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User manual ATU900 Table of Contents 1 2 INTRODUCTION .................................................................................................................................. 5 INSTALLATION .................................................................................................................................... 9 2.1 Environmental .......................................................................................................................... 9 2.2 Mechanical ............................................................................................................................... 9 2.3 Battery Power Supply............................................................................................................. 11 2.3.1 Alkaline Battery Power Supply ........................................................................................... 11 2.3.2 Alkaline Battery Removal and Replacement ...................................................................... 12 2.4 DC Power Supply ................................................................................................................... 12 2.4.1 DC Supply Module Removal and Replacement ................................................................. 13 2.5 Mains Power Supply............................................................................................................... 13 2.5.1 Mains Power Supply Module Removal and Replacement ................................................. 14 2.5.2 Back-up Battery Power Supply (Mains version) ................................................................. 14 2.5.3 Battery Pack Removal and Replacement (mains version) ................................................ 15 2.6 Battery Safety and Disposal ................................................................................................... 15 2.7 Modem Communications (units with internal modems only).................................................. 15 2.7.1 Connecting to the Telephone Line (units with internal modems only)................................ 16 2.7.2 Connecting to the GSM network (units with internal GSM units only)................................ 16 2.7.3 Connecting to the GPRS network....................................................................................... 16 2.7.4 Connecting to the LEO Satellite. ........................................................................................ 16 2.8 CPU Reset ............................................................................................................................. 16 2.9 Displays.................................................................................................................................. 17 2.9.1 LCD and LED display ......................................................................................................... 17 2.9.2 Local Display Interface ....................................................................................................... 17 2.10 Input / Output Capabilities .................................................................................................. 17 2.10.1 I/O Wiring............................................................................................................................ 17 2.10.2 Digital Inputs ....................................................................................................................... 18 2.10.3 Count (Accumulator) Inputs................................................................................................ 18 2.10.4 Digital Outputs .................................................................................................................... 18 2.10.5 Incremental Shaft Encoders ............................................................................................... 19 2.10.6 Absolute Shaft Encoders .................................................................................................... 20 2.10.7 Analogue Inputs.................................................................................................................. 20 2.10.8 MODBUS ............................................................................................................................ 22 2.11 Pseudo Analogue Inputs .................................................................................................... 23 2.11.1 Battery Powered ATU900................................................................................................... 23 2.11.2 DC Powered ATU900 ......................................................................................................... 23 2.11.3 Mains Powered or DC with NiMH Back-up ATU900 .......................................................... 23 3 COMMUNICATIONS ........................................................................................................................... 24 3.1 Masterstation (units with remote communication modules only) ........................................... 24 3.1.1 Alarm dial-outs.................................................................................................................... 24 3.1.2 Interrogations...................................................................................................................... 24 3.2 Outstation Programming Terminal for Windows (OPTwin) .................................................... 24 3.2.1 Local OPTwin (RS232)....................................................................................................... 24 3.2.2 Remote OPTwin (units with remote communication modules only)................................... 25 3.2.3 Local interrogation (RS232)................................................................................................ 25 3.3 GSM Interface Card ............................................................................................................... 25 3.4 PSTN Interface Card .............................................................................................................. 26 3.5 Auxiliary communications (RS232, RS485, SDI-12, Ethernet) .............................................. 26 3.5.1 RS232 Interface Card ......................................................................................................... 26 3.5.2 RS485 Interface Card ......................................................................................................... 27 3.5.3 SDI-12 Interface Card......................................................................................................... 28 3.5.4 Comms Expander / Ethernet Card ..................................................................................... 28 4 SHORT-FORM SPECIFICATIONS ......................................................................................................... 30 4.1 Common Specification across all Inputs ................................................................................ 30 4.2 Digital Inputs........................................................................................................................... 30 4.3 Analogue Inputs ..................................................................................................................... 30 4.4 Count inputs ........................................................................................................................... 31 4.5 Digital outputs......................................................................................................................... 31 4.7 Sequences ............................................................................................................................. 31 4.8 Site and Telephone Data ....................................................................................................... 31 ATU900 User manual 3 Communications (units with internal modems fitted) ............................................................. 32 4.9 4.10 Communications (local) ...................................................................................................... 32 4.11 Communications (auxiliary) ................................................................................................ 32 4.12 Mechanical ......................................................................................................................... 32 4.13 Electrical ............................................................................................................................. 32 4.14 Environmental..................................................................................................................... 32 4.15 Real-time clock (RTC) ........................................................................................................ 32 5 APPENDIX A – STANDARD CABLING INFORMATION ............................................................................. 33 5.1 Mains Power Cable Wiring Schedule..................................................................................... 34 5.2 DC Power Cable Wiring Schedule ......................................................................................... 34 5.3 Local (OPTwin) Serial Port Connector Wiring Schedule ....................................................... 34 5.4 32 Digital Input Cable............................................................................................................ 35 5.5 Plus 2 Incremental Shaft Encoders........................................................................................ 37 5.6 4 Analogue Input + 4 Digital Output Cable ............................................................................ 38 5.7 Plus 4 Analogue Inputs Cable (i.e. 8AI+4DO) ....................................................................... 40 5.8 Plus 4 Digital Outputs Cable (i.e. 4AI+8DO).......................................................................... 41 5.9 RS232 Wiring Schedule ......................................................................................................... 42 5.10 Simple 5-Wire RS485 Wiring Schedule.............................................................................. 42 5.11 Simple 4-Wire SDI-12 Wiring Schedule ............................................................................. 