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7.

Cold boot the controller. (Refer to section

Cold Boot Mode

in of this manual for the

Cold Boot procedure.)

WARNING

: If a cold boot is not done the behavior of the controller is unpredictable.

8.

The controller may now be programmed.

SCADAPack 350 Hardware Manual
February 14, 2007

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Summary of Contents for SCADAPack 350

Page 1: ...troller Board Hardware Manual CONTROL MICROSYSTEMS SCADA products for the distance 48 Steacie Drive Telephone 613 591 1943 Kanata Ontario Facsimile 613 591 1022 K2K 2A9 Technical Support 888 226 6876 Canada 888 2CONTROL ...

Page 2: ... SCADASense 4202 DS SCADASense 4202 DR SCADASense 4301 DS SCADASense 4301 DR SCADASense 4102 SCADASense 4012 SCADASense 4032 and TeleBUS are registered trademarks of Control Microsystems All other product names are copyright and registered trademarks or trade names of their respective owners Material used in the User and Reference manual section titled SCADAServer OLE Automation Reference is distr...

Page 3: ...es 12 4 4 1 COM3 Serial Port Power Control 13 4 4 2 VLOOP Power Control 14 4 4 3 12V to 24V DC DC Converter Control 14 5 ANALOG INPUTS 16 5 1 Internal Analog Inputs 16 5 2 I O Analog Inputs 16 5 2 1 Analog Input Wiring 17 5 2 2 Analog Input Wiring Examples 17 5 3 Analog Input Mode Jumpers 18 5 4 Analog Inputs Data Format 18 6 ANALOG OUTPUTS 19 6 1 Current Outputs 19 6 2 Voltage Outputs 19 6 3 Anal...

Page 4: ...COM2 RS 232 Serial Port 29 10 1 2 COM3 RS 232 Serial Port 32 10 1 3 RS 232 Wiring Examples 35 10 1 4 RS 232 Cables 36 10 2 RS 485 Serial Communication Ports 37 10 2 1 COM1 RS 485 Serial Port 37 10 2 2 COM2 RS 485 Serial Port 38 10 2 3 RS 485 Bias Resistors 40 10 2 4 RS 485 Termination Resistors 40 10 2 5 RS 485 Wiring Examples 41 11 ETHERNET COMMUNICATION 42 11 1 LAN Port Settings 42 11 1 1 TCP IP...

Page 5: ... 51 13 5 Status LED 51 13 5 1 I O Module Error Indication 52 13 5 2 Register Assignment Checksum Error 52 14 MAINTENANCE 53 14 1 Fuses 53 14 2 Lithium Battery 53 14 2 1 Battery Replacement Procedure 53 15 TROUBLESHOOTING 55 15 1 Analog Inputs 55 15 2 Analog Outputs 55 15 3 Digital Inputs 55 15 4 Digital Outputs 56 15 5 Counter Inputs 56 16 SPECIFICATIONS 57 16 1 General 57 16 2 Controller 57 16 3 ...

Page 6: ... Digital Input Output Wiring 24 Figure 7 Counter Input Wiring 25 Figure 8 Counter Jumpers 28 Figure 9 RJ 45 Connector Pinout 30 Figure 10 RJ 45 Connector Pinout 33 Figure 11 RS 232 DTE to RS 232 DTE without Handshaking 35 Figure 12 RS 232 DTE to RS 232 DTE with Handshaking 35 Figure 13 RS 232 DTE to RS 232 DCE With Handshaking 36 Figure 14 COM2 RJ 45 Connector 40 Figure 15 RS 485 Wiring 41 Figure ...

Page 7: ...000 Series I O modules A maximum of forty 5000 Series I O modules may be used for a total expansion capacity of 512 digital inputs 512 digital outputs 128 analog inputs 64 analog outputs and 64 counter inputs This controller board can be combined with a 5606 Integrated I O module forming a SCADAPack 357 For information on the 5606 I O module refer to the 5606 User Manual Three serial communication...

Page 8: ...Figure 1 SCADAPack 350 Controller SCADAPack 350 Hardware Manual February 14 2007 7 ...

