RuggedCom RuggedServer RS910 User manual

RuggedCom Inc. I30 Whitmore Road, Woodbridge, Ontario, Canada L4L 7Z4
Tel: [phone] I Fax: [phone] IToll Free: [phone]
RuggedS
RuggedSRuggedS
RuggedServer
ervererver
erver

 RS9
RS9RS9
RS91
11
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2-Port Serial Device Server with up to 3 Ports Managed
Ethernet Switch
Installation Guide
www.ruggedcom.com

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Federal Communications Commission
Radio Frequency Interference Statement
This equipment has been tested and found to comply with the limits for a Class A digital device
pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment This
equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications
Operation of this equipment in a residential area is likely to cause harmful interference in which
case the user will be required to correct the interference at his expense
Trademarks:
Ethernet is a trademark of Xerox Corporation
RuggedSwitch, RuggedRated, ROS and eRSTP are trademarks of RuggedCom® Inc
Caution
This product contains a laser system and is classified as a “CLASS 1 LASER PRODUCT”
Use of controls or adjustments or performance of procedures other than those specified herein
may result in hazardous radiation exposure This product contains no user serviceable parts
Attempted service by unauthorized personnel shall render all warranties null and void
Should this device require service see the “Warranty” section of this installation guide
Important
This unit should be installed in a restricted access location where access can only be gained by
service personnel or users who have been instructed about the reasons for the restrictions
applied to the location and about any precautions that shall be taken; and access is through the
use of a tool or lock and key, or other means of security, and is controlled by the authority
responsible for the location

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Table of Contents
1Product Overview ............................................................................................................................... 5
1.1 Functional Overview ................................................................................................................... 5
1.2 Feature Highlights ...................................................................................................................... 5
1.3 RS910 Front Panel Description .................................................................................................. 6
1.4 RS910 Bottom Panel Description................................................................................................ 7
2Installation........................................................................................................................................... 8
2.1 Din Rail Mounting....................................................................................................................... 8
2.2 Power Supply Wiring and Grounding ......................................................................................... 9
2.3 Failsafe Output Wiring.............................................................................................................. 12
2.4 RS232 Console Port Wiring ...................................................................................................... 13
3Serial Ports ........................................................................................................................................ 14
4Ethernet Ports ................................................................................................................................... 18
4.1 RJ45 Ethernet Ports .................................................................................................................. 18
4.2 Fiber Optic Ethernet Ports........................................................................................................ 19
4.3 Ethernet Panel Description ....................................................................................................... 19
5Technical Specifications ................................................................................................................... 21
5.1 Operating Environment............................................................................................................. 21
5.2 Power Supply Specifications ..................................................................................................... 21
5.3 Failsafe Relay Specifications .................................................................................................... 21
5.4 Serial Ports................................................................................................................................ 22
5.5 Ethernet Ports............................................................................................................................ 23
5.6 Communication Standards ........................................................................................................ 23
5.7 Mechanical Specifications......................................................................................................... 24
6Type Tests.......................................................................................................................................... 25
6.1 IEC 61850-3 Type Tests ............................................................................................................ 25
6.2 IEEE 1613 Type Tests ............................................................................................................... 26
6.3 IEC Environmental Type Tests.................................................................................................. 26
7Warranty ........................................................................................................................................... 27

