equal to zero OFF Digital input OFF ON Digital input ON OFF Digital output OFF (Output switch does not conduct) ON Digital output ON (Output switch conducts) OK RST 24Va AI 1-4 AO1 OL DI 1-4 DO 1-4 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 220 Kingfisher Plus+ Hardware Manual 14.4.3 IO-5 Specifications IO-5 Analogue / Digital Combinational Module Specifications Operating Temperature -40 to +85 °C Storage Temperature -40 to +85 °C Humidity Output Power Maximum W orking Voltage on any contact of the field connector Hot Swap 5 to 95 % RH (non-condensing) 24 VDC / 100 mA max, Isolated 42.4 VPEAK / 60 VDC relative to system (backplane) ground Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. ANALOGUE INPUTS Input Current Ranges Input Voltage Ranges * Inputs per Module Resolution Accurac y (includes Gain, Linearity and Offset errors) Update Rate Cross-Channel Rejection 4 - 20 mA or 0 - 20 mA 1 - 5 V or 0 - 5 V * 4 Unsigned 12 bit ± 0.25% @ 25 °C ± 0.50% @ -40 to +85 °C 120 ms > 115 dB from DC to 1 kHz Input Impedance 250 Ω standard 1 MΩ optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required. Input Filter Cutoff Frequenc y 7 Hz @ -3 dB AC noise attenuation Output Field Power Isolation Hardware Manual Version 7.16 16 dB @ 50 Hz 18 dB @ 60 Hz 24 VDC / 80 mA Isolated 5 kV Transient http://www.servelec-semaphore.com/ Page 221 Kingfisher Plus+ Hardware Manual ANALOGUE OUTPUT Output Current Range Outputs per Module Output Type Resolution Update Rate Accurac y (includes Gain, Linearity and Offset errors) User Load Isolation 4 - 20 mA or 0 - 20 mA 1 Isolated, Sourcing Unsigned 12 bit 250 ms Determined by I/O scan time and is application dependent ± 0.25% @ 25°C ± 0.50% @ -40 to +85 °C 0 to 850 Ω 5 kV Transient DIGITAL INPUTS Inputs per Module Input Type Maximum Input Voltage 4 with one common Optically isolated, Sinking 30 VDC Guaranteed ON-state Voltage 10 VDC minimum Guaranteed OFF-state Voltage 4.0 VDC maximum Counters Type Maximum Counters Speed Input Current Isolation Pulse, Unsigned 16-bit (all channels) 10 kHz Approx. (VIN / 4.7) mA: 2 mA @ 9.4 VIN; 6.4 mA @ 30 VIN 5 kV Transient DIGITAL OUTPUTS Outputs per Module Output Type 4 with one common Optically isolated, Solid State, Sinking Maximum Switched Voltage 30 VDC Maximum Switched Current 2 A per channel Isolation 3 kV Transient * Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: • Ch.1: R81 (or R85+R86); • Ch.2: R82 (or R87+R88); • Ch.3: R83 (or R89+R90); • Ch.4: R84 (or R91+R92). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 222 Kingfisher Plus+ Hardware Manual 14.4.4 IO-5 Wiring Diagram The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 223 Kingfisher Plus+ Hardware Manual Analogue Input Examples 2 wire transmitter (powered by module) 3 wire transmitter (powered by module) 4 wire transmitter (powered by module) 2 wire transmitter (powered externally) 3 wire transmitter (powered externally) 4 wire transmitter (powered externally) Analogue Output Example Analogue load Digital Input Example Sensing the output form a field contact Digital Output Example Driving external load from digital output Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 224 Kingfisher Plus+ Hardware Manual 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: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 225 Kingfisher Plus+ Hardware Manual Summary of available adaptors and cables Part Number Description ADP-04 Maxon and Tait radios (DB9F to RJ45 Adaptor) for 'R' option ADP-05 PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options ADP-N DB9 port saver. Used with ADP-05 for concealed PC serial ports (e.g. Current HP Notebooks) ADP-05-N PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver. ADP-07 PSTN modem external 25 pin (DB25M to RJ45 Adaptor) for 'S' options, confirm PSTN pin-outs ADP-08 RJ45 to DB9 Female Converter (Straight Connect) ADP-08 M RJ45 to DB9 Male Converter (Straight Connect) for Serial Port to MaxStream External Spread Spectrum Radio ADP-16 Trio "D" and "E" Series Radio (DB9M to RJ45 Adapter) for 'S' options ADP-25 Uni-Op Display Model - MD02R-04-00A5 (DB15M to RJ45 Adapter) for 'S' options ADP-28 Trio "H" series Spread Spectrum Radio (DB9M to RJ45 Adapter) for 'S' options ADP-29 Trio "M" series Radio (Modem fitted) (DB9M to RJ45 Adapter) for 'S' options ADP-31 Trio "M" series Radio (DB9M to RJ45 Adapter) for PC-1 'R' option RJC-05 Cable RJ45 Plug both ends "1:1" - 0.5 meters RJC-10 Cable RJ45 Plug both ends "1:1" - 1.0 meter RJC-20 Cable RJ45 Plug both ends "1:1" - 2.0 meters RJC-30 Cable RJ45 Plug both ends "1:1" - 3.0 meters RJC-50 Cable RJ45 Plug both ends "1:1" - 5.0 meters RJC-100 Cable RJ45 Plug both ends "1:1" - 10.0 meters RJC-ADP-22B Wavecom GSM Cable (RJ45 to HD15) for 'S' options, to suit Fastrack Xtend FXT009, and superseded 1205-1306, Supreme 10 RJC-ADP-26 Maxon MM-6280IND 3G Cable (RJ45 to DB15) for 'S' options RJC-ADP-27 Motorola Satellite Series 9522 L-Band Cable (RJ45 to DB25) for 'S' options RJC-ADP-30 Trio "M" series radio Cable (RJ45 to DB15) for 'L' option RJC-45/12 RJ45 to RJ12 Phone Lead - 2.0meters RJC-X-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-IO-2 External I/O cable - 2m CAB-IO-5 External I/O cable - 5m CAB-FO-PATCH-1 Patch Cable for A3 Ethernet Option Board (MTRJ to ST) CAB-FO-PATCH-2 Patch Cable for A3 Ethernet Option Board (MTRJ to SC) Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 