Motorola ACE3600 RTU User manual

Owner’s Manual
ACE3600 RTU
6802979C35-L
ab
MOTOROLA , MOTO, MOTOROLA SOLUTIONS and the
Stylized M Logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under license.
All other product or service names are the property of their
respective owners.
Copyright © 2014All rights reserved

COMPUTER SOFTWARE COPYRIGHTS
The Motorola products described in this instruction manual may include copyrighted Motorola computer programs stored in
semi conductor memories or other media. Laws in the United States and other countries preserve for Motorola certain
exclusive rights for copyrighted computer programs including the exclusive right to copy or reproduce in any form the
copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in the Motorola
products described in this manual may not be copied or reproduced in any manner without the express written permission of
Motorola Solutions, Inc. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by
implication, estoppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for
the normal non-exclusive, royalty free license to use that arises by operation of law in the sale of a product.
The ACE3600 RTU/ACE IP Gateway software includes additional third party software components governed by specific
licenses and under different copyrights. For details on how to view these legal notices and copyright notices, refer to
Viewing the Legal Notices in the Operation chapter.
EUROPEAN UNION DIRECTIVE 2002/95/EC CONFORMANCE STATEMENT
Hereby, Motorola declares that these products comply with RoHS European Directive no. 2002/95/EC (Restriction of the use
of Hazardous Substances) and WEEE Directive no. 2002/96/EC (Strategy of Waste management), with the exception of
models listed in Appendix B.
Motorola Solutions, Inc.
1301 E. Algonquin Road,
Schaumburg, IL 60196 U.S.A.

i
CONTENTS
GLOSSARY..............................................................................................................................................................VI
DESCRIPTION........................................................................................................................................................ 1-1
PRODUCT OVERVIEW.............................................................................................................................................. 1-1
GENERAL DESCRIPTION.......................................................................................................................................... 1-1
ACE3600 RTU CONSTRUCTION............................................................................................................................. 1-3
RTU COMPONENTS ................................................................................................................................................ 1-7
MODEL OPTIONS AND ACCESSORIES ...................................................................................................................... 1-9
PRODUCT SAFETY AND RF EXPOSURE.................................................................................................................. 1-10
INSTALLATION..................................................................................................................................................... 2-1
GENERAL................................................................................................................................................................ 2-1
MOUNTING THE ACE3600 FRAME ON A WALL ...................................................................................................... 2-2
INSTALLING THE ACE3600 IN A 19" RACK............................................................................................................. 2-4
INSTALLING THE ACE3600 IN A 19" RACK (FOR RTUS ORDERED BEFORE OCTOBER 2010) .................................. 2-6
MOUNTING THE ACE3600 8I/O FRAME ON A WALL.............................................................................................. 2-9
MOUNTING THE ACE3600 8I/O FRAME ON A WALL (FOR RTUS ORDERED BEFORE OCTOBER 2010)................. 2-11
MOUNTING THE ACE3600 NEMA 4HOUSING ON A WALL.................................................................................. 2-12
CONNECTING POWER AND GROUND ..................................................................................................................... 2-14
CONNECTING I/O MODULES TO GROUND ............................................................................................................. 2-20
CONNECTING AN RTU TO GROUND...................................................................................................................... 2-21
CONNECTING THE RADIO...................................................................................................................................... 2-22
OPENING/CLOSING THE HOUSING DOOR............................................................................................................... 2-22
INSTALLING ACCESSORY BOX INTERFACES.......................................................................................................... 2-23
19" FRAME METAL BACK INSTALLATION COMBINATIONS.................................................................................... 2-24
POWER SUPPLY MODULE AND BACKUP BATTERY................................................................................. 3-1
GENERAL DESCRIPTION/MODULE OVERVIEW ........................................................................................................ 3-1
REDUNDANT POWER SUPPLY.................................................................................................................................. 3-8
BATTERY CHARGER ............................................................................................................................................... 3-8
CONNECTING THE POWER SUPPLY TO A POWER SOURCE........................................................................................ 3-9
POWER SUPPLY DETAILED SPECIFICATIONS.......................................................................................................... 3-11
BACKUP BATTERY................................................................................................................................................ 3-14
CPU MODULE........................................................................................................................................................ 4-1
GENERAL DESCRIPTION.......................................................................................................................................... 4-1
FRONT PANEL......................................................................................................................................................... 4-2
CPU WITH SECURITY.............................................................................................................................................. 4-5
REDUNDANT CPU .................................................................................................................................................. 4-5
CPU FIRMWARE AND OPERATION MODES.............................................................................................................. 4-5
CPU STATUS AND DIAGNOSTICS ............................................................................................................................ 4-7
CONNECTING PLUG-IN PORTS TO THE CPU MODULE ............................................................................................. 4-7
CONNECTING SRAM EXPANSION MEMORY TO THE CPU MODULE........................................................................ 4-9
PUSHBUTTON FUNCTIONALITY ............................................................................................................................. 4-10
CPU LEDS BEHAVIOR ......................................................................................................................................... 4-12
CPU 3610*/CPU 3640 MODULE SPECIFICATIONS................................................................................................ 4-15
CPU 3680 MODULE SPECIFICATIONS ................................................................................................................... 4-16

