Control Microsystems SCADAPack 32P User manual

SCADAPack 32P Controller
Hardware Manual
CONTROL
MICROSYSTEMS
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48 Steacie Drive Telephone: [phone]
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SCADAPack 32P Controller Hardware Manual
©2000 - 2006 Control Microsystems Inc.
All rights reserved.
Printed in Canada.
Trademarks
TeleSAFE, TelePACE, SmartWIRE, SCADAPack, TeleSAFE Micro16 and
TeleBUS are registered trademarks of Control Microsystems Inc.
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 distributed under license from the OPC
Foundation.
SCADAPack 32P Controller Hardware Manual
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Table of Contents
1OVERVIEW.................................................................................................... 5
2IMPORTANT SAFETY INFORMATION ........................................................ 6
3INSTALLATION............................................................................................. 7
3.1 Field Wiring Connections ...............................................................................7
3.1.1 5232 Controller Board Field Wiring Connectors........................................7
3.2 Power Supply.................................................................................................8
3.2.1 Controller Board Power Supply.................................................................8
3.2.2 Power Supply Input Connections..............................................................8
3.2.3 Recommended AC Power Supply Configuration......................................9
3.2.4 Recommended DC Power Supply Configuration......................................9
3.2.5 Recommended 24VDC Battery Supply Configuration ............................10
3.2.6 Recommended 5103 Power Supply Configuration................................. 10
3.2.7 System Grounding.................................................................................. 11
3.3 Internal Analog Inputs..................................................................................11
3.4 Digital /Counter Inputs..................................................................................12
3.5 Interrupt Input............................................................................................... 13
3.6 Status Output............................................................................................... 13
4SERIAL COMMUNICATION........................................................................ 15
4.1 RS-232 Serial Communications Ports.......................................................... 15
4.1.1 COM1 RS-232 Serial Port.......................................................................15
4.1.2 COM2 RS-232 Serial Port.......................................................................16
4.1.3 COM4 RS-232 Serial Port.......................................................................16
4.1.4 RJ-45 Modular Connector for RS-232 ....................................................17
4.2 RS-232 Wiring Examples.............................................................................18
4.2.1 DTE to DTE without Handshaking..........................................................18
4.2.2 DTE to DTE with Handshaking...............................................................19
4.2.3 DTE to DCE with Handshaking...............................................................19
4.3 RS-232 Cables............................................................................................. 20
4.3.1 RJ-45 to DE-9S DTE ..............................................................................20
4.3.2 RJ-45 to DE-9P DCE.............................................................................. 20
4.4 RS-485 Serial Communication Port .............................................................20
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4.4.1 RJ-45 Modular Connector for RS-485 ....................................................21
4.4.2 RS-485 Bias Resistors............................................................................21
4.4.3 RS-485 Termination Resistors................................................................22
4.5 RS-485 Wiring Examples.............................................................................22
4.5.1 Four wire mode....................................................................................... 22
4.5.2 Two wire mode ....................................................................................... 23
4.6 RS-485 Cable............................................................................................... 24
5ETHERNET COMMUNICATION.................................................................. 26
5.1 LAN Port Settings......................................................................................... 26
5.1.1 TCP/IP Settings...................................................................................... 26
5.1.2 Modbus/TCP Settings............................................................................. 26
5.1.3 RJ-45 Modular Connector for Ethernet...................................................27
6OPERATION................................................................................................ 29
6.1 Run Mode .................................................................................................... 29
6.2 Service Mode............................................................................................... 29
6.3 Cold Boot Mode ...........................................................................................30
6.4 SCADAPack 32P LED Indicators................................................................. 30
6.5 LED Power Control ...................................................................................... 31
6.6 Status LED and Output................................................................................31
6.6.1 I/O Module Error Indication..................................................................... 32
6.6.2 Register Assignment Checksum Error.................................................... 32
6.6.3 Too Many I/O Operations Requested Error............................................ 32
6.7 Configuration Switches ................................................................................ 33
6.7.1 Digital Input Filters..................................................................................33
6.7.2 Line Frequency Selection ....................................................................... 34
7MAINTENANCE........................................................................................... 35
7.1 Fuses...........................................................................................................35
7.2 Lithium Battery.............................................................................................35
7.2.1 Battery Replacement Procedure............................................................. 35
8SPECIFICATIONS....................................................................................... 37
8.1 General........................................................................................................ 37
8.2 SCADAPack 32P Controller......................................................................... 37
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8.3 Communications ..........................................................................................37
8.4 Visual Indicators........................................................................................... 38
8.5 Power Supply...............................................................................................38
8.6 I/O Capacity .................................................................................................39
8.7 Digital Inputs ................................................................................................39
8.8 Digital Outputs.............................................................................................. 39
8.9 Approvals and Certifications......................................................................... 39
Index of Figures
Figure 1: SCADAPack 32P..................................................................................................5
Figure 2: 5232 Controller Module ........................................................................................8
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1 Overview
The SCADAPack 32P consists of a 5232 Controller board, see Figure 1: SCADAPack 32P.