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Table of Figures
Figure 1 - RS910 Front Panel Description ................................................................................................. 6
Figure 2 - RS910 Bottom Panel Description............................................................................................... 7
Figure 3 - RS910 DIN Rail Mounting ......................................................................................................... 8
Figure 4 - RS910 Power Supply Inputs....................................................................................................... 9
Figure 5 - DC Power supply wiring and grounding diagram ................................................................. 10
Figure 6 - Dielectric Strength Testing....................................................................................................... 11
Figure 7 - RS910 Failsafe Output Relay................................................................................................... 12
Figure 8 - RS232 Female DCE pin-out ..................................................................................................... 13
Figure 9: Fiber Serial Interface (ST Connector) ..................................................................................... 14
Figure 10: DB9 Port pin-out...................................................................................................................... 15
Figure 11: RJ45 Port pin-out..................................................................................................................... 16
Figure 12: Conceptual recommended RS485 wiring diagram ............................................................... 17
Figure 13 - RJ45 Ethernet port pin-out.................................................................................................... 18
Figure 14: 10FL ST connector.................................................................................................................. 19
Figure 15: 100FX MTRJ connector ......................................................................................................... 19
Figure 16: 100FX ST connector ............................................................................................................... 19
Figure 17: 100FX LC connector............................................................................................................... 19
Figure 18: 100FX SC connector ............................................................................................................... 19
Figure 19: Ethernet panel LED description ............................................................................................ 20
Figure 20 - Mechanical Specifications ...................................................................................................... 24
Table of Tables
Table 1 - Status LEDs................................................................................................................................... 6
Table 2 – RJ45 Ethernet port pin-out....................................................................................................... 18
Table 3 – RJ45 Ethernet port 9 LED description .................................................................................... 20
Table 4 - Operating Environment............................................................................................................. 21
Table 5 - Power Supply Specifications...................................................................................................... 21
Table 6 - Failsafe Relay Specifications...................................................................................................... 21
Table 7: Copper Port Specification........................................................................................................... 22
Table 8: Fiber Optic Port Specification.................................................................................................... 22
Table 9: Ethernet Ports - Copper Specifications ..................................................................................... 23
Table 10: Ethernet Ports – Fiber Optic Specifications........................................................................... 23
Table 11 - Communication Standard Compliance .................................................................................. 23
Table 12 - Mechanical Specifications........................................................................................................ 24
Table 13 - IEC 61850-3 Type Tests ........................................................................................................... 25
Table 14 - IEEE 1613 Type Tests .............................................................................................................. 26
Table 15 - Environmental Type Tests....................................................................................................... 26

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1 Product Overview
1.1 Functional Overview
The RuggedServerTM RS910 is an industrial hardened serial server with an integrated, fully
managed, Ethernet switch, designed to o erate reliably in electrically harsh and climatically
demanding environments. The RS910 can be configured with 2 serial orts
(RS485/RS422/RS232/fiber) and/or u to 3 Ethernet orts (co er or fiber). The RS910 is able to
interconnect multi le ty es of intelligent electronic devices (IEDs) that have different methods of
communications. Using the RS910 results in fewer connectivity devices and also extends the
useful life of existing legacy IEDs.
1.2 Feature Highlights
•Serial Device Server
oTransmit serial data over an IP network
o2 Serial Port Interfaces
oRS485/RS422/RS232 (DB9 or RJ45 connectors)
oSerial Fiber Interface (ST) o tion
oSu ort for Modbus TCP, DBP 3, TIN serial rotocols
oBaud rates u to 230 kb s
oRaw socket mode allows conversion of any serial rotocol
oPoint-to- oint and multi- oint modes
oConverts Modbus RTU to Modbus; Multi le Modbus masters
oConverts DNP 3.0 to DNP over UDP/TCP
•Ethernet Ports:
oIntegrated fully Managed Ethernet Switch
oU to 3 Fast Ethernet Ports (co er and/or fiber)
oSu orts many ty es of fiber (Multimode, Singlemode)
oMulti le connector ty es (ST, MTRJ, LC, SC)

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1.3 RS910 Front Panel Description
Failsafe Relay Power Port
Ports 1 & 2
RS485/422/232
Serial
Or
Serial over Fiber
Ports 3 & 4
10/100Base-T
or
100Base-F
Or
10Base-FL
Port 9
10/100Base-T
or
100Base-F
Power & Alarm
Figure 1 - RS91 Front Panel Description
Status LED Colour Activity Comments
Power LED Green Solid Power On
Alarm LED Red Solid Alarm condition exists
Table 1 - Status LEDs

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1.4 RS910 Bottom Panel Description
Failsafe Relay
Console Port
Power
Port
Chassis
Ground
Optional Din-Rail
Mounting Bracket
Figure 2 - RS91 Bottom Panel Description

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2 Installation
2.1 Din Rail Mounting
An o tional DIN rail mounting bracket is available for the RS910. The figure below details mounting
instructions for the standard 1” DIN Rail.
Figure 3 - RS91 DIN Rail Mounting

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2.2 Power Supply Wiring and Grounding
2.2.1 AC Power Supply Wiring and Grounding
Figure 4 - RS91 Power Supply Inputs
The RS910 AC ower su ly in uts should be connected as follows:
1. +/L should be connected to AC Line/Hot.
2. -/N should be connected to AC Neutral.
3. Surge Ground should be connected to the Chassis Ground via a braided cable or other
a ro riate grounding wire. Surge Ground is used as the ground conductor for all surge
and transient su ression circuitry internal to the unit.
4. Chassis Ground must be connected to the AC ground terminal.
NOTES:
1. Equi ment must be installed according to the a licable country wiring codes.
2. All line-to-ground transient energy is shunted to the Surge Ground terminal. In cases
where users require the in uts to be isolated from ground, remove the ground braid
between Surge and Chassis Ground. Note that all line-to-ground transient rotection
circuitry will be disabled.