43 4 ATU900 User manual Introduction 1 Introduction Figure 1: ATU900 The D714x MkII family will now be designated ATU900 family and is a range of IP65/IP67 low-power data logger/telemetry outstations. Four power options are available, each with their own method of power back-up. These are D-cell battery powered with a second bank of D-cells as back-up, DC powered with D-cell backup, DC powered with NiMH back-up and mains AC powered with NiMH backup. The name “ATU900” will be used throughout this manual as a generic name for all members of the family unless specifically stated otherwise. The many capabilities and small size of the ATU900 means that it is ideally suited to a wide range of applications in the utilities and industrial markets. These include the monitoring of: • Water Hydrology • • Zonal distribution Environmental • • • Industrial Pollution Water and Sewage Gas Installations - Rain River Tidal Flood Warning - Temperature Wind Humidity Pressure Data logging, telemetry and local intelligence (sequences) are all combined in the one unit and thus the need for separate outstations and data loggers is reduced. MODBUS, WITSDNP3, AquaCom, FSK and SDI-12 protocols are available to accept input and output data from existing PLCs and intelligent instrumentation thus integrating the islands of automation and information that may presently exist. As a telemetry outstation, the ATU900 unit is capable of reporting alarm conditions as they arise. Stored data can be retrieved at any time, over PSTN / GSM / GPRS or Satellite links to a Masterstation, or locally via direct RS232 cable connection. ATU900 User Manual 5 The ATU900 can be configured to implement a wide variety of logging strategies. Powerful bespoke logging can be achieved when sequences are employed e.g. variable rate or combined event logging to fit a daily, weekly or monthly pattern. The unit may be fully configured using Outstation Programming Terminal for Windows (OPTwin) software, available from Xylem Water Solutions UK Ltd. Key features in this unit include: • Reduced power consumption using low-voltage electronics and advanced power management. • Proven multi-microprocessor system with integral self-diagnostic electronics. • Glanded cables or military-style connectors for easy cable installation and removal. • “Green” - alkaline and NiMH batteries with lower environmental impact. • Increased battery capacity to reduce service requirements. • Intelligent charging techniques to maximise battery capacity and service life. • High-resolution analogue measurement – up to 16-bit possible. • Wide variety of analogue inputs supported. • Enhanced protocol set – Dynamic Logic FSK, AquaCom, MODBUS, SDI-12, WITSDNP, and Ethernet. • Support for both incremental and absolute shaft encoders. • Optional interface to radio, GSM, GPRS and satellite equipment - configurable as RS232, RS485 or Ethernet. • Improved operating temperature specification with internal monitoring. • Enhanced noise immunity Caution ATU900 units contain low-power CMOS components that are static-sensitive. As with all electronic equipment, standard ESD precautions must be observed when opening the enclosure to prevent possible damage through static discharge. Warning Electric shock hazard may be present in mains powered ATU900 units. ATU900 must be disconnected from the mains power supply before removing the lid 6 ATU900 User manual A summary of features is given below: Parameter Power Supply Options Internal Battery Back-up Options Operating Temperature Range Relative Humidity Digital Inputs Digital Outputs Analogue Inputs Counter Inputs (configurable as Digital Inputs) Shaft Encoder Display Serial Communication Ports Log size Sensor Connection Enclosure (W x H x D) IP ratings Specification 11-16Vdc (using ten or twenty alkaline D cells) 11Vdc to 36Vdc 100 - 240Vac @ 50-60Hz 0.4A One battery pack on both battery and dc powered units and the option of two NiMH (rechargeable battery back-up) packs on dc (NiMH) and mains units -10°C to +50°C 0 to +95% @ +45°C (non-condensing) Thirty-two Input: volt-free contacts: closed < 1kΩ, open > 100kΩ Input: open-collector (open-drain) transistor Four or Eight volt-free photoMOS relay outputs rated 24V ac/dc @ 0.5A Four or Eight 16-bit resolution max, 14-bit min. Accuracy ±0.05% Current, voltage, potentiometric 12Vdc and Vref pulsed sensor supplies with short- circuit protection Thirty-two inputs as per digital inputs. Note digital inputs can also be counters. 0 – 99999999 (eight decade) Optional 2 Incremental shaft encoders. Optional Absolute shaft encoders making use of digital inputs. LCD: 2-rows, 16-characters Up to 5 communication ports configured as one local (COM0) for OPTwin, four internal for PSTN / GSM / GPRS modems / RS232 / RS485 / SDI-12 interfaces. A further two Ethernet ports are also an option. Supported protocols include MODBUS-RTU/ASCII, SDI-12, FSK, AquaCom, and WITSDNP3. >500KB Low cost military-style circular connectors or glanded cables. 276mm x 224mm x 130mm IP67 (enclosure), IP65 connectors The ATU900 range is designed to maximise energy efficiency and employs state-of-the-art power management circuitry. The unit conserves power by switching into a “sleep” mode whenever possible, where all but the highest priority functions are inactive. The unit “wakes” periodically to perform various housekeeping duties, such as: • Reading of digital and shaft encoder inputs. • Count rate update. • Time log / analogue conversion. In addition, the unit will stay awake while carrying out particular functions: • Analogue alarm delay. • Digital output active. • All external communications. • Sequence wake states. The unit is designed to conduct wake-state functions with optimum speed and efficiency. In order to maximise battery life, it is recommended that the above functions be configured with care, keeping wake-states to a minimum. Failure to observe this operational requirement may significantly reduce battery life. ATU900 User Manual 7 A typical ATU900 unit comprises: 1. A main board, containing the major system components (processors, memory, I/O electronics). 2. A primary power supply board. On Battery units, this board houses ten battery holders and associated regulator electronics. On Mains powered units, the holders are replaced with an encapsulated power supply module and one NiMH Battery Pack as standard, (optionally two NiMH packs can be fitted). The DC units with D-cell backup have dc regulator electronic components fitted. The DC units with NiMH back-up have one NiMH battery pack, (optionally two NiMH packs can be fitted). 3. An LCD/Display board. In the battery and DC powered units this has the additional facility of holding additional D-cell backup batteries. 4. Up to eight Signal Conditioning Modules. 5. An optional Ethernet / Communication expander module (note this is require to increase from 2 serial channels to 4 serial channels. 6. Up to four communications interface units. 7. External cabling either glanded cables or cables with military-style connectors. 8 ATU900 User manual Installation 2 Installation Note: ATU900 Series Outstations should only be opened by suitably qualified personnel, as dangerous voltages may be present. 2.1 Environmental The ATU900 utilises a polycarbonate enclosure rated to IP-67. The following environmental conditions apply: Operating temperature: -10°C to +50°C. Storage temperature: -10°C to +60°C. Relative humidity: 0 to 95% @ 45°C (non-condensing). 2.2 Mechanical It is recommended that the unit is mounted vertically on a stable structure, secured using screws or bolts via the four mounting holes located in the enclosure corners – these apertures can be accessed by removing the lid. All input cabling connects to the units via glanded cable assemblies or two-part military-style connectors. A dimensioned drawing of the ATU900 and enclosure is shown in Figure 2. The main assembly comprises three PCBs mounted in a stack within the enclosure. The bottom PCB in the stack is the main board housing all the CPU and interface electronics. It is affixed directly to the mounting bosses at the bottom of the enclosure. Internal modems PSTN or GSM/GPRS and RS232/RS485/SDI-12 and Ethernet modules plug directly into this board. The I/O wiring and Signal Conditioning Modules (SCMs) also plug into this board via modular connectors. Mounted above the main board are two additional boards. These power modules house the batteries, power supplies, LCD and status LEDs as required. The primary power module, mounted above the CPU board accommodates: • ten ‘D’ cell battery holders in battery-powered units, • x ‘D’ cell battery holders in the case of DC powered units with D call backup. • one or two NiMH Battery packs in the case of DC or Mains powered units • an encapsulated power supply in the case of mains powered units along with electronic circuitry to regulate the power on dc and mains units. Mounted on the lid is the display board. The LCD and LEDs are fitted on the reverse side, facing upwards towards the user. This board also contains the secondary power module, and may house a further ten ‘D’ cell battery holders in battery powered units, allowing up to twenty batteries in total to be fitted to the unit. The PCBs are connected together such that in the case of the battery version all twenty batteries are exposed simultaneously for easy changeover. Caution These battery banks should be changed one bank completely at a time to prevent any data loss. Also polarity of all batteries must be carefully observed as described later in this document. A desiccant sachet is provided with the unit to protect against corrosion, dampness and condensation. This material can be re-activated by placing the sachet in an oven at +120°C for four hours. The material will last approximately one year before drying out is required, depending on the ambient environmental conditions and the amount of time in which the enclosure lid is opened. The unit is fitted with an internal sensor for measuring the enclosure temperature (an important parameter when charging batteries) which can be checked using OPTwin. ATU900 User Manual 9 Figure 2: ATU900 dimensions 10 ATU900 User manual 2.3 Battery Power Supply 2.3.1 Alkaline Battery Power Supply The battery-powered variant of the ATU900 