Contents
ii
I/O MODULES........................................................................................................................................................ 5-1
GENERAL DESCRIPTION.......................................................................................................................................... 5-1
INSERTING/REMOVING AN I/O MODULE FROM THE RACK ...................................................................................... 5-9
24V DC FLOATING PLUG-IN POWER SUPPLY ....................................................................................................... 5-10
24V DC FLOATING PLUG-IN POWER SUPPLY MODULE DETAILED SPECIFICATIONS.............................................. 5-12
DIGITAL INPUT MODULE.................................................................................................................................. 6-1
GENERAL DESCRIPTION.......................................................................................................................................... 6-1
DI MODULE CONFIGURATION................................................................................................................................. 6-3
MODULE STATUS AND DIAGNOSTICS...................................................................................................................... 6-5
I/O CIRCUIT DIAGRAM............................................................................................................................................ 6-6
MODULE BLOCK DIAGRAM .................................................................................................................................... 6-7
CONNECTION CHARTS ............................................................................................................................................ 6-9
I/O CONNECTION DIAGRAM.................................................................................................................................. 6-10
DI MODULE SPECIFICATIONS................................................................................................................................ 6-11
DIGITAL INPUT 120/230V MODULE................................................................................................................. 7-1
GENERAL DESCRIPTION.......................................................................................................................................... 7-1
DI MODULE CONFIGURATION................................................................................................................................. 7-2
MODULE STATUS AND DIAGNOSTICS...................................................................................................................... 7-3
I/O CIRCUIT DIAGRAM............................................................................................................................................ 7-4
MODULE BLOCK DIAGRAM .................................................................................................................................... 7-5
CONNECTION CHARTS ............................................................................................................................................ 7-6
I/O CONNECTION DIAGRAM.................................................................................................................................... 7-7
HIGH VOLTAGE DI MODULE SPECIFICATIONS ........................................................................................................ 7-8
DIGITAL OUTPUT/DIGITAL INPUT FET MODULE ..................................................................................... 8-1
GENERAL DESCRIPTION.......................................................................................................................................... 8-1
MODULE CONFIGURATION...................................................................................................................................... 8-2
MODULE STATUS AND DIAGNOSTICS...................................................................................................................... 8-4
I/O CIRCUIT DIAGRAM............................................................................................................................................ 8-5
MODULE BLOCK DIAGRAM .................................................................................................................................... 8-6
CONNECTION CHARTS ............................................................................................................................................ 8-8
I/O CONNECTION DIAGRAM.................................................................................................................................... 8-9
DO/DI FET MODULE SPECIFICATIONS ................................................................................................................. 8-10
DIGITAL OUTPUT RELAY MODULE............................................................................................................... 9-1
GENERAL DESCRIPTION.......................................................................................................................................... 9-1
MODULE CONFIGURATION...................................................................................................................................... 9-3
MODULE STATUS AND DIAGNOSTICS...................................................................................................................... 9-5
I/O CIRCUIT DIAGRAM............................................................................................................................................ 9-6
MODULE BLOCK DIAGRAM .................................................................................................................................... 9-8
CONNECTION CHARTS .......................................................................................................................................... 9-10
DO RELAY MODULE SPECIFICATIONS .................................................................................................................. 9-11
DIGITAL OUTPUT RELAY 120/230V MODULE............................................................................................ 10-1
GENERAL DESCRIPTION........................................................................................................................................ 10-1
MODULE CONFIGURATION.................................................................................................................................... 10-4
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 10-6
MODULE BLOCK DIAGRAM .................................................................................................................................. 10-7
I/O CIRCUIT DIAGRAM.......................................................................................................................................... 10-8
CONNECTION CHARTS .......................................................................................................................................... 10-9
DO RELAY 120/230V MODULE SPECIFICATIONS................................................................................................ 10-10

