Talgil DREAM 2 User manual

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TALGIL COMPUTING & CONTROL LTD.
NAAMAN CENTER, HAIFA - ACCO ROAD
ISRAEL
P.O. BOX 775 KIRYAT MOTZKIN 26119
TEL: [phone]
FAX: [phone]
2007
DREAM 2 WIRED
RTU SYSTEM
GUIDE

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CONTENTS
1. SYSTEM OVERVIEW...............................................................................................................3
1.1 THE PARTS OF THE SYSTEM AND THEIR FUNCTION.......................................................3
2. INSTALLATION DIRECTIONS..................................................................................................4
2.1 CABLE TESTING....................................................................................................................4
2.2 GROUND CONNECTIONS......................................................................................................4
2.3 SETTING THE ADDRESSES..................................................................................................4
2.4 DEFINITIONS TO BE MADE INSIDE THE DREAM................................................................5
2.4.1 DECLARING THE 2W RTU INTERFACE....................................................................5
2.4.2 DEFINING THE CONNECTIONS ...............................................................................5
2.4.3 CHECKING COMMUNICATION WITH THE RTUs.......................................................6
3. THE VARIOUS TYPES OF RTU UNITS .....................................................................................6
3.1 MODULAR RTUS....................................................................................................................6
3.1.1 SETTING THE ADDRESSES OF THE DIGITAL AND ANALOG INPUTS .......................7
3.1.2 SETTING THE JUMPERS OF THE ANALOG “PLUG-IN” BOARD .................................7
3.1.3 THE LEDS AND THE BUZZER INDICATIONS ............................................................8
3.1.4 TESTING INPUTS AND OUTPUTS OF THE MODULAR RTU ......................................8
3.2 COMPACT RTUS....................................................................................................................9
3.2.1 THE LEDS AND THE BUZZER INDICATIONS .......................................................... 10
3.2.2 TESTING INPUTS AND OUTPUTS OF THE COMPACT RTU .................................... 10
3.2.3 SELECTING THE DESIRED ANALOG INPUT TYPE .................................................10
Appendix "A" –DECIMAL TO BINARY CONVERTION.................................................................11
Appendix "B" –ABOUT THE CABLE.......................................................................................... 12
Appendix "C" –TESTING PROCEDURE ..................................................................................... 13
Appendix "D" –MULTIPLE INTERFACES WIRING...................................................................... 14

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DREAM
Interface
2W
RTU
RTU
7
RTU
8
RTU
1
RTU
13
RTU
15
RTU
9
RTU
10
RTU
2
RTU
3
RTU
11
RTU
12
RTU
5
RTU
6
RTU
4
RTU
14
Charger
Battery
+ -
RS485
Remote
I/O
2 wired RTU line
the charger can be
replaced by a
solar panel
THE TWO WIRED SINGLE CABLE SYSTEM OF
THE DREAM
1. SYSTEM OVERVIEW
The DREAM TWO WIRED SINGLE CABLE SYSTEM utilizes Remote Terminal Units for
connecting remote valves and distant meters to the control system covering territories of up to
10 Km radius by use of 2 wired cables.
The Remote Terminal Units (RTU) have the ability to communicate with the DREAM, to carry
out the received commands and to report back the status of the meters connected to them.
The 2 wired line may handle as many as 60 RTUs. There are two types of RTUs: the
MODULAR RTUs and the COMPACT RTUs.
Each MODULAR RTU can handle up to 8 outputs (in steps of 2,4,6,8),and up to 8 digital
inputs (in steps of 4,8) . Each COMPACT RTU may have 0,1 or 2 outputs and 0,1 or 2 inputs
The outputs activate 2 wired 12v DC pulse latching solenoids. The inputs are dry contacts.
The system is a DC system designed for low power consumption and may be powered by
solar energy.
One DREAM may handle several single cable channels, each channel may contain up to 60
RTUs all of them will be scanned second by second.
1.1 THE PARTS OF THE SYSTEM AND THEIR FUNCTION
The heart of the system is the DREAM control unit that controls the whole system. The two-
wired RTU system is connected to the DREAM by a special interface called 2W RTU
INTERFACE which will be connected through the REMOTE I/O serial communication line
(RS485). The 2W RTU INTERFACE handles both the communication and the energy supply
to all the RTU units. The 2 wired line between the interface and the RTU units goes like
branches of a tree whose root is at the interface and the leaves are the RTUs.
The whole system can be powered either from the mains or by a 20 Watt solar panel using a
rechargeable car battery of 40 Ah or more, for backup. However when the DREAM contains
more than one 2W RTU channel ( more than one 2W interface), the additional 2W channels
will have their own separate power supply/charger and another car battery of 40 Ah or more.
The system will usually have a lightning protection unit installed close to the 2W interface.
When the area is known to be lightning prone, more protection units may be installed in the
field.

