IPCOMM IPC191X1 User manual

Walter-Bouhon-Straße 4
90427 Nuremberg
Germany
Edition June 2022
Version 1.0
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IPC191X1
Gateway hardware with Linux OS
General Operating-, Maintenance- and
Installation Manual

Subject to alterations Version 1.0
IPCOMM GmbH - 1 - IPC191X1 Manual
Walter-Bouhon-Straße 4 Copyright © IPCOMM GmbH, 2022
90427 Nuremberg All rights reserved
Germany
Table of Contents
1Introduction...................................................................................................................................... 2
2Hardware Description...................................................................................................................... 3
2.1 General.................................................................................................................................... 3
2.2 IEC 61850-3; EN 61850-3 ....................................................................................................... 3
2.3 Front View................................................................................................................................ 3
2.4 Rear View................................................................................................................................ 4
2.5 Hardware Components............................................................................................................ 5
2.5.1 Mainboard........................................................................................................................ 5
2.5.2 RS-232 Interfaces............................................................................................................ 5
2.5.3 8/16-Port RS-232 Serial Interface ................................................................................... 6
2.5.4 Protecting RS-232 Interfaces according to IEC 61850-3 / EN 61850 ............................. 6
2.5.5 Ethernet Interfaces .......................................................................................................... 7
2.5.6 CFast Memory Card ........................................................................................................ 7
2.5.7 Lithium Battery................................................................................................................. 8
2.5.8 CPU LED ......................................................................................................................... 9
2.5.9 Power Supply................................................................................................................. 10
2.5.9.1 AC Power Supply....................................................................................................... 10
2.5.9.2 DC Power Supply ...................................................................................................... 10
3Overview of Variants / Interface Configuration.............................................................................. 11
3.1 Variant L ................................................................................................................................ 11
3.2 Variant A................................................................................................................................ 11
3.3 Variant B................................................................................................................................ 12
3.4 Variant E4.............................................................................................................................. 12
3.5 Variant E8.............................................................................................................................. 13
3.6 Variant E4M........................................................................................................................... 14
4Technical Data Sheet .................................................................................................................... 14
5EU Declaration of Conformity........................................................................................................ 14
6Nomenclature of the IPC191X1 Article Number............................................................................ 15
7Dimensions IPC191X1 (CAD) ....................................................................................................... 16

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1 Introduction
All technical information, descriptions and illustrations contained in this ‘Operating, Maintenance and
Installation Manual’ remain our property and shall not be used otherwise than for operating this system,
nor shall they be copied, reproduced or passed on to third parties or brought to their notice without our
prior written consent.
The information represented in this manual is in keeping with current standards and is subject to later
alterations.
This manual contains important instructions referring to safe installation, commissioning, operation and
maintenance.
Read this manual carefully before starting up the gateway and observe the instructions.
In order to comply with the guidelines for electro-magnetic compatibility in industrial PCs (or other
variants) only CE-certified components are used in compliance with project-specific requirements.
Finally we want to draw your attention to the fact that any warranties with respect to the gateway
hardware will be invalid in the event that:
Operation, servicing and maintenance are not carried out accurately according to the
instructions; repairs are not carried out by our personnel or without our prior written consent.
Commissioning is not carried out by our personnel or we have not given our approval for the
commissioning or the commissioning is carried out by untrained personnel.
The unit is used inadequately, incorrectly, negligently or inappropriately or for a purpose other
than that originally intended.
The serial number is removed from the product.
For your protection, observe the following safety precautions when setting up your equipment:
Follow all cautions and instructions marked on the equipment.
Ensure that the voltage and frequency of your power source match the voltage and frequency
inscribed on the equipment's electrical rating label.
Never push objects of any kind through openings in the equipment. Dangerous voltages may
be present. Conductive foreign objects could produce a short circuit that could cause fire,
electric shock, or damage to your equipment.
The industrial PC must be mounted on an equipment carrier (1U) in a 19" rack.
A free floating or unilateral mounting may cause defects.
It is imperative to ensure a consequent strain relief to avoid damage to the connector of the
‘8-port DB9-male connector cable’.
All trademarks or brand marks mentioned in this document are used for identification purposes only and
are property of their respective owners.