Page 9: ...G EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1 DIVISION 2 WARNING EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS TURN OFF POWER BEFORE REPLACING OR WIRING MODULES WARNING EXPLOSION HAZARD DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS WARNING USB PORTS MAY BE PERMANENTLY USED IN NON HAZARDOUS APPLICATIONS USB P...

Page 10: ...wiring for the connector to be removed CAUTION Remove power before servicing unit To remove the termination connector Pull the connector upward from the board Apply even pressure to both ends of the connector To install the termination connector Line up the pins on the module with the holes in the connector Make sure all the pins line up properly Push the connector onto the pins Apply even pressur...

Page 11: ...Figure 2 SCADAPack 350 Board Layout SCADAPack 350 Hardware Manual February 14 2007 10 ...

Page 12: ...mA and depends on the controller features enabled For 12VDC input voltages an onboard DC DC converter with an output capacity of 3 36W 24V at 140mA can be used to power five 20mA analog inputs and two 20mA output devices loop powered transmitters The 12 24V DC DC converter is controlled by the user application program and may turned on or off Refer to section 4 4 3 12V to 24V DC DC Converter Contr...

Page 13: ... in the table below 5V Current 24V Current 5209 Controller Board base current in reduced power mode 40mA 20mA x 5 100mA Vloop 5305 Analog output 0mA 20mA X 2 40mA Vloop Total 40mA 140mA operation Available for I O expansion LAN USB and COM Visions 1160mA remaining 1 2A capacity 0mA In this case 1160mA is available to power the LAN and USB ports COM Vision displays as well as other expansion module...

Page 14: ...n using and controlling the internal Digital Outputs 12V to 24V boost ON OFF Dout 9 P10 Vloop P2 I O Expansion 3 3 5V supply P3 Power In Dout 8 Sleep open P6 COM1 RS 485 P8 COM2 RS 232 485 P9 COM3 RS 232 Dout 10 J13 5305 Analog Output Module P4 5 USB P7 LAN Figure 3 Power Management 4 4 1 COM3 Serial Port Power Control The COM3 serial port is intended for use with the SCADAPack Vision or other Hum...

Page 15: ... VLOOP output Internal Digital Input 8 indicates the status of VLOOP power Digital Input 8 is set when VLOOP power is on and is cleared when VLOOP power is off Note When VLOOP is first turned on the user application program must wait some period of time for input readings to stabilize This time period is dependent on the field sensors and transmitters connected Documentation for these devices shou...

Page 16: ...og Output module use is the applied input power Internal Digital Input 9 indicates the status of the 12V to 24V DC DC converter Digital Input 9 is set when the 12V to 24V DC DC converter is on and is cleared when the 12V to 24V DC DC converter is off The 12V to 24V DC DC converter is turned on when the LED power is enabled This feature is provided for service and diagnostics Refer to section 13 3 ...

Page 17: ...attery voltage can be accessed from a user application program The ambient temperature input measures the temperature at the controller circuit board It is useful for measuring the operating environment of the controller and returns an integer value in the range 40 C to 75 C or 40 F to 167 F The temperature reading represents temperatures in the range 40 C to 75 C or 40 F to 167 F Temperatures out...

Page 18: ... all cases it is important for the user to ensure that the transmitter has enough voltage for proper operation The transmitter manufacturer supplies the minimum operating voltage specification of the transmitter The analog input requires a minimum of 5V The first option is to use the SCADAPack 350 VLOOP Supply that steps up the input voltage to 24V The stepped up voltage is available on the Analog...

Page 19: ...ts Data Format The I O analog inputs have a 16 bit unipolar analog to digital A D converter that measures input voltages from 0 to 10V The analog inputs are factory calibrated to scale the data and represent it with a 15 bit unsigned number When an analog input is configured for voltage mode 10V input is represented with 15 bits of data The input resolution is 0 305mV count When an analog input is...

Page 20: ...her information Figure 5 Analog Output Wiring shows example wiring of the analog outputs 6 2 Voltage Outputs To obtain voltage outputs connect a load resistor in series with the current output channel and the voltage device across the load resistor The table below list resistance values and output range settings for two common voltage ranges The resistance value listed is the parallel resistance o...