range is designed to operate from up to twenty alkaline ‘D’ cells on two independent power supply boards. The battery holders are arranged in two arrays of ten. These arrays are as below and the orientation is shown as if the unit is vertically wall-mounted i.e. the lid folds down toward you. CAUTION The proper battery polarity is moulded into the battery holder and all batteries in the array MUST be positioned correctly. Failure to do this can result in battery leakage and subsequent unit damage. Ensure the batteries are inserted properly. Figure 3: Alkaline Battery Holder Arrays Electrical power is applied to the ATU900 electronics as soon as the last battery is inserted into the battery holder. The working voltage of this unit is nominally 15Vdc. The condition of each battery array is monitored by the system and alerts are generated if faults are detected. In addition, the gradual decline in battery-array voltage is measured and when the levels drop below defined thresholds, the unit can be configured to generate an alarm dial-out. The gentle slope of the alkaline discharge curve means that low-battery warnings can be generated far in advance of complete power failure, allowing reasonable time to change the cells. Eventually, when the end-of-discharge-voltage (EODV) is reached, the unit will inhibit LED operation to extend the battery life thus safeguarding plant and preserving data. The unit will remain in this state until the batteries are replaced. Note: - new batteries must be replaced in one array at a time if data is to be preserved. A dedicated fuse, adjacent to the holders, protects each battery array. The fuse will rupture if all the batteries are inserted the wrong way round. However if only one battery is inserted with the wrong polarity then this may lead to electrolyte leakage which will destroy the unit’s electronics and poses a potential fire hazard. Reference should be made to the polarity symbols on the battery holders, reproduced in Figure 3. The operational life of alkaline batteries is largely defined by a combination of the following parameters: • Rated battery capacity. The rated capacity of a particular alkaline ‘D’ cell is dependent on model and manufacturer. Xylem Water Solutions UK Ltd recommends that high-capacity batteries (Duracell M3, Procell or similar) are used to reduce service requirements. ATU900 User Manual 11 2.3.2 • Shelf life. All batteries are subject to loss of capacity due to self-discharge. A five to seven year shelf life is quoted for Duracell M3 or Procell alkaline batteries. The shelf life of cheaper brands may be considerably less. • Temperature. Battery self-discharge increases above +50°C because of the deterioration of the chemical cells. A more severe effect occurs below 0°C, in which the capacity is degraded due to a reduction in electrochemical activity within the battery. Ideally, the unit should be protected from temperature extremes. • Sensor loading Sensors that are powered from the unit obviously place a load on it and therefore a drain on the batteries. In terms of energy requirements, the most demanding sensors are incremental shaft encoders, current transducers PSTN, GSM/GPRS and radio communications. Battery service life can be maximised by the use of low-power sensors, by selecting low scan-rates and by minimising the communications and log transfers. • Operational usage The unit is designed to minimise the quiescent power requirements that occur during sleep mode. The majority of battery energy is consumed during sequence wake-states and when communications are active. Minimising these operations will extend battery life. Alkaline Battery Removal and Replacement CAUTION When replacing batteries, always change one array at a time in order to ensure continuity of supply. Failure to observe this procedure will cause loss of data. Ensure that the batteries are inserted with the correct polarity as indicated on the battery holder. • • • • • Unscrew the two corner screws and open downward gently to expose the batteries. The batteries are arranged in arrays as shown in Figure 3 – observe the battery polarities shown. Remove the cells in one array and replace with fresh batteries. Repeat each battery in turn until all the batteries have been replaced. Carefully replace the lid of the outstation, and firmly screw in place to ensure a good seal. 2.4 DC Power Supply The dc-powered variant in the ATU900 range can be connected to an 11Vdc to 36Vdc supply. The dc supply is protected with a slow-blow 20mm fuse. This fuse is designated FS5 and is located on the dc power supply module. The unit should only be opened by suitably qualified personnel and the fuse should only be replaced with one of the same type and rating. WARNING Short-circuiting when the unit is disassembled may damage live electronics. Disconnect from the dc supply before removing the lid. Battery back-up is provided in the event of mains failure either by optional alkaline batteries that are not charged during normal operation or NiMH battery packs that are trickle charged and power cycled. This allows the unit to dial out and report any power failure while continuing to operate for a period of time without a dc supply, depending on ambient temperature and usage. In the D-cell backup Pseudo Analogue 6 is the external DC Input monitor. This can be configured to indicate when the dc power is disconnected. Alarm dial-outs may be generated on this input, thus providing the facility to inform the Masterstation of DC power supply failure on site. Similarly Pseudo Analogue 5 is the back-up battery monitor that can also be configured to dial out when the back-up battery voltage is getting low. In the case of the NiMH back-up Pseudo Analogues 7, 8, 9 and 10 can be used in battery pack diagnostic. They may also be configured to cause a dial out when an abnormal condition arises. 12 ATU900 User manual 2.4.1 DC Supply Module Removal and Replacement CAUTION Removal of the dc power supply module will result in loss of data. To avoid this, read and store the live data before disconnecting the module and then set this as the preset (via OPTwin) after replacement. WARNING Unit may be damaged if live terminals are short-circuited. Removal and replacement of the power supply module should only be carried out by suitably qualified personnel. • • • • • • • • Disconnect unit from external power supply. Unscrew the two corner screws and open downward gently to expose the dc power supply module. Disconnect the power plug from the DC power supply module and in the case where NiMH battery packs are present – remove their plugs from the PCB Disconnect the ribbon cables from the dc power supply module. In the case of D-cell backup, unscrew the six screws that secure the dc power supply module and remove. In the case of NiMH backup, unscrew the four screws that hold the NiMH cover plate and remove. Unscrew the two screws and four hex pillars that secure the dc power supply module and remove. DC power supply module replacement is the reverse of the above procedure. Carefully replace the lid of the outstation, and firmly screw in place to ensure a good seal. 2.5 Mains Power Supply The mains powered variant in the ATU900 range can be connected to an 100Vac to 240Vac supply at 50Hz to 60Hz. The mains supply is protected with a slow-blow 20mm fuse. This fuse is located on the mains power supply module. The unit should only be opened by suitably qualified personnel and the fuse should only be replaced with one of the same type and rating. WARNING Electric shock hazard may be present when the unit is disassembled. Disconnect from the mains supply before removing the lid. Battery back-up is provided in the event of mains failure by NiMH batteries that are trickle charged during normal operation. This allows the unit to dial out and report the mains failure while continuing to operate for a period of time without a mains supply, depending on ambient temperature and usage during this time. Pseudo Analogue 11 is the Mains Fail monitor. This will be ‘Failed’ when the mains supply is disconnected. Alarm dial-outs may be generated on this input, thus providing the facility to inform the Masterstation of mains failure on site. Pseudo Analogues 7, 8, 9 and 10 can be used in battery packs diagnostic. They may also be configured to cause a dial out when an abnormal condition arises. ATU900 User Manual 13 2.5.1 Mains Power Supply Module Removal and Replacement CAUTION Removal of the mains power supply module will result in loss of data. In order to avoid this, upload the live data before disconnecting the module and set this as the preset (via OPTwin) after replacement. WARNING Hazardous voltages are present on the mains power supply module. Disconnect from the supply before removal. Removal and replacement of the power supply module should only be carried out by suitably qualified personnel. • • • • • • • • 2.5.2 Disconnect unit from mains supply. Unscrew the two corner screws and open downward gently to expose mains power supply module. Disconnect the power plug from the AC power supply module and disconnect the NiMH plugs from the PCB Disconnect the ribbon cables from the mains power supply module. Unscrew the four screws that hold the NiMH cover plate and remove. Unscrew the two screws and four hex pillars that secure the mains power supply module and remove. Mains power supply module replacement is the reverse of the above procedure. Carefully replace the lid of the outstation, and firmly screw in place to ensure a good seal. Back-up Battery Power Supply (Mains version) In the event of external supply failure, back-up power can be provided by one or two 9.6Vdc battery packs. These packs are available from Xylem Water Solutions UK Ltd and the basic mains powered ATU900 comes with one NiMH cell fitted. The mains units feature comprehensive battery management circuitry, designed to charge NiMH cells safely and effectively. When two NiMH packs are fitted the batteries are conditioned to maximise capacity and service life and are monitored to ensure availability of a reliable back-up supply. (i.e. the batteries are checked regularly to ensure they have adequate capacity rather than assuming everything is o/k until proven otherwise.). The description on this page is for two NiMH packs fitted. Each