Contents
iii
DIGITAL OUTPUT SBO RELAY MODULE.................................................................................................... 11-1
GENERAL DESCRIPTION........................................................................................................................................ 11-1
MODULE CONFIGURATION.................................................................................................................................... 11-4
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 11-6
I/O CIRCUIT DIAGRAM.......................................................................................................................................... 11-7
MODULE BLOCK DIAGRAM .................................................................................................................................. 11-9
CONNECTION CHARTS .......................................................................................................................................... 11-1
DO SBO RELAY MODULE SPECIFICATIONS........................................................................................................ 11-12
ANALOG INPUT MODULE ............................................................................................................................... 12-1
GENERAL DESCRIPTION........................................................................................................................................ 12-1
AI MODULE CONFIGURATION............................................................................................................................... 12-3
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 12-4
I/O CIRCUIT DIAGRAM.......................................................................................................................................... 12-7
MODULE BLOCK DIAGRAM .................................................................................................................................. 12-8
CONNECTION CHARTS ........................................................................................................................................ 12-10
I/O CONNECTION DIAGRAM................................................................................................................................ 12-11
AI MODULE SPECIFICATIONS.............................................................................................................................. 12-12
ANALOG OUTPUT MODULE........................................................................................................................... 13-1
GENERAL DESCRIPTION........................................................................................................................................ 13-1
AO MODULE CONFIGURATION ............................................................................................................................. 13-3
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 13-6
I/O CIRCUIT DIAGRAM.......................................................................................................................................... 13-7
MODULE BLOCK DIAGRAM .................................................................................................................................. 13-8
CONNECTION CHARTS .......................................................................................................................................... 13-9
I/I CONNECTION DIAGRAM ................................................................................................................................. 13-10
AO MODULE SPECIFICATIONS ............................................................................................................................ 13-11
MIXED I/O MODULE.......................................................................................................................................... 14-1
GENERAL DESCRIPTION........................................................................................................................................ 14-1
MIXED I/O MODULE CONFIGURATION.................................................................................................................. 14-3
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 14-4
MODULE BLOCK DIAGRAM .................................................................................................................................. 14-5
CONNECTION CHARTS .......................................................................................................................................... 14-6
MIXED I/O MODULE SPECIFICATIONS................................................................................................................... 14-7
MIXED ANALOG MODULE.............................................................................................................................. 15-1
GENERAL DESCRIPTION........................................................................................................................................ 15-1
MIXED ANALOG MODULE CONFIGURATION ......................................................................................................... 15-2
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 15-3
MODULE BLOCK DIAGRAM .................................................................................................................................. 15-4
CONNECTION CHARTS .......................................................................................................................................... 15-5
MIXED ANALOG MODULE SPECIFICATIONS .......................................................................................................... 15-6
I/O EXPANSION................................................................................................................................................... 16-1
GENERAL DESCRIPTION........................................................................................................................................ 16-1
I/O EXPANSION FRAME ........................................................................................................................................ 16-4
I/O EXPANSION POWER ........................................................................................................................................ 16-4
STATUS AND DIAGNOSTICS................................................................................................................................... 16-5