Application programs for the controller can be written in either TelePACE Ladder Logic, or
optionally IEC61131, and C/C++ language.
The 5232 Controller provides an integrated power supply, three digital/counter inputs, an interrupt
input and a status output. The 10-BaseT Ethernet port and three serial communication ports enable
connection to a large variety of communication networks. Two of the serial communication ports are
RS-232 and the third is configurable for RS-232 or RS-485.
The RS-232 serial communication ports on the controller board support half-duplex and full-duplex
communication. They support RTS/CTS hardware handshaking for connection to modems and radio
modems. The RS-232 and RS-485 ports operate at baud rates from 300 baud to 38400 baud.
Using 5000 Series I/O modules can expand the I/O capacity of SCADAPack 32P Controllers. A
maximum of forty 5000 Series I/O modules may be connected for an expansion of up to 512 digital
outputs, 512 digital inputs, 128 analog inputs, 32 counters and 32 analog outputs.
The 5232 Controller memory has 8 Mbytes SDRAM, 4 Mbytes flash ROM, and 1 Mbyte CMOS
SRAM. The CMOS SRAM is non-volatile (battery backed.). A real time clock calendar provides for
time of day operations and alarms. A hardware watchdog timer protects against application program
failures.
Low power applications also benefit from the SCADAPack 32P ability to enable and disable status
LED’s on all modules connected to the 5000 Series I/O bus including the controller board.
Figure 1: SCADAPack 32P
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2 Important Safety Information
Power, input and output (i/o) wiring must be in accordance with Class I, Division 2 wiring methods
Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as
specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in
accordance with the authority having jurisdiction.
WARNING !
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.
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3 Installation
The installation of SCADAPack 32P controllers requires mounting the SCADAPack 32P controller
on the 7.5mm by 35mm DIN rail and connecting the SCADAPack controller to the system I/O Bus.
Refer to the System Configuration Guide for complete information on system layout, I/O Bus cable
routing and SCADAPack 32P controller installation.
3.1 Field Wiring Connections
SCADAPack 32P controllers use screw termination style connectors for termination of field wiring.
These connectors can accommodate solid or stranded wires from 22 to 12 AWG.
The termination connectors fit over pins on the 5232 controller board. The connectors are removable
allowing replacement of the SCADAPack 32P Controller without disturbing the field wiring. Leave
enough slack in the field 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 pressure to both ends of the connector.
3.1.1 5232 Controller Board Field Wiring Connectors
The 5232 Controller board has six termination connectors for the connection of field wiring. Refer to
the diagram Figure 2: 5232 Controller Module for field wiring connector locations.
Primary power input connections; output power connection and ground connections are wired to a
six-pole connector labeled P3. Refer to section 3.2.1-Controller Board Power Supply for more
information on these connections.
The three digital/counter inputs (DIN/Counters), interrupt input/counter (INT/Cntr) and status output
(STATUS) are wired to an eight-pole connector labeled P4. Refer to section 3.4-Digital /Counter
Inputs, 3.5-Interrupt Input and 3.6-Status Output for more information on these connections.
Each of the three serial communication ports is wired to black 8 pin modular RJ-45 connectors.
COM1 connector is labeled P6, COM2 connector is labeled P7, and COM4 connector is labeled P8.
Refer to section 4-Serial Communication for more information on serial communication
connections.
The Ethernet LAN Port is wired to a gray 8 pin modular RJ-45connector labeled P5. Refer to section
5-Ethernet Communication for more information on Ethernet connections.