pack is connected to a conditioning circuit that controls the battery charge and discharge cycles. There are four modes of operation, listed as follows: • Trickle charge The battery packs are subjected to a trickle charge regime to overcome self-discharge. • Fast charge The battery packs receive full-rated charge current for up to eighteen hours. • Discharge Periodically, a battery pack in turn is completely discharged to prevent a reduction in capacity and then fully recharged. This cycle is then repeated for the other battery pack. The packs are independent so one can supply the back-up power while the other is in a discharged state. • Back-up powered This mode is implemented when the mains fail and the unit is operating from the back-up power. Visual indications of the charger modes are provided by LEDs adjacent to each pack. The LEDs are illuminated as shown in the following table: 14 ATU900 User manual Trickle charge Fast charge Discharge cycle Back-up powered Discharging LED OFF OFF ON OFF Trickle LED ON ON OFF OFF Charging LED OFF ON OFF OFF The battery pack capacities are measured periodically by the system. If a pack is faulty or its capacity has dropped below a minimum threshold, the unit can be configured to generate an alarm dial-out. 2.5.3 Battery Pack Removal and Replacement (mains version) CAUTION If operating from battery back-up supply, always change one pack at a time in order to ensure continuity of supply. Failure to observe this procedure will cause loss of data. Ensure that the battery plugs are inserted into the PCB socket correctly. • • • • • • • Unscrew the two corner screws and open downward gently to expose the batteries. Unscrew the four screws on the NiMH safety plate to access the two battery packs that are mounted one behind the other. Remove the cells in one pack replace with a new pack. Replace the power plug correctly. Repeat for other pack if it requires replacing. Replace safety cover with label to front. Carefully replace the lid of the outstation, and firmly screw in place to ensure a good seal. 2.6 Battery Safety and Disposal Alkaline batteries do not contain heavy metals such as cadmium and are not classified as hazardous waste. NiMH batteries have a lesser impact on the environment than other types of cells (i.e. NiCad cells), but may still be subject to local regulations in some areas. It is recommended that the local authorities be contacted to obtain their disposal guidelines. Incorrect handling may cause the batteries to rupture, leak or decrease in performance. To prevent this, please observe the following precautions: • • • • • • • • For best performance and longevity, it is recommended that alkaline batteries, such as Duracell M3 or Procell, be used. Replace battery with same type only. Using another battery may present a risk of fire or explosion. Do not short-circuit, disassemble, heat above 100°C or incinerate batteries. Do not compact, mutilate or physically abuse the batteries. Do not re-charge alkaline batteries. Dispose of batteries promptly with observance of local guidelines. Keep batteries away from children. Do not consume. 2.7 Modem Communications (units with internal modems only) For communicating over PSTN it is recommended that the unit be connected to an ex-directory, data quality, dedicated telephone line. Line loss must not exceed 27dB. The ATU900 modem can operate in pulse or DTMF modes – in order to save power, it is recommended that the ATU900 be connected to a DTMF telephone line that provides a quicker connection. If unsure of the type of telephone line connected to the unit, contact your service provider. PSTN can be used as a fallback option if GSM, GPRS, Radio or Private Wire is used as primary communication. Full configuration and set-up of the fallback functionality including timeouts is detailed in the OPTwin manual. ATU900 User Manual 15 2.7.1 Connecting to the Telephone Line (units with internal modems only) The ATU900 modem is ready for connection to the PSTN. Xylem Water Solutions UK Ltd strongly recommends that a Lightning Protection Unit (LPU) is used with every ATU900 outstation. An LPU is located between the telephone line and the ATU900 as shown in Figure 4. A suitable LPU for PSTN applications is available from Xylem Water Solutions UK Ltd. If using a Lightning Protection Unit then reference to the LPU instruction should be made. Telephone Jack Boxes ATU900 Outstation LPU Telephone Line Figure 4: Lightning Protection Unit connections 2.7.2 Connecting to the GSM network (units with internal GSM units only) The ATU900 GSM is ready for connection to Vodafone, O2 or Orange GSM networks; however the SIM card inserted into the units must be an analogue data SIM and set accordingly. This analogue data service is also known as Circuit Switched Data or CSD. The SIM can be obtained from your network service provider. For further information regarding telephone number configuration and set-up please refer to the OPTwin manual. 2.7.3 Connecting to the GPRS network The ATU900 GSM modem is suitable for connection to Vodafone, or Orange GPRS and can be configured to operate either as a Server or as a Client. Server Mode requires the unit to be fitted with a fixed IP address SIM card. Configuration of the GPRS interface is performed using the OPTwin configuration tool and details of this are in the OPTwin manual. 2.7.4 Connecting to the LEO Satellite. The ATU900 is ready for connection to a LEO, (low earth orbit), satellite system in two flavours. • Satellite modem to satellite modem, thus eliminating any dependence on terrestrial telecommunication network infrastructure • Satellite modem to PSTN modem eliminating the need for remote PSTN installation costs where none already exist. The data transfer speed is 2400Baud. Currently the ATU900 will control the external power to the satellite modem so that remote unattended battery operation is a viable option. For further information regarding Satellite number configuration and set-up please refer to the OPTwin manual. 2.8 CPU Reset The ATU900 unit is monitored by sophisticated watchdog circuitry. In the unlikely event of the outstation “hanging up” then a pushbutton, mounted on the power supply board, is provided for manual reset. Note that logged data and unit configuration are unaffected by pressing this button. However, depending on their type, some sequences may require to be re-started (via OPTwin). 16 ATU900 User manual 2.9 Displays 2.9.1 LCD and LED display The ATU900 unit is supplied with an integral display as shown in Figure 2, comprising a two-line by sixteen-character liquid crystal display (LCD) and up to eight light emitting diodes (LEDs). These are visible via windowed areas in the lid. The following table defines the function of each LED when illuminated. When active, the LEDs are pulsed in order to save power. Label Description Actions LED Connect Test dial active & call status. Power Mains or DC power is connected. Battery Battery power on. Comm 1 Modem serial port 1 active. Comm 2 Modem serial port 2 active. Comm 3 Modem serial port 3 active. Comm 4 Modem serial port 4 active. Local* Local indication of Alarm status Option selected Connected Acknowledged Power OK Power Low No Power Battery OK Battery Low No Battery Powered but no connection Connected GSM/PSTN Call GPRS connected to network GPRS in Use – TCP Connection Powered but no connection Connected GSM/PSTN Call GPRS connected to network GPRS in Use – TCP Connection Powered but no connection Connected GSM/PSTN Call GPRS connected to network GPRS in Use – TCP Connection Powered but no connection Connected GSM/PSTN Call GPRS connected to network GPRS in Use – TCP Connection Unacknowledged Active Alarm No Alarms Full On Slow Flash Fast Flash Full On Medium Flash Off Full On Medium Flash Off Full On Flashing Medium Flash Slow Flash Fast Flash Full On Flashing Medium Flash Slow Flash Fast Flash Full On Flashing Medium Flash Slow Flash Fast Flash Full On Flashing Medium Flash Slow Flash Fast Flash Medium Red Flash Full On Red *Note the Local LED is intentionally dimmer than the other LEDs 2.9.2 Local Display Interface The local interface operates in conjunction with the integral display components detailed in the previous section. Two switches are concealed behind the LCD and MODE labels on the lid which are operated using the orange Data Collector key supplied with the unit. To activate the LCD, briefly place the flat end of the key on the LCD label and then remove in a “dabbing” motion. This should initiate a scrolling display, in which the salient details such as sensor data, status information etc. are shown in a sequential manner (if required the ATU900 can be programmed so that only important data is displayed). To freeze the scroll at a particular point, dab the MODE label. To continue scrolling, dab the MODE label again. Finally, the display can be de-activated by dabbing the LCD label. In the absence of user activity, the LCD will automatically de-activate after 30 minutes. An additional switch is concealed behind the test DIAL. In units fitted with PSTN or GSM modems, dabbing the test DIAL label will cause the unit to dial the number in the test dial phone field and transmit a low-level alarm. The unit reports the result of the test dial on the LCD. 2.10 Input / Output Capabilities The full I/O capability is described in Sections 1 and 4 of this document. The customer specifies the exact I/O mix at the order stage. 2.10.1 I/O Wiring The ATU900 unit is fitted with circular military –type connectors or glanded, flying leads to suit the I/O requirements of the unit. The pin assignments of each connector are specified in the appendices of this ATU900 User Manual 17 document. The connectors are rated to IP-65 on standard units. Unused connectors are fitted with dust caps. Note: where possible, the sensor wiring should have the signal and return wires running together as twisted pairs. In order to minimise noise-related problems, ensure that the sensor wiring is separate from any mains or three-phase supplies that may be present on site. 2.10.2 Digital Inputs Up to thirty-two digital inputs can be connected to an ATU900 unit. Volt-free contacts, open collector and open-drain inputs are supported as shown in the drawing below. PLANT D7000 DIGITAL INPUT VOLT-FREE CONTACT 0V DIGITAL INPUT OPEN-DRAIN MOSFET 0V DIGITAL INPUT OPEN-COLLECTOR TRANSISTOR 0V Figure 5: Digital Input Connections The digital inputs are protected against reversal, transients, AC mains interference and contact bounce. 