226 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 RJ45 to Kingfisher RTU Ethernet Port http://www.servelec-semaphore.com/ Page 227 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To PC Serial Port http://www.servelec-semaphore.com/ Page 228 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To External Device http://www.servelec-semaphore.com/ Page 229 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To Operators Panel http://www.servelec-semaphore.com/ Page 230 Kingfisher Plus+ Hardware Manual ADP-16: Serial Port to Trio D-Series Radio or Trio E/K/M Series Radio Hardware flow control supported. To Kingfisher Serial Port To Trio Radio RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio For TC-450SR, TC-900SR or RTU Serial Port to Trio S-Series Radio with 24/48SR modem. To Kingfisher Serial Port Hardware Manual Version 7.16 To Trio Radio http://www.servelec-semaphore.com/ Page 231 Kingfisher Plus+ Hardware Manual RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125) To Kingfisher Serial Port Hardware Manual Version 7.16 To Maxon Radio http://www.servelec-semaphore.com/ Page 232 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To Tait Radio http://www.servelec-semaphore.com/ Page 233 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To GSM or GPRS Modem http://www.servelec-semaphore.com/ Page 234 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 To Satellite Transceiver http://www.servelec-semaphore.com/ Page 235 Kingfisher Plus+ Hardware Manual ADP-28: RTU Serial Port to Trio H–Series Spread Spectrum Radio To Kingfisher Serial Port To Trio Radio ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR450 For hardware flow control see the ADP-16. To Kingfisher Serial Port Hardware Manual Version 7.16 To Trio Radio http://www.servelec-semaphore.com/ Page 236 Kingfisher Plus+ Hardware Manual RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio (no modem fitted) E.g. MR450 To Kingfisher Serial Port To Trio Radio ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g. MR450 To Kingfisher Serial Port Hardware Manual Version 7.16 To Trio Radio http://www.servelec-semaphore.com/ Page 237 Kingfisher Plus+ Hardware Manual 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 Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 238 Kingfisher Plus+ Hardware Manual 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-12PLUS 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 239 Kingfisher Plus+ Hardware Manual 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). Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 240 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 241 Kingfisher Plus+ Hardware Manual 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 242 Kingfisher Plus+ Hardware Manual Symbols The module can only be used in not-tropical climate regions. The module can only be used at altitude not exceeding 2000 metres. This point can be used for Functional Earthing connection. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 243 Kingfisher Plus+ Hardware Manual 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: Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 244 Kingfisher Plus+ 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 245 Kingfisher Plus+ Hardware Manual 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 RTU CABINET DEVICE BACKPLANE BACKPLANE NOTE: SIGNAL AND POWER CONNECTIONS NOT SHOWN MOTOR DRIVES AND OTHER ELECTRICAL CONTROL EQUIPMENT MACHINERY CENTRAL GROUND POINT EARTH GROUND 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. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 246 Kingfisher Plus+ Hardware Manual Safety Earth / Ground Although safety of the Power Supply Module and other modules with the potentially hazardous voltage levels have been assessed and found to be in compliance with the appropriate requirements, an additional level of protection from a potential electrical shock can be provided by connecting the RTU backplane to the safety earth / ground. The Earth / Ground rail of the backplane PCB can be grounded by mounting screws to the metal back-plate of the backplane when properly installed. Additional grounding wire straps should be used in case reliable screw connections cannot be assured. Earth / Ground connections should be made from one of the PCB mounting tabs to a system earth / ground terminal (usually a threaded stud) using a minimum AWG#12 wire and ring terminals. Use of a nut and star washer for each wire on the ground connection lug is recommended to ensure adequate grounding. Ensure the paint coating is removed under the lug to make good electrical contact. All backplanes grouped together in a RTU system must have a common ground connection. This is especially important for backplanes that are not mounted in the same enclosure. The best way to provide proper ground connections is to ensure that the RTU backplane metal frame is directly connected to the mounting panel (or rear plate) by connecting a ground strap from one of the ground lugs on either side of the backplane to the mounting panel or cabinet in accordance with local safety requirements. Functional Earth / Ground Yellow / Green wire in the mains power cord provides only functional (NOT Safety) Earth / Ground connection and cannot be relied upon for safety purposes. Hardware Manual Version 7.16 http://www.servelec-semaphore.com/ Page 247