Page 21: ...Data Current 0 0mA 8 4 88µA 6552 4mA 16384 10mA 24576 15mA 32760 19 995mA SCADAPack 350 Hardware Manual February 14 2007 20 ...

Page 22: ...The SCADAPack 350 also provides three internal digital outputs that can be controlled by the user application to manage power saving features unique to the SCADAPack 350 Refer to the TelePACE or ISaGRAF software manuals for information on how to use the SCADAPack 350 Analog Outputs in application programs Access to the analog output registers is achieved using a Register Assignment in TelePACE or ...

Page 23: ...the following digital inputs Input Type Description 0 to 7 external Dry contact inputs These inputs are located on terminal P3 0 contact open associated is LED off 1 contact closed associated is LED on 8 internal VLOOP output status 0 off 1 on See section 4 4 2 VLOOP Power Control for details 9 internal DC DC converter status This bit reports the true status of the DC DC converter If over current ...

Page 24: ...rol for details 10 internal VLOOP over current status Indicates VLOOP over current has been detected This input clears when VLOOP output is off or the over current condition clears 0 off 1 on See section 4 4 2 1 VLOOP Over Current Protection for details 11 internal Digital output mismatch Known outputs are compared to the corresponding inputs to detect incorrect outputs A point is compared if it h...

Page 25: ...own connected to a 24V load and external 24V power supply Digital I O point 2 is shown monitoring a dry contact Digital I O point 5 is shown monitoring an open collector contact Transient voltage suppression is included on each I O point 10 9 8 7 6 5 4 3 GND 0 1 2 3 4 5 P3 DC Power In and Digital I O 24V Load 1 2 11 12 6 7 GND 12Vdc Power Supply _ 24Vdc Power Supply _ 12V Load Figure 6 Digital Inp...

Page 26: ...for an example of wiring to an open collector output 5 4 3 2 1 0 1 2 P5 Counters GND Turbine Meter Sensor GND Turbine Meter Amplifier Consult manufacturer of amplifier for wiring details J9 J10 J11 J12 1 2 1 2 Without external amplifier Internal amplifier With external amplifier Dry contact input Figure 7 Counter Input Wiring Counter 1 is shown as a millivolt input with a direct connection to a tu...

Page 27: ...ctly to counter input 1 enable the SCADAPack s internal pre amplifier on this input as follows 1 Install jumper J11 on the Int Amplifier position 2 Install jumper J9 on the See J11 position as shown below Int Amplifier J9 J11 Internal amplifier See J11 Counter 1 input SCADAPack 350 Figure 8 Setting Jumpers on Counter Input 1 for Low Voltage Turbine Meters Similarly when connecting a low voltage mi...

Page 28: ...1 Counter 1 input Internal 1000 ohms connected to Input Voltage J10 J12 Counter 2 input Internal 1000 ohms connected to Input Voltage 12V DC SCADAPack 350 Ext Amplifier Ext Amplifier See J11 See J12 Figure 10 Setting Counter Input 1 and 2 for Turbine Meters with amplified signals Your standalone amplifier may have a specific current requirement as specified by the manufacturer As shown in the figu...

Page 29: ...e J11 position and install on the other two pins For Counter 2 3 Install jumper J12 in the Ext Position 4 Remove jumpers J10 from the See J12 position and install on the other two pins Note Note that the above configuration applies only when the controller is being powered using 12V If 24V is used to power the controller the internal 1000 Ohm pull up resistor should not be used as power dissipatio...

Page 30: ...e RS 485 port For RS 232 operation J13 on the controller board must have the jumper link installed in position RS 232 This section covers RS 232 operation For RS 485 operation refer to section 10 2 2 COM2 RS 485 Serial Port The following table shows the serial and protocol communication parameters supported by COM2 These parameters are set from TelePACE ISaGRAF Workbench or from an application pro...

Page 31: ...tion 1 5V Output This pin can be connected to the 5V power supply by installing a jumper at J14 on the SCADAPack 350 Warning This 5V output is used to power Vision terminals and other Control Microsystems accessories DO NOT apply 5V to this pin Ensure that cables connecting this pin do not have any voltage 2 DCD Input The DCD led is on for a MARK level 3 DTR Output This pin is normally at a MARK l...