2.10.3 Count (Accumulator) Inputs Count inputs provide a totalled count for digital inputs Using OPTwin, any digital input can be configured as a count input. Volt-free contacts, open collector and open-drain inputs are supported. The following states can be counted: • Opening contacts. • Closing contacts. • Opening and closing contacts. Each count input can be configured with up to two independent trip points. These trip points (Rate Alarm detectors – RADs) may be used to trigger an alarm dial-out or an ‘event’ log on breaching a set value in any direction. 2.10.4 Digital Outputs The four/eight digital outputs utilise single pole normally open photoMOS relay contacts to provide switching functions. These outputs may be configured to close for any period up to 65535 seconds. As the unit is intended primarily for low-power operation, it is recommended that these outputs be used to provide brief and infrequent signals e.g. process or initialisation. To comply with the low-voltage directive, voltages applied to the digital output relay contacts must be limited to 24Vdc (0.5A maximum) or 24Vac (0.5A maximum), thus complying with safe extra low voltage (SELV). Note: All dangerous live voltages greater than SELV (50Vac or 75Vdc) must be terminated externally to the ATU900 enclosure, and be isolated from the ATU900 circuitry e.g. via interposing relays. 18 ATU900 User manual When wiring digital outputs to plant it is preferable to run a twisted-pair from the outstation to the power supply unit and relay, where possible. This reduces the risk of RFI pick-up. 2.10.5 Incremental Shaft Encoders The ATU900 unit has the option of supporting up to two incremental shaft encoders. These encoders should be located as close as possible to the ATU900 to reduce any electrical or RFI noise interference affecting readings. The cabling between the ATU900 and the shaft encoders should be of high quality manufacture with twisted cores, have an overall screen and be low capacitance and low resistance. The adjacent diagram gives a representative view of the internals of the incremental shaft encoder. The ATU900 unit employs both hardware and software strategies to ensure the integrity of the incremental shaft encoder readings without needlessly sacrificing battery life. However, in the case of the battery powered units, care should be exercised to ensure the sampling rate is fast enough to follow the Figure 6: Incremental Shaft Encoder schematic speed of rotation without being over fast and sacrificing battery life. If rapid sampling is required and battery life is at a premium (i.e. installed in remote locations), then it may be that the better option is to implement an absolute shaft encoder system. Please contact Xylem Water Solutions UK Ltd Limited for advice. ATU900 User Manual 19 2.10.6 Absolute Shaft Encoders The ATU900 unit has the option of supporting one absolute or grey code shaft encoder. As with all digital inputs shaft encoders should be located as close as possible to the ATU900 to reduce any electrical or RFI noise interference affecting readings. The cabling between the ATU900 and the shaft encoder should be of high quality manufacture with twisted cores, have an overall screen and be low capacitance and low resistance. The adjacent diagram gives a representative view of the internals of the absolute shaft encoder. The ATU900 unit employs both hardware and software strategies to ensure the integrity of the absolute shaft encoder readings without needlessly sacrificing battery life. However, in the case of the battery powered units, care should be exercised to ensure the Figure 7: Absolute Shaft Encoder schematic sampling rate is fast enough to follow the speed of rotation, (sampling at least twice the maximum rotational speed is required), without being over fast and sacrificing battery life. Please contact Xylem Water Solutions UK Ltd for advice. 2.10.7 Analogue Inputs The ATU900 unit will support up to eight analogue inputs. The inputs are galvanically isolated from the unit and are configured using a range of plug-in Signal Conditioning Modules (SCM). Each supported sensor input type, and corresponding SCM number is listed in the following table: Sensor Type SCM Number 0 – 1 mA 0 – 10 mA 1 – 10 mA 0 – 20 mA 4 – 20 mA 1 2 3 4 5 0 – 1Vdc 0 – 2Vdc 0 – 5Vdc 1 – 5Vdc 0 – 10Vdc Potentiometric 6 7 8 9 10 11 The required SCMs are specified at the customer order stage. The plug-in design allows field retrofits to be accomplished with relative ease. The ATU900 unit is fitted with integral power supplies for sensor excitation. To save energy, the sensors are powered during the scan interval only. Two supply options are available: • 12Vdc for current and voltage sensors • 2.048Vdc for potentiometric sensors Using OPTwin, the unit may be configured with a pre-scan power-up time to power the sensor prior to measurement. This starts at 1mS and has an upper limited depending on the firmware version in the outstation. Outstations with firmware version 2.021 and greater and pic firmware versions 1.10 or 1.11 can have a pre-power time of up to 60 seconds. OPTWin Version 2.01 or greater is also required to enable this to be set. Units with firmware earlier than these releases are limited to 1999mS. 20 ATU900 User manual All analogue inputs can be configured with up to four independent trip points. These trip points (Level Alarm Detectors - LADS) may be used to trigger an alarm dial-out or an ‘event’ log on breaching a set value in any direction. Figures 9A to 9D show example wiring diagrams for the supported sensor types. PLANT D7000 ATU900 Fig 9A Example of Voltage Input Connection V VOL TAGE INP UT AI_ 1+ AI_ 1- E XTE RNAL 12Vdc SUPPLY (ALTERNATIVE) + +V_1 - GND_1 VOLTAGE SIGNA L CONDITIONING MODUL E (S CM) ISO LATED CO NVE RSION ELE CTRONICS 12Vdc ON-BO ARD SENSOR SUPPLY Fig 9B Example of 4 Wire Current Input Connection mA CURRENT TRANSMITTER INPUT AI_ 1+ AI_ 1- E XTE RNAL 12Vdc SUPPLY (ALTERNATIVE) + +V_1 - GND_1 CURRENT SIG NAL CONDITIONING MODUL E (S CM) ISO LATED CO NVE RSION ELE CTRONICS 12Vdc ON-BO ARD SENSOR SUPPLY Fig 9C Example of 2 Wire Current Input Connection mA CURRENT L OOP INPUT AI_ 1+ AI_ 1- E XTE RNAL 12Vdc SUPPLY (ALTERNATIVE) + +V_1 - GND_1 CURRENT SIG NAL CONDITIONING MODUL E (S CM) ISO LATED CO NVE RSION ELE CTRONICS 12Vdc ON-BO ARD SENSOR SUPPLY Fig 9D Example of Potentiometric Input Connection POTENTIOMETRIC INPUT >2K AI_ 1+ AI_ 1- EXTERNA L 2.048Vdc SUPPLY (ALTERNATIVE) + +VREF_1 - GND_1 POTENTIOMETRIC SIGNA L CONDITIO NING MO DULE (SCM) ISO LATED CO NVE RSION ELE CTRONICS 2.048Vdc O N-BO ARD SENSOR SUPPLY Figures 9A to 9D: Examples of Analogue Input Connections ATU900 User Manual 21 2.10.8 MODBUS The ATU900 unit will support MODBUS data both from the masterstation via a dial-up connection and to other outstations / PLCs hardwired onto either of the optional RS232 or RS485 serial communications module. A maximum of 32 outstations / PLCs may be daisy chained on the RS458 data bus each individually addressed and scanned. (Note the maximum of 32 assumes that each PLC has the same single data-type e.g. digital inputs.) This maximum of 32 is reduced by each of the different types of inputs present e.g. if digital inputs and digital outputs are to be read in or out of each of the attached PLCs then the maximum number of PLCs that can be attached is reduced to 16. Similarly if digital inputs and outputs along with analogue inputs and outputs are to be read then the maximum number of PLCs that can be attached is reduced to 8. The ATU900 unit can be configured to be master, where it will control the polling and data transfer to other MODBUS units / systems, or it can be set to be a slave where it will respond to other MODBUS masters. The ATU900 MODBUS can be configured to communicate RTU or ASCII protocol. Note however that the serial port settings differ depending on the type of MODBUS selected. Both options are given below: • MODBUS RTU – 8 data bits, 1 stop bit, no parity • MODBUS ASCII – 7 data bits, 1 stop bit, no parity A fully integrated solution is available where MODBUS inputs and outputs are treated as native direct inputs and outputs. The ATU900 unit will time-stamp these inputs on receipt from the PLC. These may subsequently be used in sequences or other ATU900 control or monitoring strategies. Note however that inputs from the MODBUS port will not be available at exactly the same time as native inputs therefore any strategy that combines local and MODBUS inputs to form alarm or control actions must take this delay into account. With the limitations of processing power and memory and providing concurrent MODBUS and SDI-12 capability the maximum inputs and outputs that can be treated as native inputs and outputs are as follows: I/O DI Digital Input DO Digital Output AI Analogue Input AO Analogue Output CI Count Input DD Derived Digital DA Derived Analogue DC Derived Count Onboard MODBUS CARD 1 MODBUS CARD 2** MODBUS CARD 3 SDI-12 Card 1 32 128 256 256 288 8 32 128 128 136 8 64 144 80 152 4 32 64 64 64 SDI-12 Card 2** 64 Total 68 32 32 50 50 75 75 25 55 **Note when mixing MODBUS and SDI-12 slaves MODBUS Card 2 and SDI-12 Card 2 cannot be used. The total cannot be exceeded. Only one MODBUS card and One SDI-12 card may be installed at any one time. An alternative method of interfacing to MODBUS data is PASSTHRU mode. This is in effect MODBUS in and MODBUS out. The ATU900 does not perform any processing on the data but becomes a telemetry MODBUS data gateway. In this mode there is no effective limit on the I/O other than what the PLC(s) already place. In this mode the limit on the number of external PLCs able to be connected to the RS485 data bus is 32. 