Contents
iv
EXPANSION MODULE....................................................................................................................................... 17-1
GENERAL DESCRIPTION........................................................................................................................................ 17-1
FRONT PANEL....................................................................................................................................................... 17-2
MODULE FIRMWARE AND OPERATION MODES ..................................................................................................... 17-3
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 17-6
CONNECTING THE EXPANSION MODULE ............................................................................................................... 17-7
SETTING THE FRAME NUMBER ............................................................................................................................. 17-8
PUSHBUTTON FUNCTIONALITY ........................................................................................................................... 17-10
LEDS BEHAVIOR................................................................................................................................................ 17-11
EXPANSION MODULE SPECIFICATIONS................................................................................................................ 17-16
EXPANSION LAN SWITCH............................................................................................................................... 18-1
GENERAL DESCRIPTION........................................................................................................................................ 18-1
FRONT PANEL....................................................................................................................................................... 18-2
INSERTING/REMOVING AN EXPANSION LAN SWITCH FROM THE FRAME .............................................................. 18-3
SWITCH STATUS AND DIAGNOSTICS...................................................................................................................... 18-3
CONNECTING THE EXPANSION LAN SWITCH TO THE MAIN CPU.......................................................................... 18-3
CONNECTING THE EXPANSION LAN SWITCH TO I/O EXPANSION FRAMES............................................................ 18-3
EXPANSION LAN SWITCH LEDS BEHAVIOR......................................................................................................... 18-5
EXPANSION LAN SWITCH SPECIFICATIONS........................................................................................................... 18-6
EXPANSION POWER SUPPLY MODULE ...................................................................................................... 19-1
GENERAL DESCRIPTION/MODULE OVERVIEW ...................................................................................................... 19-1
MODULE STATUS AND DIAGNOSTICS.................................................................................................................... 19-4
CONNECTING THE EXPANSION POWER SUPPLY TO THE MAIN FRAME POWER SUPPLY ......................................... 19-4
CONNECTING THE EXPANSION POWER SUPPLY TO GROUND................................................................................. 19-4
EXPANSION POWER SUPPLY FUSES....................................................................................................................... 19-5
EXPANSION POWER SUPPLY MODULE DETAILED SPECIFICATIONS........................................................................ 19-6
ACE IP GATEWAY MODULE........................................................................................................................... 20-1
GENERAL DESCRIPTION........................................................................................................................................ 20-1
FRONT PANEL....................................................................................................................................................... 20-3
ACE IP GATEWAY FIRMWARE AND OPERATION MODES...................................................................................... 20-5
ACE IP GATEWAY STATUS AND DIAGNOSTICS..................................................................................................... 20-7
PUSHBUTTON FUNCTIONALITY ............................................................................................................................. 20-8
ACE IP GATEWAY LEDS BEHAVIOR.................................................................................................................. 20-10
ACE IP GATEWAY MODULE SPECIFICATIONS .................................................................................................... 20-12
RADIO TYPES AND INSTALLATION KITS................................................................................................... 21-1
ACE3600 RADIO TYPES....................................................................................................................................... 21-1
RADIO INSTALLATION KITS................................................................................................................................... 21-4
MOUNTING THE ACE3600 RADIOS ON A WALL.................................................................................................. 21-83
RS485 CONNECTION BOX................................................................................................................................ 22-1
GENERAL DESCRIPTION........................................................................................................................................ 22-1
INSTALLATION ...................................................................................................................................................... 22-2
AUDIO CONTROL AND TONE (ACT) MODULE.......................................................................................... 23-1
INTRODUCTION..................................................................................................................................................... 23-1
FRONT PANEL DESCRIPTION ................................................................................................................................. 23-1
ACT MODULE FEATURES..................................................................................................................................... 23-2
AUDIO HANDLING CAPABILITIES .......................................................................................................................... 23-4
INTERFACE TO THE RTU....................................................................................................................................... 23-4
INSTALLATION AND WIRING ................................................................................................................................. 23-6