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2. INSTALLATION DIRECTIONS
Wiring must be done while the system is not energized. Remember to
disconnect both the charger/solar- panel and the rechargeable battery.
2.1 CABLE TESTING
Prior to connecting the 2 wired line to the RTUs and to the DREAM they must be checked
as explained in appendix "B".
The following picture shows in details the wiring between the various parts of the system.
In case of multiple 2 wired channels connected to the same Dream, special wiring is
required see appendix "D"
2.2 GROUND CONNECTIONS
Inside the "2W RTU interface", inside the "lightning protection" and in each "RTU" there
are grounding points which have to be well "grounded" otherwise the lightning protection
will not function properly. The resistance to the ground should not exceed 4 ohms.
2.3 SETTING THE ADDRESSES
In order for the DREAM to be able to differentiate between the "2W RTU interface" and
the other I/O interfaces that may exist in the system, each interface must be given a
The polarity is
important !!
The polarity is
important !!

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unique address and in order for the "2W RTU interface" to be able to differentiate
between the various RTUs, each RTU must have it's own address. So each output and
input in the 2 wired system will have it's location defined by 3 numbers: II;RR;L –"II" is the
address of the interface, "RR" is the address of the RTU and "L" is the location of the
specific output or input in the terminal block of the actual RTU. The addressing is done
by dipswitches onboard the interface and onboard each RTU. The range of the RTU
addresses is 1-60. The following drawing demonstrates the dipswitches block used for
addressing the RTUs:
The micro switches are numbered 1 to 6. Each micro switch according to it's ordinal number
represents a value between 1 and 32 as shown above. The values are used in the binary
coding system. The address is calculated by summing up the values of the micro switches
that are in the ON position. Appendix "A" supplies a conversion table from binary to decimal
and shows the setting of the switches required for each address.
2.4 DEFINITIONS TO BE MADE INSIDE THE DREAM
2.4.1 DECLARING THE 2W RTU INTERFACE
During system configuration the DREAM has to be told about the 2W RTU interface that is
connected to its "Remote I/O" line. This is done during the HARDWARE DEFINITION as
shown below:
2.4.2 DEFINING THE CONNECTIONS
During the definition of the physical connection point of each output and each input device,
the DREAM is told which of them reside on the 2W RTUs and where exactly each of them is
connected. An example can be seen below:
All outputs that have the interface
address "3" reside on the 2W RTUs.
Taking for example the Main valve No.
4, it has to be connected to RTU 7
position 1. A more detailed explanation
of this step can be found in the
"INSTALLATION MANUAL" of the
DREAM.
It is strongly recommended not to include in the connections definition
references to nonexistent RTUs. Otherwise each second the DREAM will try
to communicate the nonexistent units and when not receiving answer, it
will try again, causing all other units to wake up unnecessarily, this is a
significant waste of energy.
1 2 3 4 5 6
ON
1 2 4 8 16 32
The value represented
by each micro switch
Declaring
the 2W
interface
The
address of
the 2W
interface
Address of
Interface (II)
Number of
RTU (RR)
Location on
the board (L)