22 ATU900 User manual 2.11 Pseudo Analogue Inputs As well as having 8 unassigned physical analogue inputs for customer use the ATU900 has a number of Pseudo Analogue Inputs that are used for diagnostic purposes. These are assigned depending on the particular ATU model i.e. Battery, DC or Mains powered. For each the following gives how they are used. For each power variation the first four are common namely: PA 1 = PSTN Powered-on Time in minutes PA 2 = PSTN Dial-out Counter PA 3 = PSTN Ring or Dial-in Counter PA 4 = PSTN Connection Failed Counter Note these only apply to the Primary channel and only on PSTN. 2.11.1 Battery Powered ATU900 PA5 = Battery Bank 1 Voltage PA6 = Battery Bank 2 Voltage (if fitted) PA7 = ATU900 Internal Temperature in 1/10th ˚C 2.11.2 DC Powered ATU900 PA5 = Battery Bank Voltage PA6 = Input Voltage PA7 = ATU900 Internal Temperature in 1/10th ˚C 2.11.3 Mains Powered or DC with NiMH Back-up ATU900 PA5 = Rechargeable Cells Bank 1 Status PA6 = Rechargeable Cells Bank 2 Status (if fitted) PA7 = Rechargeable Cells Bank 1 Capacity mAHr PA8 = Rechargeable Cells Bank 2 Capacity mAHr (if fitted) PA9 = Rechargeable Cells Bank 1 Voltage Level PA10 = Rechargeable Cells Bank 2 Voltage Level (if fitted) PA11 = DC Input Voltage (after PSU). PA12 = ATU900 Internal Temperature in 1/10th ˚C ATU900 User Manual 23 Communications 3 Communications There are five communication ports available on the ATU900 with Com 0 reserved for local configuration / interrogation. The remaining four are flexible and can be configured with communication modules to suit the particular users’ needs. Note however only 1 Master and one Secondary remote communications module is allowed. The remaining two ports are available for communicating with MODBUS in either RS232 or RS485 format and for SDI-12. Note also that only one MODBUS and one SDI-12 may be used and that the SDI-12 module must be located in Comm 1 or Comm 2 position. 3.1 Masterstation (units with remote communication modules only) The ATU900 outstation communications with Masterstations can be either outgoing (alarm) or incoming (interrogation). The following sections describe the general sequence of events in both alarm and interrogation modes. 3.1.1 Alarm dial-outs Up to five different telephone numbers may be programmed into the ATU900 unit, each up to eighteen digits long (including pauses). The status of each telephone number may be designated as Master or Back-up. Each Sensor configured on the ATU900 for alarm dial-outs may be linked to any back-up number via the special phone index (see OPTwin guide). When an alarm condition arises on that sensor, then the corresponding backup is promoted to Master status for that alarm condition only. On waking from the low-power “sleep” mode, if a valid alarm is detected, the unit will dial ALL enabled Master telephone numbers in order (from 1 to 5). If a number fails to respond it will go on to the rest of the numbers before retrying the failed one. Backup telephone numbers will be dialled if ANY Master telephone number has failed to respond correctly. They will be dialled, in order, until a successful attempt to ONE of them has been made. Each telephone number will be tried in turn up to four times, with a delay of one minute between different numbers and three and a half minutes before dialling the same failed number again. 3.1.2 Interrogations Approximately six seconds after detecting an incoming-ringing signal the ATU900 unit will answer the call and commence communications with the interrogating equipment. Once communications have finished, the ATU900 and the interrogating equipment will release the communications path line. The unit will then return to “sleep” mode. 3.2 Outstation Programming Terminal for Windows (OPTwin) OPTwin is a proprietary application program available from Xylem Water Solutions UK Ltd. It may be used to both configure and interrogate an ATU900 unit. The host PC must be IBM-compatible, running Microsoft Windows 95 or better. The host PC may be connected locally to the ATU900 unit on COM 0 using RS232. Alternatively, the PC may remotely access the outstation via the PSTN or GSM links. The details are given in the following sections. 3.2.1 Local OPTwin (RS232) Local communications requires a custom cable to connect from an RS232 serial port of a host PC to the local RS232 programming port connector on the ATU900 enclosure. The connection will automatically activate the LCD and LEDs. Details of this cable are provided in the appendices The communication settings in the host PC must be configured in OPTwin to match the settings on the ATU900 unit. The usual data format is 8-bit, no parity, 1-stop bit. The transmission speed is set at 115200 baud. 24 ATU900 User manual 3.2.2 Remote OPTwin (units with remote communication modules only) Remote communications require no additional wiring or setting up at the ATU900 but make use of a compatible PSTN modem or GSM / GPRS or Satellite module connected to the host PC. On detection of an incoming call, e.g. the ringing signal on PSTN, the ATU900 will “wake-up”. Approximately six seconds later it will answer the call and commence communications with the host PC. Once communications are finished, the ATU900 and the host PC will release the communication line and the outstation will then return to “sleep” mode. Full details for using OPTwin and ATU900 programming are covered in the OPTwin Operators Guide. 3.2.3 Local interrogation (RS232) The ATU900 unit can also be interrogated by data gathering equipment via the local RS232 port in the manner described in the previous sections. 3.3 GSM Interface Card The GSM option is a quad band module. On-board these cards are 5 diagnostic LEDs controlled either from the main microprocessor or permanently in circuit when Link LK1 is inserted. A sixth LED shows the status of the GSM module and its connection to the network. Looking at the card from the component side with the 5 LEDs on the right they are: Signal LED Colour Description POWER TX Red Green RX Red DCD Data Carrier Detect RI Ring Indicator Yellow On when the GSM card is powered Flashes in synchronism with data being transmitted from the ATU900 to any external device. Flashes in synchronism with data being received from an external device into the ATU900. On indicates a connection has been established with the remote device. Flashes on and off indicating the ATU900 is receiving a call. Orange The separate 6th Red LED, below the main group, flashes 1 per second indicating it is searching for the GSM network and flashes slow about 1 per 2 seconds indicating it is established on the GSM network. Customer connection to the GSM module is via a MMCX socket i.e. the connection to the antenna is a plug with the centre pin. For country settings and initialisation strings please see the separate Telit manual. ATU900 User Manual 25 3.4 PSTN Interface Card The PSTN option is a full V92 modem. On-board these cards are 5 diagnostic LEDs controlled either from the main microprocessor or permanently in circuit when Link LK1 is inserted. Looking at the card from the component side with the 5 LEDs on the right they are: Signal LED Colour Description POWER TX Transmit Data RX Received Data RTS Request To Send DCD Data Carrier Detect RI Ring Indicator Red Green On when the PSTN card is powered Flashes in synchronism with data being transmitted from the ATU900 to any external device. Flashes in synchronism with data being received from an external device into the ATU900. On indicates the ATU is ready to send data. Red Yellow Yellow Orange On indicates a connection has been established with the remote device. Flashes on and off indicating the ATU900 is receiving a call. LK2 allows the card to be configured for passive or active ring detect which allows the ATU900 to sleep and wake-up when it is being contacted from a remote system. Customer connection to the PSTN module is via a standard RJ11 socket. For country settings and initialisation strings please see Telit manual. 3.5 Auxiliary communications (RS232, RS485, SDI-12, Ethernet) All of the general purpose communication ports can be populated with a mix of RS232, RS485 or SDI12 cards with the latter only being available on Comm 1 or Comm 2. However, to enable all four ports the Comms Expander card, which also carries the Ethernet interface, must be installed. These options may be specified at order time. These interface cards will also allow the ATU900 unit to be used as a MODBUS and/or SDI-12 interface. Note power to these interface cards is controlled by the main microprocessor which may be configured to be off most of the time conserving power. 3.5.1 RS232 Interface Card The RS232 option is a full V24-compliant serial port, designed to interface with approved third-party communication equipment with a similar interface e.g. radio modems, GSM transceivers, satellite terminals, etc. A full list of compliant equipment is available from Xylem Water Solutions UK Ltd. 26 ATU900 User manual On-board these cards are 9 diagnostic LEDs controlled either from the main microprocessor or permanently in circuit when Link LK1 is inserted. .Looking at the card from the component side with the LEDs on the right they are: Signal POWER TX LED Colour Red Green RX Red RTS Request To Send CTS Clear To Send DTR Data Terminal Ready DSR Data Set Ready DCD Data Carrier Detect RI Ring Indicator 0V Enable Power Enable Relay RS232 Power Relay Switched power Yellow Yellow Yellow Yellow Yellow Orange Description On when the RS232 card is powered Flashes in synchronism with data being transmitted from the ATU900 to any external device. Flashes in synchronism with data being received from an external device into the ATU900. On indicates the remote device is ready to send data to the ATU900. On indicates the ATU900 is ready to accept data. On indicates the remote device is ready to accept a connection. On indicates the ATU900 is ready for communicating. On indicates a connection has been established with the remote device. Flashes on and off indicating the ATU900 is receiving a call. Connect to 0V to select Connect to 0V to select +12V +12V 20 Way connector 1 11 2 12 3 13 4 14 5, 15, 8, 18 6 16 9, 19 10,20 On-board this card is the ability to either power the RS232 external device or to switch a +12V via a relay under the control of the ATU900 (not both). These signals are available on the 20 way connector as shown previously. 