Contents
v
RTU PORT CONFIGURATION................................................................................................................................. 23-8
CONTROLLING THE MODULE ................................................................................................................................ 23-9
ACT MODULE SPECIFICATIONS .......................................................................................................................... 23-12
CONFIGURATION .............................................................................................................................................. 24-1
GENERAL.............................................................................................................................................................. 24-1
OPTIMIZATION .................................................................................................................................................. 25-1
GENERAL.............................................................................................................................................................. 25-1
OPERATION......................................................................................................................................................... 26-1
GENERAL.............................................................................................................................................................. 26-1
VIEWING THE LEGAL NOTICES.............................................................................................................................. 26-1
MAINTENANCE................................................................................................................................................... 27-1
GENERAL.............................................................................................................................................................. 27-1
TROUBLESHOOTING........................................................................................................................................ 28-1
BREAK-FIX PROCEDURES .............................................................................................................................. 29-1
GENERAL.............................................................................................................................................................. 29-1
REPLACING A CPU/GATEWAY MODULE............................................................................................................... 29-1
REPLACING A POWER SUPPLY MODULE................................................................................................................ 29-2
REPLACING AN I/O MODULE OR EXPANSION LAN SWITCH .................................................................................. 29-3
INSERTING A NEW I/O MODULE INTO AN EMPTY SLOT......................................................................................... 29-4
REPLACING A PLUG-IN PORT ON THE CPU MODULE............................................................................................. 29-4
REPLACING A PLUG-IN SRAM MEMORY CARD IN THE CPU MODULE.................................................................. 29-4
REPLACING THE MOTHERBOARD.......................................................................................................................... 29-5
REPLACING THE FUSES ON THE POWER SUPPLY MODULE FOR AUX1/AUX2 OR I/O EXPANSION ........................ 29-6
REPLACING THE BACKUP BATTERY ON THE RTU................................................................................................. 29-6
INTERCONNECTION DIAGRAMS............................................................................................................................. 29-6
APPENDIX A: GENERAL SPECIFICATIONS ................................................................................................. A-1
SPECIFICATIONS......................................................................................................................................................A-1
APPENDIX B: ENVIRONMENTAL PROTECTION.........................................................................................B-1
DISPOSAL OF COMPONENTS....................................................................................................................................B-1
APPENDIX C: ACCESSORIES, ADAPTORS AND CABLES ......................................................................... C-1
GENERAL................................................................................................................................................................C-1
APPENDIX D: ACE3600 MAXIMUM POWER RATINGS.............................................................................. D-1
POWER RATING TABLES ........................................................................................................................................ D-1
APPENDIX E: CPU AND POWER SUPPLY REDUNDANCY.........................................................................E-1
GENERAL................................................................................................................................................................E-1
REDUNDANT CPU AND POWER SUPPLY FRAME .....................................................................................................E-1
REDUNDANCY DEFINITIONS....................................................................................................................................E-1
REDUNDANT CPU ..................................................................................................................................................E-2
REDUNDANT POWER SUPPLY..................................................................................................................................E-3
REDUNDANT CPU AND POWER SUPPLY RTU CONFIGURATION .............................................................................E-3

vi
GLOSSARY
ACE Advanced Control Equipment
AI Analog Input
AO Analog Output
AWG American Wire Gauge
DCD Data Carrier Detect
DFM Direct Frequency Modulation
DI Digital (Discrete) Input
DNP Distributed Network Protocol
DO Digital (Discrete) Output
DPSK Differential Phase Shift Keying
EMI Expansion Microcode Interface
EPP Environmentally Preferred Product
ESD Electrostatic Discharge
EU European Union
FCC Federal Communication Commission
FEP Front End Processor (MCP-M, MCP-T, or FIU)
FET Field Effect Transistor
FPGA Field Programmable Gate Array
FSK Phase Shift Keying
FIU Field Interface Unit
GND Ground
GPRS General Packet Radio Service
GPS Global Positioning Satellite
GSM Global System for Mobile Communications
GW ACE IP Gateway
HV High Voltage
HW Hardware
IEC International Electrotechnical Commission
IO (I/O) Inputs Outputs
IP Internet Protocol

Glossary
vii
IPGW IP Gateway
LAN Local Area Network
LED Light Emitting Diode
MCC Master Control Center
MCP-M Motorola Communication Processor – MODBUS
MDLC Motorola Data Link Communication
MODBUS MODICON BUS Protocol
MOSCAD Motorola SCADA
MOSCAD-L Motorola SCADA-Light
NEMA National Electrical Manufacturers Association (issues enclosure standards)
NTP Network Time Protocol
OPC Open Connectivity
OVF Overflow
PC Personal Computer
PLC Programmable Logic Controller
PPC Power PC
PPH Pulse per Hour
PPM Parts Per Million
PPP Point-to-Point Protocol
PPS Pulse per Second
PSTN Public Switched Telephone Network
RAM Random Access Memory
RF Radio Frequency
ROM Read Only Memory
RST Reset
RTS Request to Send
RTU Remote Terminal Unit (can be MOSCAD or MOSCAD-L)
RX Receive
SCADA Supervisory Control and Data Acquisition
SBO Select Before Operate
SDRAM Synchronous Dynamic Random Access Memory
SNMP Simple Network Management Protocol
SNTP Simple Network Time Protocol
SPDT Single Pole Double Trigger