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2.2.2 DC Power Supply Wiring and Grounding
Figure 5 - DC Power supply wiring and grounding diagram
The RS910 low voltage DC ower su ly features reverse olarity rotection and dual inde endent
in uts. The latter feature allows the connection of two DC sources with the same nominal voltage
to rovide redundant ower su ly in uts.
The RS910 DC ower su ly in uts should be connected as follows:
1. Connect to the DC in uts according to the olarity markings on the unit.
2. Surge Ground should be connected to the Chassis Ground via a braided cable or other
a ro riate grounding wire. Surge Ground is used as the ground conductor for all surge
and transient su ression circuitry internal to the unit.
3. Chassis Ground must be connected to the rotective earth.
NOTES:
1. Equi ment must be installed according to the a licable country wiring codes.
2. All line-to-ground transient energy is shunted to the Surge Ground terminal. In cases
where users require the in uts to be isolated from ground, remove the ground braid
between Surge and Chassis Ground. Note that all line-to-ground transient rotection
circuitry will be disabled.

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2.2.3 Dielectric Strength Testing
Units which are to have dielectric strength testing (HIPOT testing) done in the field must have the
braided ground cable disconnected during the test. This is required in order to revent the surge
su ression circuitry, which is connected to surge ground, from being activated.
Figure 6 - Dielectric Strength Testing

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2.3 Failsafe Output Wiring
The Failsafe out ut relay is rovided to signal critical error conditions that may occur on the
RS910. The contacts are energized u on ower u of the unit and remain energized until an alarm
condition or ower loss occurs. The behavior of the failsafe relay is configurable via the
RuggedSwitch O erating System. Consult the RuggedSwitch Users Guide for details.
Figure 7 - RS91 Failsafe Output Relay

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2.4 RS232 Console Port Wiring
The RS232 ort is used for configuring the RS910. A straight-through serial cable with a DB-9
connector is required. There is no need to crossover the TxD and RxD signals from the PC side
since this has been done internally as is shown in the figure below.
Pin Signal
1 Internal Connection
2 Transmit Data
3 Receive Data
4 Internal Connection
5 Ground
6 Internal Connection
7 Internal Connection
8 Internal Connection
9 No Connection
Figure 8 - RS232 Female DCE pin-out
NOTE: This ort is not intended to be a ermanent connection and the cable length should not
exceed 2m (6.5 feet). Pins 1,4,6 are connected internally, and ins 7, 8 are connected internally.

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3 Serial Ports
The RS910 can be equi ed with a Fiber Serial Interface, RS232/RS485/RS422 DB9 serial orts
or RS232/RS485/RS422 RJ45 serial orts.
3.1.1 Fiber Serial Interface
The RS910 can be equi ed with a Fiber Serial Interface (ST connector only) which allows RS485,
RS422, or RS232 devices to communicate over secure, noise immune, o tically isolated, fiber
o tic cabling at extended distances as well as rotocol inde endent conversion to multimode fiber
o tics.
Figure 9: Fiber Serial Interface (ST Connector)
3.1.2 RS232/RS485/RS422 via DB9
Each ort is individually selectable via software to be RS232, RS485 or RS422. The DB9 ort and
in-out is shown in Figure 10.

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Pin RS232 Mode RS485 Mode RS422 Mode
1 CD - -
2 TX TX/RX+ (A) TX+
3 RX - RX+
4 DTR - -
5
6 DSR - RX-
7 CTS TX/RX - (B) TX-
8 RTS -
9 RI (NC) - -
Shield
Common (Isolated Ground)
Chassis Ground
Figure 1 : DB9 Port pin-out
NOTE: Pins 1, 4, and 6 are connected internally. Pins 7 and 8 are connected internally. No internal
termination is rovided.
3.1.3 RS232/RS485/RS422 via RJ45
Each ort is individually selectable via software to be RS232, RS485 or RS422. The RJ45 ort and
in-out is shown in Figure 11.