Page 32: ... data 8 RTS Output This pin is a MARK if full duplex operation is selected for the port This pin is set to a MARK just before and during transmission of data if half duplex operation is selected This pin is set to a SPACE when no data is being transmitted The LED is ON for a MARK level SCADAPack 350 Hardware Manual February 14 2007 31 ...

Page 33: ...ended Default Standard Connections to COM3 are made through a RJ 45 modular connector COM3 supports six signals plus Ground and 5V power The SCADAPack 350 COM3 is designed to be able to operate with the SCADAPack Vision operator interface and has several special features noted below Two of the signals DTR and DCD are shared with the test signals used to detect the ON switch closure on the Vision i...

Page 34: ...generate RS 232 compatible 5V levels Cables should be limited to a maximum of 10 ft 3m The following table provides a description of the function of each pin of the RJ 45 connector In this table a MARK level is a voltage of 3V or greater and a SPACE level is a voltage of 3V or lower Pin Function Description 1 5V Output 5V power for the SCADAPack Vision Warning This 5V output is used to power Visio...

Page 35: ...is signal the controller keeps the line at a MARK When the attached device does provide this signal it must set CTS to MARK to allow the controller to transmit data 8 RTS Output This pin is a MARK if full duplex operation is selected for the port This pin is set to a MARK just before and during transmission of data if half duplex operation is selected This pin is set to a SPACE when no data is bei...

Page 36: ... RS 232 DTE to RS 232 DTE without Handshaking 10 1 3 2 DTE to DTE with Handshaking Some DTE devices may require hardware handshaking lines The most common are the CTS and RTS lines Less common are the DTR and DCD lines The controller does not require these lines Refer to the specifications of the external device for exact requirements The following diagram shows a common connection of an RS 232 CO...

Page 37: ...2 Cables 10 1 4 1 RJ 45 to DE 9S DTE This cable is used to connect from an RJ 45 based RS 232 port on the SCADAPack 350 controller to DE 9P connector on a DTE such as a PC A 10 ft long cable is available from Control Microsystems as part number 297217 RJ 45 8 Pins SCADAPack DTE Function DE9S DTE Function DE9S Shield connects to shell 6 TxD RxD 2 5 RxD TxD 3 4 GND GND 5 1 2 3 7 and 8 are not connec...

Page 38: ...DAPack 350 DTE Function DE 9P DCE Function DE 9P Shield connects to shell 3 DTR DTR 4 6 TxD TxD 3 5 RxD RxD 2 2 DCD DCD 1 4 GND GND 5 7 CTS CTS 8 8 RTS RTS 7 1 5V 5V 9 10 2 RS 485 Serial Communication Ports 10 2 1 COM1 RS 485 Serial Port Serial port COM1 on the SCADAPack 350 controller is configured as a two wire RS 485 serial communication port The following table shows the serial and protocol co...

Page 39: ... but instead are referenced to their respective incoming electrical grounds The grounds of the RS 485 devices on the network must be within several volts of each other The SCADAPack 350 ground is connected to the chassis 10 2 2 COM2 RS 485 Serial Port Serial port COM2 can be configured as either a six line RS 232 port or as a two wire RS 485 port For RS 485 operation J13 must have the jumper link ...

Page 40: ...ages to other RS 485 devices on a network The RS 485 specification allows a maximum of 32 devices connected on a single RS 485 network The specification for RS 485 recommends that the cable length should not exceed a maximum of 4000 feet or 1200 meters The signal grounds of the RS 485 devices in the network are not connected together but instead are referenced to their respective incoming electric...

Page 41: ... following diagram shows the pin connections for the RS 485 RJ 45 port connector for COM2 operating in RS 485 mode RJ 45 Modular Jack 1 5V 2 NC 3 NC 4 GND 5 B 6 A 7 NC 8 NC Should be left open 2 1 8 7 6 5 4 3 Figure 17 COM2 RJ 45 Connector 10 2 3 RS 485 Bias Resistors The RS 485 receiver inputs on the controller are biased to ensure that that received data is driven to a valid state space when the...