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2 Hardware Description
2.1 General
As hardware platform for the protocol converter a 19" industrial PC is used. This solution offers a high
degree of flexibility, performance and reliability.
Important for the selection of our components are particular items like quality, availability and a high
durability.
Mounting and intensive tests of the gateway hardware are done in our company. Each device runs
through an intensive function test. This function test includes a burn-in test with full communication of
all interfaces (min. 48 hours). Drops of communication, transmission errors and every important
component with regard to function, temperature, voltages etc. are monitored. Hundreds of restarts are
executed whereby a connection to all interfaces is established at each reboot.
Quality assurance is done according to the four-eye principle. Each device passes a number of quality
inspections.
2.2 IEC 61850-3; EN 61850-3
The special requirements of the IEC 61850-3 standard for electromagnetic compatibility and power
supply are fulfilled by this hardware model, provided that signal cables with a maximum length of 10
meters are used.
2.3 Front View
Figure 1: IPC191X1 front view
S/N, model, voltage
CFast card
power LED
power button
HDD/SSD caddy or
DVD RW drive
(optional)
CPU LED
COM2
CFast
activity LED

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2.4 Rear View
Figure 2 shows the reverse side of the device. The PCIe card varies depending on the model. An
overview of the different models can be found in chapter 3 “Overview of Variants / Interface
Configuration”.
Figure 2: interface overview
Figure 3: 8-port DB9 male connector cable for 8-port serial interface card
main power supply
input
PCIe slot 2
COM1
HDMI
ETH0
1 GbE
4x USB 3.0
PCI slot 2
ETH1
2.5 GbE
8-port DB9-male connector cable
for 8-port serial interface card
Attention! It is imperative to ensure a consequent strain relief to avoid damage to the
connector, see figure above!

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2.5 Hardware Components
The IPC191X1 consists of a 19" housing (1U) with industrial motherboard, integrated network interfaces,
and all other required interfaces. The basic system can be expanded with appropriate PCIe plug-in
cards.
The CPU must be actively cooled. Only if critical system temperatures are reached, two additional
housing fans are switch on automatically.
2.5.1 Mainboard
The Mini-ITX Mainboard is an ultra-compact x86 platform. Its heart consists of an active cooled Intel®
six-core processor. The mainboard provides two DIMM slots for DDR4 memory module and supports
up to 64 GB system memory. Two Ethernet and two serial interfaces are also available. The gateway
can be expanded with two PCI Express cards.
Additional interfaces:
1x Ethernet interface up to 1 Gbps BaseT (RJ45)
1x Ethernet interface up to 2.5 Gbps BaseT (RJ45)
2x RS-232 (DB9)
1x SATA
USB 2.0 and USB 3.0 ports
2x PCIe x8
HDMI
Keyboard and mouse via USB
2.5.2 RS-232 Interfaces
The installed mainboard provides two integrated serial interfaces.
COM 2 front side and COM1 rear side
SERIAL PORT
RS232 DTE
DB9 male connector
Pin
Direction
Description
1
INPUT
DCD Data Carrier Detect
2
INPUT
RXD Receive Data
3
OUTPUT
TXD Transmit Data
4
OUTPUT
DTR Data Terminal Ready
5
GND Ground
6
INPUT
DSR Data Set Ready
7
OUTPUT
RTS Request To Send
8
INPUT
CTS Clear To Send
9
INPUT
RI Ring Indicator
Figure 4: pin assignment of DB9 DTE RS-232 interfaces