Glossary
viii
SPST Single Pole Single Trigger
STS System Tools Suite
SW Software
TB Terminal Block
TCP Transmission Control Protocol
TDPSK Trunked Differential Phase Shift Keying
TX Transmit
UDF Underflow
UDP User Datagram Protocol
UHF Ultra High Frequency
USB Universal Serial Bus
VHF Very High Frequency
WAN Wide Area Network
WB Wire Break

1-1
DESCRIPTION
Product Overview
The ACE3600 is a programmable Remote Terminal Unit (RTU). Almost any automation task
can be implemented with a suitable choice of ACE3600 components. Typically the RTU
monitors and controls local equipment and communicates with a control center and with other
RTUs in the system. The ACE3600 is the newest Motorola SCADA (MOSCAD) RTU, a
member of MOSCAD family of RTUs and Control Center Front End Processors.
The ACE3600 System Tools Suite (STS) can be run on a local or remote PC to perform all the
setup, programming and monitoring operations such as RTU configuration,
system/application, download, monitoring, etc.
Features of the ACE3600
The ACE3600 combines all the advantages of the legacy MOSCAD and MOSCAD-L RTUs
with those of modern hardware and software technologies.
Among these are:
•A modern CPU platform with powerful microprocessor
•Real-time operating system based on Wind Rivers VxWorks OS
•Enhanced communication and networking capabilities
•Rugged modular design
•Extended operating temperature range
•Improved power supply/charger
•Modules with a high component density
•System building tools
•Interoperability with legacy MOSCAD family RTUs
General Description
The ACE3600 RTU is a modular unit, comprised of removable modules installed in a multi-
slot frame. These modules include
•Power supply
•CPU
•I/O modules

Description
1-2
The basic (default) model includes one power supply and one CPU module. The number of
I/O modules is selected as an option of the base model.
Figure 1-1 provides a general view of the ACE3600 RTU with five I/O modules.
Figure 1-1 ACE3600 RTU – General View
I/O Module Options
The following types of I/O modules are available:
•Digital Inputs (DI), including High Voltage
•Digital Outputs (DO), including High Voltage
•Analog Inputs (AI)
•Analog Outputs (AO)
•Mixed I/O
•Mixed Analog
Communication Interfaces
The ACE3600 CPU includes the following serial ports:
•Configurable RS232 or RS485 serial port
•Configurable RS232 with GPS receiver support (for time sync)
•Ethernet 10/100 Mb/s (ACE3600 CPU 3640, CPU 3680 models)
POWER
SUPPLY
MODULE
CPU MODULE
MOUNTING
PLATE
I/O MODULES

Description
1-3
•Two USB full speed host ports (12 Mbs) for MotoTrbo radios only (ACE3600 CPU 3680
and ACE IP Gateway only)
•One USB device port (ACE3600 CPU 3680 and ACE IP Gateway only)
Two additional plug-in ports can be added to the CPU. The following types of communication
modules are available for the plug-in ports:
•RS232
•RS485
•General radio interface (Conventional or Trunking, DPSK 1200, FSK 2400, DFM 4800)
•Ethernet 10 Mb/s
•Ethernet 10/100 Mb/s (on plug-in Port 1 only)
ACE3600 RTU Construction
The ACE3600 is available in various structures:
•Frame which can accommodate a varied number and type of modules
•Metal chassis which accommodates the frame, and optional radios, backup battery and
communication interfaces
•Protective housing which accommodates the frame, and optional radios, backup
battery and communication interfaces (suitable for outdoor installation)
The ACE3600 frame consists of the following elements:
•Plastic slots which accommodate the power supply, CPU and I/O modules, and
backplane bus motherboard
•Mounting plate for attaching the plastic slots together and mounting the frame on a
wall
•Backplane bus motherboard which connect the modules to each other via the signal
buses and connects the modules with operating voltages
•Power junction box for AC or DC power source and ground connections
A frame can be mounted on the wall or installed in a 19” rack or customer enclosure. For
more information, see the Installation chapter below
The ACE3600 frame can include wide or narrow plastic slot units:
•Wide slot unit - can hold a power supply and a CPU or up to three I/O modules
•Narrow slot unit - can hold up to two I/O modules