Page 42: ...he second bias resistor is installed from the A signal to 5V 5V is available on P8 pin 1 when J14 is installed 10 2 5 RS 485 Wiring Examples A typical RS 485 wiring example is shown below COM1 is shown connected to a multivariable transmitter such as a Control Microsystems 4000 series MVT The power for the transmitter can come from the SCADAPack 350 power input source or can be obtained from the 2...

Page 43: ... In the format 255 255 255 255 Default 255 255 0 0 Gateway In the format 255 255 255 255 Default 0 0 0 0 The IP Address is the address of the controller The IP address is statically assigned Contact your network administrator to obtain an IP address for the controller The Subnet Mask is determines the subnet on which the controller is located The subnet mask is statically assigned Contact your net...

Page 44: ... to the maximum allows the server to use all connections for incoming connections Setting the value below the maximum limits the number of incoming connections from remote devices This reserves the remaining connections for use by the controller for outgoing connections The TCP Port parameter sets the port used by the Modbus TCP protocol In almost all cases this should be set to 502 This is the we...

Page 45: ... a maximum run of 100m or 350 feet but the actual limit is based on signal loss and the noise in the environment This may limit the practical distance to less than 100m or 350 feet The Ethernet cables should not be run in parallel with power or any cables that generate noise SCADAPack 350 Hardware Manual February 14 2007 44 ...

Page 46: ... to be in a non hazardous state 12 1 USB Connections The connectors used for the USB ports are compliant with the USB specification 12 1 1 Host Port The host port features a USB series A receptacle For bus powered USB devices the host port can provide up to 100mA at 5V The following diagram shows the connections for the host USB port USB series A receptacle 1 VBUS 2 D 3 D 4 GND 3 4 1 2 Figure 20 H...

Page 47: ...N mode is the normal operating mode of the controller No action is required to select RUN mode When power is applied to the controller board The user defined serial communication parameters for all COM ports are used If a TelePACE Ladder Logic or ISaGRAF application program is loaded in RAM it is executed If a TelePACE or ISaGRAF C application program is loaded in RAM and the program checksum is c...

Page 48: ...T using the following procedure 1 Remove power from the SCADAPack controller 2 Hold down the LED POWER button 3 Apply power to the SCADAPack controller 4 Continue holding the LED POWER button for 25 seconds until the STAT LED begins to flash on and off continuously 5 Release the LED POWER button Note If the LED POWER button is released before the STAT LED begins to flash the SCADAPack controller w...

Page 49: ... Effects The table below summarizes the effects of the various boot modes Run Boot Service Boot Cold Boot Re entry Boot Factory Boot Action X X X IP Address set to default X X X X serial settings set to default X X X Lock settings set to default X X X S F settings set to default X X X FIP set to default X X X LED power set to default X X X Register assignment erased X X X Database initialized X X ...

Page 50: ...ected together indicating the SCADAPack Vision is to be turned on This can only occur if COM3 is configured to operate with SCADAPack Vision operator interface 13 1 7 Reduced Power Mode A SCADAPack 350 Controller is capable of lower power operation when in Reduced Power Mode The controller enters this mode under control of the application program During in Reduced Power Mode the following happens ...

Page 51: ...points are forced LINK On when the LAN port has established a link ACT On to signal activity on the LAN port RX On when receiving data on the corresponding serial port TX On when transmitting data on the corresponding serial port CTS On when the CTS input is asserted COM2 DCD On when the DCD input is asserted COM2 Digital I O On when the corresponding I O point is on LEDs are dim in Sleep Mode whe...

Page 52: ...og Input 2 Range Figure 4 Analog Input Wiring J4 Analog Input 3 Range Figure 4 Analog Input Wiring J5 Analog Input 4 Range Figure 4 Analog Input Wiring J8 Reset Jumper Performs a controller board reset similar to power cycle J9 Counter Input 1 Type Figure 7 Counter Input Wiring J10 Counter Input 2 Type Figure 7 Counter Input Wiring J11 Counter Input 1 Type Figure 7 Counter Input Wiring J12 Counter...

Page 53: ...d the changes to the controller The Status LED should stop flashing If a module is currently not connected to the controller delete it from the Register Assignment Table Download the changes to the controller The Status LED should stop flashing If unused modules must be intentionally left in the Register Assignment Table the I O error indication may be disabled from a selection box on the Register...