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Pin RS232 Mode RS485 Mode RS422 Mode
1 DSR - RX-
2 DCD - -
3 DTR - -
4
5 RX - RX+
6 TX TX/RX + (A) TX +
7 CTS - -
8 RTS TX/RX - (B) TX -
Shield
Common (Isolated Ground)
Chassis Ground
Figure 11: RJ45 Port pin-out
NOTE: Pins 1, 2, and 3 are connected internally. Pins 7 and 8 are connected internally. No internal
termination is rovided.
3.1.4 RS485 Wiring
Each RS485 ort can communicate to multi le RS485 devices by daisy chaining devices over a
single twisted air with transmit and receive signals on the same two wires (half du lex). The
following guidelines should be followed to ensure reliable continuous communication:
1. To minimize the effects of ambient electrical noise, shielded cabling is recommended
2. The correct olarity must be observed throughout a single daisy chain
3. The number of devices wired should not exceed 32, and total distance should be less than
4000 feet (at 100Kb s)
4. The COM terminals should be connected to the common wire inside the shield.
5. The shield should be connected to earth ground at ONE single oint to avoid loo currents.
6. The twisted air should be terminated at each end of the chain.
Figure 12 shows the recommended RS485 wiring.

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Figure 12: Conceptual recommended RS485 wiring diagram
3.1.5 Serial Port Transient Protection
RuggedCom does not recommend the use of co er cabling of any length for critical real-time
substation automation a lications. However, transient su ression circuitry is resent on all
co er orts to rotect against damage from electrical transients and to ensure IEC 61850-3 and
IEEE 1613 Class 1 conformance. This means that during the transient event communications
errors or interru tions may occur but recovery is automatic. RuggedCom also does not recommend
to use these orts to interface to field devices across distances which could roduce high levels of
ground otential rise, (i.e. greater than 2500V) during line to ground fault conditions.

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4 Ethernet Ports
4.1 RJ45 Ethernet Ports
The RS910 has several 10/100Base-TX orts that allow connection to standard category 5 (CAT-5)
unshielded twisted- air (UTP) cable with RJ45 male connectors. The RJ45 rece tacles are directly
connected to the chassis ground on the unit and can acce t CAT-5 shielded twisted- air (STP)
cables. If shielded cables are used, care must be taken to ensure the shielded cables do not form a
ground loo via the shield wire and the RJ45 rece tacles at either end. The figure below shows the
RJ45 ort in-out.
Figure 13 - RJ45 Ethernet port pin-out
Pin Signal
1 +Rx
2 -Rx
3 +Tx
4 No Connection
5 No Connection
6 -Tx
7 No Connection
8 No Connection
Case Shield (Chassis Ground)
Table 2 – RJ45 Ethernet port pin-out
NOTE: RuggedCom does not recommend the use of CAT-5 (10/100Base-TX communications)
cabling of any length for critical real-time substation automation a lications. However, transient
su ression circuitry is resent on all co er orts to rotect against damage from electrical
transients and to ensure IEC 61850-3 and IEEE 1613 Class 1 conformance. This means that
during the transient event communications errors or interru tions may occur but recovery is
automatic.

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RuggedCom also does not recommended to use these orts to interface to field devices across
distances which could roduce high levels of ground otential rise, (i.e. greater than 2500V) during
line to ground fault conditions.
4.2 Fiber Optic Ethernet Ports
De ending on the order code of the roduct, the RS910 can be equi ed with several different
fiber o tic orts. The Transmit (Tx) and Receive (Rx) connections of each ort must be ro erly
connected and matched for ro er link and o eration. The drawings in the following figures show
each fiber o tical connector style with a side and to view to allow the user to identify the ro er
cable connection orientation.
Figure 14: 1 FL ST connector
Figure 15: 1 FX MTRJ connector
Figure 16: 1 FX ST connector
Figure 17: 1 FX LC connector
Figure 18: 1 FX SC connector
4.3 Ethernet Panel Description
Each Ethernet and Serial ort, excluding RJ45 Ethernet on ort 9, is equi ed with one LED that
indicates link/activity status information. The LED will be solid for orts with link, and will blink for
activity. The diagram in Figure 19 highlights the ort and the associated link/activity LED. RJ45
Ethernet ort on ort 9 consists of two LEDs and the table below shows the LED descri tion.

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Figure 19: Ethernet panel LED description
Status LED Colour Activity Comments
Off 10 Mb s
S eed LED Yellow On 100 Mb s
Solid Link Established
Link LED Yellow Blinking Tx/Rx Activity
Table 3 – RJ45 Ethernet port 9 LED description