Description
1-4
RTU Options
Each RTU can include a number of options, including portable and mobile radios, and plastic
accessory boxes with interface card for communication, etc.
Housing/Mounting Type Capacity/Options Illustration
No I/O slot frame
Basic (default) model.
Can be installed on a wall.
Power supply and CPU
Can be ordered with metal
chassis or housing options.
Can be ordered with 19"
frame metal back.
2 I/O slot frame
Can be installed on a wall.
Power supply and CPU,
up to 2 I/Os
Can be ordered with small
metal chassis.
3 I/O slot frame
Can be installed on a wall.
Power supply and CPU,
up to 3 I/Os
Can be ordered with metal
chassis or housing.
Can be ordered with 19"
frame metal back.
5 I/O slot frame
Can be installed on a wall.
Power supply and CPU,
up to 5 I/Os
Can be ordered with large
metal chassis or housing.
Can be ordered with 19"
frame metal back.
7 I/O slot frame
Can be installed on a wall.
Power supply and CPU,
up to 7 I/Os
Can be ordered with large
metal chassis or housing.

Description
1-5
Housing/Mounting Type Capacity/Options Illustration
8 I/O slot frame
Can be installed on a wall or in
19” rack/enclosure.
Power supply and CPU,
up to 8 I/Os
Can be ordered with metal
chassis option for
accessories: 6.5 or 10 Ah
Lead-Acid backup battery
1 radio; up to 4 accessory
boxes.
For all possible
combinations, see 19” Metal
Back Installation
Combinations in the
Installation chapter below.
I/O expansion frame
2 I/O slot, 3 I/O slot, 5 I/O slot,
7 I/O slot, or 8 I/O slot
I/O expansion power supply,
I/O expansion module, up to
8 I/Os.
Can be connected to the main
RTU frame.
Can be ordered with large
metal chassis or housing.
Redundant CPU and power
supply frame
Can be installed on a wall, in
housing, or in 19”
rack/enclosure.
2 power supplies and 2
CPUs, 4 I/Os.
Can be ordered with large
metal chassis, housing or 19”
frame metal back.
Small metal chassis
Enables installation of radio,
backup battery and other
accessories.
Can be installed on a wall or in
housing.
Power supply and CPU,
up to 2 I/Os,
1 mobile/portable radio,
6.5Ah Lead-Acid backup
battery, (or 10 Ah battery
with portable radio only,)
1 accessory box can be
installed in place of the radio.
Medium metal chassis
Enables installation of radio,
backup battery and other
accessories.
Can be installed on a wall or in
housing.
Power supply and CPU,
up to 3 I/Os,
1 mobile/portable radio,
1 accessory box,
6.5 Ah Lead-Acid backup
battery

Description
1-6
Housing/Mounting Type Capacity/Options Illustration
Large painted metal chassis
Enables installation of radio,
backup battery and other
accessories.
Can be installed on a wall or in
housing.
Power supply and CPU,
up to 7 I/Os,
1 accessory box,
up to 2 mobile/portable
radios,
6.5 or 10 Ah Lead-Acid
backup battery
19" frame metal back
Enables installation of radio,
backup battery and other
accessories.
Can be installed in 19” rack or
on a wall.
Power supply and CPU,
0, 3, 5, or 8 I/Os, 1 radio, 6.5
or 10 Ah Lead-Acid backup
battery, and up to 4 accessory
boxes. (Not all combinations
are valid together.)
Can be ordered with ACE IP
Gateway, power supply,
radio, 6.5 or 10 Ah Lead-
Acid backup battery and up
to 2 accessory boxes.
For all possible
combinations, see 19" Metal
Back Installation
Combinations in the
Installation chapter below.
Small NEMA 4X/IP66 housing
Enables installation of radio,
backup battery and other
accessories.
Can be installed on a wall.
Power supply and CPU,
up to 3 I/Os,
1 mobile/portable radio,
1 accessory box,
6.5 Ah Lead-Acid backup
battery
Large metal NEMA 4X/IP66
housing
Enables installation of radio,
backup battery and other
accessories.
Can be installed on a wall.
Power supply and CPU,
up to 7 I/Os,
1 accessory box,
up to 2 mobile/portable
radios,
6.5 or 10 Ah Lead-Acid
backup battery
For installation instructions of each housing/mounting type, see the Installation chapter.
For information on I/O expansion, see the I/O Expansion chapter.
For the dimensions and weight of each combination, see Appendix A: General Specifications.