3.5.2 RS485 Interface Card The RS485 option can be configured as either a 2 wire or 4 wire RS485 multi-drop interface and has two links (LK1 and LK2) for connecting the terminating resistors on the final ATU900 in a multi-drop RS485 network. Link LK4 is used to provide external power at either 12V or 15 Volts. The maximum current that can be drawn is 80mA. ATU900 User Manual 27 On-board these cards are 8 diagnostic LEDs controlled either from the main microprocessor or permanently in circuit when Link LK1 is inserted. .Looking at the card from the component side with the LEDs on the right they are: Signal POWER Tx LED Colour Red Red Rx Red CD1 CD2 2 Wire 4 Wire RQW Request Wake Wake request Yellow Yellow Red Red Green Loop Common 0V A2 B2 +12V 0V Description 6 Way connector On when the RS485 card is powered Flashes in synchronism with data being transmitted from the ATU900 to any external device. Flashes in synchronism with data being received from an external device into the ATU900. Low input from remote RS485 device to wake-up the ATU900 Low output from ATU900 to remote RS485 device to wake-up. Only used for 4 wire RS485 Only used for 4 wire RS485 1 2 4 5 3 6 1 2 3 4 3.5.3 SDI-12 Interface Card The Serial Data Interface at 1200 baud (SDI-12) option is an asynchronous, ASCII Serial communications card that provides the means for interfacing to intelligent sensory instruments. Note: This card can only be installed in communication ports Comm 1 or Comm 2. Included on the card is the means of supplying +12V (LK 3 between 1&2) or +15V (LK 3 between 2&3) On-board these cards are 3 diagnostic LEDs controlled either from the main microprocessor or permanently in circuit when Link LK1 is inserted. Looking at the card from the component side with the LEDs on the right they are: Signal POWER TX Data RX Common +Power 12V or 15V LED Colour Red Red Red Description On when the SDI-12 card is powered Flashes in synchronism with data being transmitted from the ATU900 to any external device. Flashes in synchronism with data being received from an external device into the ATU900. Power dependent on position of LK3 4 Way connector 1 2, 3 4 3.5.4 Comms Expander / Ethernet Card This communication port expander and dual Ethernet card comes in 4 flavours which are defined at order time. 28 ATU900 User manual • • • • For battery powered ATU900s, only one Ethernet port is available a) because of the physical size constraints and b) because of the electrical power required when driving dual Ethernet channels would deplete the D-cell batteries in a very short time. For DC powered ATU900s with D-cell back-up the comms expander circuitry and single Ethernet channel is available. Physical space limitations prevent the second Ethernet channel being present. The D-cell battery back-up may be replaced with smaller NiMH battery packs. In this instance dual Ethernet channels are available at the expense of battery back-up time. For AC powered ATU900s full comms and dual Ethernet is available. Dual Port Comms Expander Card The diagnostic LEDs are the 2 normal LEDs on each Ethernet socket. The card is defined for dual serial communication and/or dual Ethernet at order time. ATU900 User Manual 29 Short-form Specifications 4 Short-form Specifications 4.1 Common Specification across all Inputs Alarm delay period Alarm Inhibit Period Special Phone Index 4.2 0 to 65535 seconds 0 to 65535 seconds Promotes any back-up number in the telephone list to a Master number. Digital Inputs Number of real digital inputs. Number of pseudo digital inputs. Number of derived digital inputs. Engineer-on-site timer. Scanning period. Signal detection. Electrical characteristics: Scan interval Holding current Wetting current Activation 4.3 Thirty two. Two Fifty. 0 to 65535 minutes (default = 60 minutes). One second for all digital inputs. Any duration down to one second. Non-isolated. Internally pulled-up to +3Vdc. 15mSecs to 1 Sec 3μA minimum. 32mA peak (4.7μs time constant). Connect to 0V via external volt-free contacts, open-drain or opencollector inputs. Analogue Inputs Number of real analogue inputs. Number of derived analogue inputs. Number of pseudo analogue inputs. Battery: DC: Mains: Number of LADs per analogue Scanning period. Time logging period. Input ranges and input impedance, Current: Input ranges and input impedance, Voltage: Four or Eight. Twenty-five or seventy-five (configurable) Seven (Modem 1-4, Battery 5-6, Temperature 7). Seven (Modem 1-4, DC 5, Battery 6, Temperature 7). Twelve (Modem 1-4, Batt state 5-6, Batt Capacity 7-8, Batt 9-10, Mains 11, Temperature 12). 4 1 to 65535 seconds (default = 900 seconds) 0 (disabled) to 65535 minutes between readings 0 – 1 mA, 1 kΩ minimum. 0 – 10 mA, 100 Ω minimum 1 – 10 mA, 100 Ω minimum 0 – 20 mA, 50 Ω minimum 4 – 20 mA, 50 Ω minimum 0 – 1Vdc, 500 kΩ minimum 0 – 2Vdc, 490 kΩ minimum 0 – 5Vdc, 470 kΩ minimum 1 – 5Vdc, 470 kΩ minimum 0 – 10Vdc, 470 kΩ minimum Input ranges, Potentiometric: The parallel resistance of potentiometric inputs on the unit must not fall below 2 kΩ. Potentiometric input, Reference voltage. Isolation between input channels. Isolation between input channel and ATU900. Measurement resolution. Accuracy over operating temperature range. Transducer power supply. Pre-scan power-up time. 2.048Vdc ± 5% 30 30Vdc 500Vdc 16-bits / 15bit + sign (14-bits minimum) ±TBA% full scale 11.5 to 15V 0 to 4000ms, settable in 15ms increments ATU900 User manual 4.4 Count inputs Count detection (contact only). Number of count inputs. Configurable as Digital Inputs) Closing, opening or both. Thirty two Number of RADs per count. Scale factor (per pulse). Preset value. Roll-over value. Scanning period Time logging period Stored data format Signal detection Maximum frequency. Electrical characteristics (non-isolated) Holding current Wetting current Activation Two. 0.01 to 99.99 0 to 99999999 (8 decades maximum). 0 to 99999999 (8 decades maximum). 15ms to 1 s 0 (disabled) to 65535 minutes between readings 5 or 8 decades (for all count inputs) Any duration down to 20ms. 25Hz Internally pulled-up to +3Vdc. See digital inputs for details See digital inputs for details Connect to 0V via external volt-free contacts, open-drain or open-collector inputs 4.5 Digital outputs Output type: Number of digital outputs. Inch delay period. Isolation between digital outputs. Isolation between digital outputs and ATU900. Rating (per output) PhotoMOS relay Four or Eight. 0 to 65535 seconds in 1ms increments. >5kVac. 5kVac. 24V ac or dc, 500mA maximum. 4.7 Sequences Sequences are user-written programs that provide flexible, local processing, calculation and control facilities within the ATU900 outstation, giving them a high level of local intelligence. Up to sixteen individual sequences may be concurrently active within the ATU900 with varying degrees of interaction possible, together with automatic re-start on power-up (if this is required). Each sequence program may accept up to ten parameters, which are then allocated to specific I/O or values at download time. In addition to the full range of real I/O, the sequences may also write data to and read data from:• • • • Up to seventy-five Derived Analogues. Up to fifty Derived Digitals. Up to twenty-five Derived Counts. Up to fifty inter-sequence variables (used to pass information from one sequence to another). The complete list of reserved words, symbols and commands is in the OPTwin manual. 4.8 Site and Telephone Data Site identity range. Security code range. 0001 to 9999. 0001 to 9999. The following applies to units with internal modems fitted: Telephone number list. Up to five telephone numbers + one test dial number. Digits per telephone number (including pauses) Communications type. Up to eighteen digits. ATU900 User Manual PSTN, GSM, GPRS, Satellite 31 4.9 Communications (units with internal modems fitted) Telephone numbers, communication rotas, protocols, baud rates etc are all configurable with OPTwin and are described in the OPTwin manual 4.10 Communications (local) OPTwin communication protocol. D1236 FSK plus D4100 superset+ D7xxx superset. Logging communication protocols. D1236 FSK plus D4100 superset+ D7xxx superset. Transmission (RS232). 300 baud to 115200 baud. 8 data bits, no parity, 1 stop bit. 4.11 Communications (auxiliary) Communications Protocol. DL FSK, MODBUS (optional) RTU or ASCII, DNP, WITSDNP, AquaCom Transmission. RS232/v24, RS485 300 baud to 115200 baud 8 data bits, 1 stop bit., no parity MODBUS RTU 8 data bits, 1 stop bit., no parity MODBUS ASCII 7 data bits, 1 stop bit., no parity 4.12 Mechanical Enclosure dimensions. Height: 224 mm excluding connectors Width: 276 mm Depth: 130 mm 3 kg. (ATU900) 1.5mm2 maximum. Polycarbonate Base unit: Light-grey – RAL 7032 Lid: Clear polycarbonate with adhesive diagnostic label. Average weight Maximum sensor wiring size. Enclosure material. Enclosure finish. 4.13 Electrical Operating voltage. Battery: DC: Mains: 11Vdc to 16Vdc (using ten or twenty alkaline D cells) fused 11Vdc to 36Vdc (dc-powered option) fused 100 - 240Vac @ 50-60Hz 0.4A (ac-powered option) fused Sensor wiring. Use screened twisted-pairs for all I/O. Connect screen to 0V. Digital output loads. Directly connected – do not exceed 24V ac or dc @ 500mA. Indirectly connected – larger loads may be switched if external interposing relays are used 4.14 Environmental Operating temperature range. Storage temperature range. Temperature sensor accuracy Relative humidity at 45°C. Enclosure ingress rating. Connector ingress rating. 