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2.5.3 8/16-Port RS-232 Serial Interface
8-port or 16-port serial interface cards can be installed in each IPC191X1. The following pin assignment
is realized with an 8-port DB9 male connector cable (see Figure 3).
SERIAL PORT
RS232 DTE
DB9 male connector
Pin
Direction
Description
1
INPUT
DCD Data Carrier Detect
2
INPUT
RXD Receive Data
3
OUTPUT
TXD Transmit Data
4
OUTPUT
DTR Data Terminal Ready
5
GND Ground
6
INPUT
DSR Data Set Ready
7
OUTPUT
RTS Request To Send
8
INPUT
CTS Clear To Send
9
Figure 5: pin assignment of DB9 serial interface
2.5.4 Protecting RS-232 Interfaces according to IEC 61850-3 / EN 61850
For the adequate protection against the impact of switching interferences (Burst) and surge voltage, we
recommend the use of our 4 kV isolated RS-232 isolator. The used RS-232 transceivers have ESD
protection up to 15 kV. The isolator was tested according to EMC guidelines, climatic and mechanical
requirements in compliance with the standard IEC 61850-3.

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2.5.5 Ethernet Interfaces
The industrial PC features two Ethernet interfaces (RJ45) interfaces with link and activity LEDs.
ETH0 supports up to 1 GBit and ETH1 up to 2.5 GBit Base-T.
ETH0 ETH1
Figure 6: RJ45 network interface
Additional interfaces with 10/100/1000 Mbps BaseT can be realized on request. The IPC191X1 can be
equipped with up to 10 Ethernet interfaces.
2.5.6 CFast Memory Card
The CFast card serves as a mass storage device, i.e. for storing the operating system, the applications
and configuration data. As a result the disadvantages involved with the use of a rotating hard disk are
avoided, thus improving the reliability of the system substantially since a CFast has an MTBF of at least
4,000,000 hours.
The CFast adapter is simply connected to the SATA bus of the mainboard and treated just like a hard
disk.
Figure 7: CFast adapter
When the power supply is switched off the CFast card with the entire software can simply be taken out
or inserted enabling a quick change to different hardware.
Push to take
out CFast

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2.5.7 Lithium Battery
The BIOS settings of the system are stored on a battery-backed CMOS. The long-life lithium battery has
normally a lifetime of at least 5 years.
If the CMOS battery is empty and the CMOS information has been deleted, the CMOS-RAM is
programmed by the BIOS with default settings.
The converter can be operated faultlessly even if the CMOS RAM is not provided by the battery. After
the battery has been changed only time and date must be input.
To open the housing, loosen 6 screws from the top cover using a T10 size Torx screwdriver.
When replacing the battery, charge transfers to the circuit board and components must be avoided and
ESD protection measures, such as the use of a grounding wrist strap, are therefore required. The
operation may only be performed on a grounded and conductive surface.
The battery is attached to the case with a double-sided adhesive dot. This must be carefully detached
and can then be pulled off the mainboard with the two-pin cable and connector (JST-PH 2.0 mm).
Figure 8: battery
Attention! Open-frame power supplies are used. Because of this, the process should be carried
out only by experienced electronic engineers.
The device must be completely disconnected from any power supply.
Before opening please push the power button (without electricity supply) several times to
eliminate residual voltages of the power supply.
Battery
Molex-Plug
Attention!
Battery replacement must be carried out by qualified specialists.
Replace the battery exclusively by the same type
(Manganese Dioxide Lithium Button Cell 3 V DC, CR2032).
The battery is not rechargeable.
When replacing, pay attention to the polarity of the battery.
Batteries must not be disposed of with household waste or incinerated. At the end of its service
life, the battery must be taken to a collection point for the recycling of electrical and electronic
equipment in accordance with the ElektroG or the EU RoHS directive.
There is a risk of explosion if the battery is handled improperly!

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2.5.8 CPU LED
The CPU LED shows the states of conversion software and operating system.
Following figure shows all possible indications:
Figure 9: CPU LED indications
ON
OFF
0,5 s
ON
OFF
0,5 s
5 s
ON
OFF
passive
mode
(standby)
active
mode
software has
sopped