Description
1-7
For a detailed list of all ACE3600 options, see the ACE3600 price pages and ordering
information.
For a detailed description of the individual modules, see the appropriate chapter below.
RTU Components
The ACE3600 RTU can include the following components.
Component Function Notes
Power supply module Converts the main AC or DC
power source to the voltages
required by the modules,
radio/modems and
accessories.
Charges the backup battery
and switches to the battery
voltage when the main power
fails (in models with
charger.)
See Power Supply Module
and Backup Battery
chapter.
CPU module Stores and runs the user
application program, stores
data collected by the I/O
modules and communicates
with the control center, RTUs
and other devices via the
communication ports.
See CPU Module chapter.
CPU plug-in port Enables adding various
communication ports to the
CPU modules.
See CPU Module chapter.
CPU plug-in SRAM Provides static RAM. See CPU Module chapter.
I/O module Matches between the
ACE3600 and signals of
various types/levels.
Interfaces between the
ACE3600 and the process
signals.
See I/O Modules chapter.
Terminal blocks (TB) Connects the signals to the
I/O modules. See I/O Modules chapter.
Plug-in 24V DC power supply Enables adding 24 V floating
power supplies to I/O
modules for contact
“wetting” and sensor
operation.
See I/O Modules chapter.

Description
1-8
Component Function Notes
I/O expansion module Connects the I/O modules on
an I/O expansion frame to the
CPU module on the RTU’s
main frame (frame 0),
directly or via an expansion
LAN switch).
See Expansion Module
chapter.
I/O expansion power supply Connects 12V power and
12V DO from the power
supply on the RTU’s main
frame to an I/O expansion
frame, or from one I/O
expansion frame to another.
See Expansion Power
Supply Module chapter.
I/O expansion LAN switch One switch enables
connection of up to seven
expansion frames to the main
frame CPU.
Two switches allow
connection of up to thirteen
expansion frames to the main
frame CPU.
See Expansion LAN Switch
chapter.
ACE IP Gateway module Serves as a front end unit
between
ACE3600/MOSCAD RTUs
and control center SCADA
clients using TCP/IP
protocol.
See ACE IP Gateway
Module chapter.
TB holder kit Holds Module TBs. See I/O Modules chapter.
Cable with TB holder A cable to connect signals to
the I/O modules. See I/O Modules chapter.
Backup battery Enables backup RTU
operation when main power
fails.
See Power Supply Module
and Backup Battery
chapter.
Radio installation kit Mechanical support and
cables that enable installation
of radio.
See Radio Types and
Installation Kits chapter.
RS485 Connection Box Enables connection of up to 6
devices to the RS485 port on
the CPU (2W multi-drop).
See the RS485 Connection
Box chapter.

Description
1-9
Component Function Notes
RTU to PC RS232 cable Enables connection of the
RTU to a PC via the RS232
port.
For use of the ACE3600
Software Tools Suite (STS)
to perform operations such
as RTU configuration,
system/application,
download, monitoring, etc.
See the ACE3600 STS User
Guide.
RTU to PC Ethernet cable Enables connection of the
RTU to a PC via the Ethernet
port.
For use of the ACE3600
Software Tools Suite (STS)
to perform operations such
as RTU configuration,
system/application,
download, monitoring, etc.
See the ACE3600 STS User
Guide.
Ethernet cable Enables the following
connections:
1. CPU to LAN switch
2. LAN switch to expansion
frame
3. LAN switch to LAN
switch
See Expansion Module
chapter.
Ethernet cross cable Enables the following
connections:
1. A single I/O expansion
frame directly to the RTU
main frame.
2. PC (STS) directly to one of
the CPU Ethernet ports.
See Expansion Module
chapter.
Model Options and Accessories
F7500 - ACE3600 System Tools Suite Software
F7600 - ACE3600 ‘C’ Toolkit Software
The full list of ACE3600 options and accessories are listed in the ACE3600 System Planner.

Description
1-10
Product Safety and RF Exposure
Before using an ACE3600 RTU model with a radio installed, read the operating instructions
and RF exposure booklet for the specific radio contained in the product.