4.15 Real-time clock (RTC) +10°C to +40°C. 0°C to +50°C. -10°C to +60°C. Date. 32 -10°C to +50°C. -10°C to +60°C. ±1°C Up to 95% (non-condensing). IP67. IP65 (IP67 available as an option). better than 25 seconds per month – TBA better than 50 seconds per month – TBA better than 90 seconds per month - TBA Valid until year 2135. ATU900 User manual Appendices 5 Appendix A – Standard Cabling Information Comm 2 Comm 4 Digital I/P Inc. Shaft Enc Analogue I/P Digital O/P OPT Power Ethernet 2 Digital Connector Analogue Connector Ethernet 1 Comm 1 Comm 3 Fig 10: Position of plant input cables shown above (Military Connectors). With the exception of Power, Communication channels and Ethernet connections all inputs and outputs are connected to the ATU900 via military style connectors. These can be obtained directly from Xylem Water Solutions UK Ltd. The pin-out arrangements of these sockets are shown in the next pages. Comm 2 Comm 4 Analogue I/P Digital I/P Inc. Shaft Enc Digital O/P OPT Power Ethernet 2 Ethernet 1 Comm 1 Digital Cable Analogue Cable Comm 3 Fig 11: Position of plant input cables shown above (Glanded Cables). ATU900 User Manual 33 5.1 Mains Power Cable Wiring Schedule ATU900 CORE PLANT SIGNAL BROWN 1 LIVE BLUE 2 NEUTRAL FUNCTION EARTH GREEN/YELLOW 5.2 WIRE NUMBER DC Power Cable Wiring Schedule ATU900 CONNECTION PLANT SIGNAL RED 1 DC+ BLUE 2 DC- FUNCTION EARTH GREEN/YELLOW 5.3 WIRE NUMBER Local (OPTwin) Serial Port Connector Wiring Schedule A B D C Figure 12: Connector Insert Arrangement and Contact Identification The table below indicates the pin connections required to make an RS232 interface cable between the ATU900 and a host PC. Suitable cables are available from Xylem Water Solutions UK Ltd. ATU900 CONNECTION HOST PC SIGNAL 9-way D socket 25-way D socket OV A Red GND 5 7 /OPT B Blue LINK 5 7 RXD (in) C Green RXD 3 3 TXD (out) D Yellow TXD 2 2 34 ATU900 User manual 5.4 32 Digital Input Cable (Digital Connector) A U T B V W S k X m w j Y p x i E y Z q aa P D n v R C u h z t g a b s c f e N F r G d H J M K L Figure 13: Plug Arrangement and Contact Identification (Viewed from front on to PINS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour DI_1 A Digital Input 1 Black DI_2 B Digital Input 2 White DI_3 C Digital Input 3 Red DI_4 D Digital Input 4 Green 0V E Dig I/P 1-4 0V common Orange DI_5 U Digital Input 5 Blue DI_6 V Digital Input 6 White/Black DI_7 W Digital Input 7 Red/Black DI_8 X Digital Input 8 Green/Black 0V Y Dig I/P 5-8 0V common Orange/Black DI_9 T Digital Input 9 Blue/Black DI_10 k Digital Input 10 Black/White DI_11 m Digital Input 11 Red/White DI_12 n Digital Input 12 Green/White 0V p Dig I/P 9-12 0V common Blue/White DI_13 S Digital Input 13 Black/Red DI_14 j Digital Input 14 White/Red DI_15 w Digital Input 15 Orange/Red DI_16 x Digital Input 16 Blue/Red 0V y Dig I/P 13-16 0V common Red/Green DI_17 i Digital Input 17 Orange/Green DI_18 v Digital Input 18 Black/White/Red DI_19 aa Digital Input 19 White/Black/Red DI_20 z Digital Input 20 Red/Black/White 0V t Dig I/P 17-20 0V common Green/Black/White Wire Number Function Note 1) Screen is to be left on at free-end of cable and connected to customers 0V. 2) Colour identifier is ‘Base colour/Stripe 1/Stripe 2’ 3) Table shows the basic (minimum) configuration. ATU900 User Manual 35 32 Digital Input Cable (Continued) A U T V B W S k X w j Y p x i E y Z q aa P D n v R C m u h z t g a b s c f e N F r d G H J M K L Figure 13: Plug Arrangement and Contact Identification (Viewed from front on to PINS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour DI_21 R Digital Input 21 Orange/Black/White DI_22 P Digital Input 22 Blue/Black/White DI_23 h Digital Input2 3 Black/Red/Green DI_24 g Digital Input 24 White/Red/Green 0V u Dig I/P 21-24 0V common Red/Black/Green DI_25 K Digital Input 25 Green/Black/Orange DI_26 J Digital Input 26 Orange/Black/Green DI_27 L Digital Input 27 Blue/White/Orange DI_28 c Digital Input 28 Black/White/Orange 0V d Dig I/P 25-28 0V common White/Red/Orange DI_29 F Digital Input 29 Orange/White/Blue DI_30 H Digital Input 30 White/Red/Blue DI_31 G Digital Input 31 Black/White/Green DI_32 b Digital Input 32 White/Black/Green 0V a Dig I/P 29-32 0V common Red/White/Green Wire Number Function Note 1) Screen is to be left on at free-end of cable and connected to customers 0V. 2) Colour identifier is ‘Base colour/Stripe 1/Stripe 2’ 3) Table shows the basic (minimum) configuration. 36 ATU900 User manual 5.5 Plus 2 Incremental Shaft Encoders (Digital Connector) U T S T S k j j v R i R A U k w v A V m w x u h P g h t g f N u f e x M ts d e K L C W n n y y aa z N M B W m i aa P B V r z sc d C X p D X p q q r b Y E Z E Z F a F a b G c H J D Y G H J K L Figure 13: Plug Arrangement and Contact Identification (Viewed from front on to PINS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour SE1 Supply N ISE 1 +5V Green/White/Blue SE1 PH1 M ISE 1 Phase A Orange/Red/Green SE1 PH2 f ISE 1 Phase B Blue/Red/Green SE1 0V e ISE 1 0V Black/White/Blue SE2 Supply s ISE 2 +5V White/Black/Blue SE2 PH1 r ISE 2 Phase A Red/White/Blue SE2 PH2 q ISE 2 Phase B Green/Orange/Red SE2 0V Z ISE 2 +5V Orange/Red/Blue Wire Number Function Note 1) Screen is to be left on at free-end of cable and connected to customers 0V. 2) Colour identifier is ‘Base colour/Stripe 1/Stripe 2’ 3) Table shows the basic (minimum) configuration. ATU900 User Manual 37 5.6 4 Analogue Input + 4 Digital Output Cable (Analogue Connector) A U T V B W S k X w j Y p x i E y Z q aa P D n v R C m u h z t g a b s c f e N F r G d H J M K L Figure 14: Plug Arrangement and Contact Identification (Viewed from front on to SOCKETS) ATU900 Signal Military Pin Description PLANT Glanded Cable Colour Ch_1 0V A Analogue 1 Supply 0V Black Ch_1 –ve B Analogue 1 Signal –ve White Ch_1 +ve C Analogue 1 Signal +ve Red Ch_1+Vref* D Analogue 1 Supply +ve Green Ch_2 0V U Analogue 2 Supply 0V Orange Ch_2 –ve V Analogue 2 Signal –ve Blue Ch_2 +ve W Analogue 2 Signal +ve White/Black Ch_2+Vref* X Analogue 2 Supply +ve Red/Black Ch_3 0V T Analogue 3 Supply 0V Green/Black Ch_3 –ve k Analogue 3 Signal –ve Orange/Black Ch_3 +ve m Analogue 3 Signal +ve Blue/Black Ch_3+Vref* n Analogue 3 Supply +ve Black/White Ch_4 0V p Analogue 4 Supply 0V Red/White Ch_4 –ve Y Analogue 4 Signal –ve Green/White Ch_4 +ve Z Analogue 4 Signal +ve Blue/White Ch_4+Vref* E Analogue 4 Supply +ve Black/Red Wire Number Function Note 1 ) Screen is to be left on at free-end of cable and connected to customers 0V. 2 ) Colour identifier is ‘ Base colour/Stripe1/Stripe2 ‘ 3) Table shows the basic (minimum) configuration. * +12V dc for current & voltage personality cards and +2.048V dc for potentiometric personality card. 38 ATU900 User manual 4 Analogue Input + 4 Digital Output Cable (Cont’d) A U T V B W S k X m w j Y p x i E y Z q aa P D n v R C u h z t g a b s c f e N F r d G H J M K L Figure 14: Plug Arrangement and Contact Identification (Viewed from front on to SOCKETS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour DO_1 R Digital Output 1 Blue/White/Orange DO_1 h Digital Output 1 Black/White/Orange DO_2 P Digital Output 2 White/Red/Orange DO_2 g Digital Output 2 Orange/White/Blue DO_3 u Digital Output 3 White/Red/Blue DO_3 t Digital Output 3 Black/White/Green DO_4 s Digital Output 4 White/Black/Green DO_4 f Digital Output 4 Red/White/Green Wire Number Function Note 1 ) Screen is to be left on at free-end of cable and connected to customers 0V. 2 ) Colour identifier is ‘ Base colour/Stripe1/Stripe2 ‘ 3) Table shows the basic (minimum) configuration. * +12V dc for current & voltage personality cards and +2.048V dc for potentiometric personality card. ATU900 User Manual 39 5.7 Plus 4 Analogue Inputs Cable (i.e. 8AI+4DO) (Analogue Connector) A U T V B W S k X w j Y p x i E y Z q aa P D n v R C m u h z t g F r a b s c f e N d G H J M K L Figure 14: Plug Arrangement and Contact Identification (Viewed from front on to SOCKETS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour Ch_5 0V S Analogue 5 Supply 0V White/Red Ch_5 –ve j Analogue 5 Signal –ve Orange/Red Ch_5 +ve w Analogue 5 Signal +ve Blue/Red Ch_5+Vref* x Analogue 5 Supply +ve Red/Green Ch_6 0V y Analogue 6 Supply 0V Orange/Green Ch_6 –ve q Analogue 6 Signal –ve Black/White/Red Ch_6 +ve a Analogue 6 Signal +ve White/Black/Red Ch_6+Vref* F Analogue 6 Supply +ve Red/Black/White Ch_7 0V i Analogue 7 Supply 0V Green/Black/White Ch_7 –ve v Analogue 7 Signal –ve Orange/Black/White Ch_7 +ve aa Analogue 7 Signal +ve Blue/Black/White Ch_7+Vref* z Analogue 7 Supply +ve Black/Red/Green Ch_8 0V r Analogue 8 Supply 0V White/Red/Green Ch_8 –ve c Analogue 8 Signal –ve Red/Black/Green Ch_8 +ve b Analogue 8 Signal +ve Green/Black/Orange Ch_8+Vref* G Analogue 8 Supply +ve Orange/Black/Green Wire Number Function Note 1 ) Screen is to be left on at free-end of cable and connected to customers 0V. 2 ) Colour identifier is ‘ Base colour/Stripe1/Stripe2 ‘ 3) Table shows the basic (minimum) configuration. * +12V dc for current & voltage personality cards and +2.048V dc for potentiometric personality card. 40 ATU900 User manual 5.8 Plus 4 Digital Outputs Cable (i.e. 4AI+8DO) (Analogue Connector) A U T V B W S k X w j Y p x i E y Z q aa P D n v R C m u h z t g F r a b s c f e N d G H J M K L Figure 14: Plug Arrangement and Contact Identification (Viewed from front on to SOCKETS) ATU900 PLANT Signal Military Pin Description Glanded Cable Colour DO_5 N Digital Output 5 Green/Black/White DO_5 M Digital Output 5 Orange/Black/White DO_6 L Digital Output 6 Blue/Black/White DO_6 e Digital Output 6 Black/Red/Green DO_7 d Digital Output 7 White/Red/Green DO_7 K Digital Output 7 Red/Black/Green DO_8 J Digital Output 8 Green/Black/Orange DO_8 H Digital Output 8 Orange/Black/Green Wire Number Function Note 1 ) Screen is to be left on at free-end of cable and connected to customers 0V. 2 ) Colour identifier is ‘ Base colour/Stripe1/Stripe2 ‘ 3) Table shows the basic (minimum) configuration. * +12V dc for current & voltage personality cards and +2.048V dc for potentiometric personality card. ATU900 User Manual 41 5.9 RS232 Wiring Schedule The RS232 link is rated at 115200 baud maximum over a 30M link. ATU900 5.10 Connection Cable Colour Alternative Cable Colour Signal TX White White TXD (output) RX Turquise Tan (Light Brown) RXD (input) RTS Brown Brown Ready to Send CTS Orange Orange Clear to Send DTR Purple Violet Data Terminal Ready DSR Blue Blue Data Set Ready DCD Green Green Data Carrier Detect RING Pink Pink Ring 0V Black Black Signal Ground 0V Red Red Signal Ground Simple 5-Wire RS485 Wiring Schedule ATU900 Connection 42 Glanded Cable Colour Data A Blue Data B Green Loop Common Yellow +12V DC Sensor Red 0V Black Signal ATU900 User manual 5.11 Simple 4-Wire SDI-12 Wiring Schedule ATU900 ATU900 User Manual Connection Glanded Cable Colour Data Signal Blue Data Common Green +12V DC Red Gnd Black Signal 43 ATU900 User manual 44 ATU900 User Manual 45 Xylem |’zīləm| 1) The tissue in plants that brings water upward from the roots 2) A leading global water technology company We're 12,000 people unified in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efficiently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation. For more information on how Xylem can help you, go to xyleminc.com Xylem Water Solutions UK Head Office Colwick Nottingham NG4 2AN Tel 0115 940 0111 Fax 0115 940 0444 Email [email protected] www.xylemwatersolutions.com/uk