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0 1 2 COM
DIN/COUNTER
+ –
STA TU S
+ –
INT
AC/DC
PWR IN + –
DCPW
R
5V LED
S
STA
T
RUN FORCE IN
T
CTR1 CTR2CTR0 LAN LIN
K
TX RX CTS DCD TX RX CT
S
DCD T
X
R
X
CTS DCD
Power Supply and CPU Interupt and Counters COM1 COM4
LAN COM2
SW 1
P11
F2
F1
J5
TX
RX
RS485 RS232
J7
J8
J9 J10
COM Port
J4
P1 P2
BT1
P6
COM1
RS-232/485
P7
COM2
RS-232
P8
COM4
RS-232
P5
LAN
LED POWER
P4
P3
P11
P9 J2
J3
Figure 2: 5232 Controller Module
3.2 Power Supply
The SCADAPack 32P controller is primarily a DC input powered device but can be powered with
16Vac under some conditions. The power supply requirements for the 5232 Controller board are
each explained in the following sections.
NOTE: Voltages referred to as Vrms (or Vac) indicate AC power. Voltages referred to as V (or
Vdc) indicate DC power.
3.2.1 Controller Board Power Supply
The 5232 Controller board can be powered from a 12Vdc to 24Vdc power source applied to the DC
PWR input or a 16Vac power source applied to the AC PWR IN input. With input power applied the
5232 Controller board power supply provides an internal 5V output to power 5000 Series modules
through the inter module cable (IMC).
The 5V supply has a 1.3A output capacity of which 500mA is required by the 5232 Controller board.
The remaining capacity, 800mA, is used to power 5000 Series modules connected through the IMC
cable.
When the 5232 Controller board is powered with 16Vac power applied to the AC PWR IN input a
limited amount of 24Vdc power is provided on the DC PWR terminals. The amount of 24Vdc power
available is dependent on the amount of 5V output power used in the system. With a 5Vdc output
power of 500mA there is 300mA is available and this value is derated linearly to 100mA with a
5Vdc output power of 1.3A.
3.2.2 Power Supply Input Connections
Input power is connected to the SCADAPack 32P controller in one of the following ways:
• A 16Vac source connects to the AC PWR IN terminals on the 5232 Controller board. See section
3.2.3-Recommended AC Power Supply Configuration for an example of using a 16Vac
transformer to power the SCADAPack 32P controller.
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• An 11 to 24Vdc source connects to the DC PWR terminals on the 5232 Controller board. See
section 3.2.4-Recommended DC Power Supply Configuration for an example of using a DC
power source.
• An 11 to 24Vdc high current capacity source, such as batteries, connects to the AC PWR IN and
DC PWR IN terminals on the 5232 Controller Board. See section 3.2.5-Recommended 24VDC
Battery Supply Configuration for a wiring example.
• A 5103 UPS Power Supply supplies 5Vdc to the controller board through the IMC cable and
supplies 24Vdc through the 24Vdc output. See section 3.2.6-Recommended 5103 Power Supply
Configuration for an example of using the 5103 UPS Power Supply.
CAUTION: Power can be applied to either the AC/DC power input OR the DC power input of
the controller module. DO NOT apply power to both inputs. Damage to the power
supply may result.
3.2.3 Recommended AC Power Supply Configuration
This configuration uses a single Class 2 transformer to power the SCADAPack 32P. 24V are
available on the controller module connector P3. They are used to power the analog circuitry for the
analog input circuits on additional 5000 Series Analog I/O modules.
AC/DC
PWR IN DCPWR + –
120
Vrm
s
16 Vrm
s
123456
Class 2
Transformer
P3
+ 24 V for transmitters
SCADAPack 32P
3.2.4 Recommended DC Power Supply Configuration
This configuration uses a single power supply to power the SCADAPack 32P. A 12-24VDC source
is applied to the DC PWR inputs (+) and (-).
The DC power supply input inrush current can be reduced if required. Some DC power supplies will
go into current limit when starting up into a high inrush current load. Battery operated systems have
high current capabilities that may cause nuisance fuse blowing. If either of these situations are
present in an installation, it possible to reduce the DC power supply inrush current by cutting link J3.
J3 is located on the controller next to the power input connector and fuses. This link may be cut in
DC applications only.
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