Page 54: ...ll cases investigate and correct the cause of the fuse failure before replacement Common causes of fuse failure are short circuits and excessive input voltages 14 2 Lithium Battery A small lithium battery powers the CMOS memory and real time clock when input power is removed The voltage of a functioning battery should be greater than 3 0V An application program can monitor this voltage Refer to th...

Page 55: ...on 13 1 3 Cold Boot Mode in of this manual for the Cold Boot procedure WARNING If a cold boot is not done the behavior of the controller is unpredictable 8 The controller may now be programmed SCADAPack 350 Hardware Manual February 14 2007 54 ...

Page 56: ... analog outputs are not forced 15 3 Digital Inputs Problem Action Input LED does not come on when input signal is applied Check the input signal at the termination block It should be at least 50 of the digital input range If this is a DC input check the polarity of the signal Input is on when no signal is applied The LED is off Check that the digital inputs are not forced on Input is off when a si...

Page 57: ...should be on Check that the output is not forced off The LED is dim This normal operation when the controller is in sleep mode or when the LEDs are turned off Check the controller digital I Os are in the register assignment 15 5 Counter Inputs Problem Action Input LED does not come on when input signal is applied Check the input signal at the termination block It should be at least 50 of the count...

Page 58: ...timer Two Microcontroller co processors 20 MHz clock Memory 16MBytes FLASH ROM 4MBytes CMOS RAM 4kBytes EEPROM Non volatile RAM CMOS RAM with lithium battery retains contents for 2 years with no power Clock calendar 1 minute month at 25 C 1 3 minutes month 0 to 50 C Internal temperature Measurement range 40 C to 75 C Accuracy 5 C Measurement range 40 F to 167 F Accuracy 9 F Lithium battery Monitor...

Page 59: ...rotection COM1 COM2 2 5kV surge withstand capability as per ANSI IEEE C37 90 1 1989 Isolation Common ground return connected to Chassis Ground Cable Length RS 232 maximum 10 ft 3 m RS 485 maximum 4000 ft 1200 m Protocol TeleBUS compatible with Modbus RTU and Modbus ASCII DF1 or DNP Protocol Modes Slave master master slave store and forward 16 4 USB Ports USB Peripheral One Port B connector USB Hos...

Page 60: ...he LEDs 12W at 24V maximum 5V supply fully loaded and Vloop on and boosted fully loaded Output capacity 5V at 1 2A capacity 5V at 80mA required by 5209 controller LAN and USB disabled 5V at 40mA required by 5209 controller LAN and USB disabled in reduced power mode 5V at 160mA required by 5209 controller to enable the LAN 5V at 50mA required by 5209 controller to enable the USB 5V at 1 1A current ...

Page 61: ...d Response Time 100ms typical for 10 to 90 signal change 16 9 Analog Outputs Output Points 2 when optional 5305 analog outputs installed Output Signal Range 0 20mA Maximum Load Resistance 925Ω with 24Vdc input voltage or when internal 24V power supply is on 375Ω with 12Vdc input voltage 250Ω with input voltage at power supply turnoff Output Type Single ended regulation on positive side with common...

Page 62: ...tion 2 5kV surge withstand capability as per ANSI IEEE C37 90 1 1989 Isolation Common ground return connected to Chassis Ground 16 11 Digital Inputs Outputs I O points 8 points Each point is an input and an output Output Rating 1 0A maximum 0 35V maximum drop at 1 0A 0 05V maximum drop at 0 1A Open drain sinking when ON 28V maximum when OFF Input Rating Dry contact input Wetting current typically ...

Page 63: ...Protection C37 90 1 1989 Isolation Common ground return connected to Chassis Ground SCADAPack 350 Hardware Manual February 14 2007 62 ...

Page 64: ...Tick compliance Registration number N15744 Immunity EN61000 6 2 2001 Electromagnetic Compatibility Generic Standards Immunity for Industrial Environments Declaration This product conforms to the above Emissions and Immunity Standards and therefore conforms with the requirements of Council Directive 89 336 EEC as amended relating to electromagnetic compatibility and is eligible to bear the CE mark ...

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