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2.4.3 CHECKING COMMUNICATION WITH THE RTUs
The fifth screen to the right in the subject of "CURRENT STATUS" shows the quality of
communication with each of the 2W RTUs. An RTU with communication problem will be
underlined.
3. THE VARIOUS TYPES OF RTU UNITS
There are two kinds of RTU units for the 2 wired single cable system, there are modular RTUs
and compact RTUs. The following paragraphs describe both types.
3.1 MODULAR RTUS
The modular RTUs can handle up to 8 outputs and 8
digital inputs. The outputs are built of "plug in" modules
with 2 outputs each, there can be up to 4 modules per
RTU, therefore the units may come with 0, 2, 4 6 or 8
outputs.
The digital inputs are built of "plug in" modules of 4 inputs,
there can be up to 2 modules per RTU, and therefore we
may have RTUs with 0, 4 or 8 digital inputs.
The address of the 2W RTU
interface
There are 17 RTUs. No
16,17 not responding
The sound of the buzzer
of the RTUs can be
turned ON or OFF.
Activates a counter of communication
errors per each RTU
Reset
button
Address
switches
SW4 - I/O
selection
for test
SW3-Test
triggering
4 digital
input
module
2 outputs
module
Socket of
outputs
module
The 2 wired line
connection point
To be
grounded
4 inputs
"plug in"
module
2 outputs
"plug in"
module
Socket of
Inputs
module
Sockets of
Inputs
module
Sockets of
outputs
module

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The system can handle analog inputs as well. There are "plug in" modules of 2 analog inputs that
can be used in place of each module of 4 digital inputs, using the same sockets. Therefore, each
analog inputs module reduces the number of left digital inputs of that RTU by 4.
Analog inputs
Possible digital inputs
0
Up to 8
1 or 2
Up to 4
3 or 4
0
3.1.1 SETTING THE ADDRESSES OF THE DIGITAL AND ANALOG INPUTS
We shall now explain how to decide about the addresses of the digital and analog inputs. Let
us assume a modular RTU whose address is "N".
When there are only digital inputs they will be numbered as follows:
Input No.
of RTU No.
1
N
2
N
3
N
4
N
5
N
6
N
7
N
8
N
When there are both digital (up to 4) and analog (up to 2) inputs, the digital inputs will
be numerated as above but the analog inputs will occupy the addresses following
RTU “N” as follows:
Analog input
Will be known as input No.
of RTU No.
1
1
N+1
2
1
N+2
When there are only analog inputs
Analog input
Will be known as input No.
of RTU No.
1
1
N
2
1
N+1
3
1
N+2
4
1
N+3
Notice that the addresses N+1, N+2, N+3 which became occupied by the
analog inputs cannot be used for addressing other RTUs, they must be
skipped.
3.1.2 SETTING THE JUMPERS OF THE ANALOG “PLUG-IN” BOARD
On the analog "plug in" board there are 3 jumpers which are used for deciding the followings:
Jumper No.
When removed indicates
When inserted
1
1 analog input in use
2 analog inputs in use
2
First input uses 4-20 mA
First input uses 0-2.5 v
3
Second input uses 4-20 mA
Second input uses 0-2.5 v

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3.1.3 THE LEDS AND THE BUZZER INDICATIONS
Green LED blinking slowly - After resetting the RTU, there is a delay before
starting the capacitor charging. The delay
depends on the RTUs address, and it is calculated
by the RTU's address multiplied by 2. During the
delay, there will be slow blinking of the green led.
Green LED blinking fast  - The fast blinking exists during the charging of the
capacitor.
Usually the charging takes a few seconds, but if it
keeps going on for 10 minutes it indicates a
problem. The charging stops and the unit
disconnects itself from the communication. Both
the green and the red LEDs will be switched off.
The only way to exit this status is by resetting the
RTU.
Red LED blinking each second - Indicates that the RTU recognizes being called by
it's address and it is responding.
The buzzer when enabled from the center, sounds a double beep  every 5 seconds
indicating normal operation. Otherwise, there will be a long beep every 5 seconds. During
output test mode, there is a short beep for "open" and 2 short beeps for "close" commands.
3.1.4 TESTING INPUTS AND OUTPUTS OF THE MODULAR RTU
The inputs and outputs are tested one by one. The number of the input and output to be tested is
selected by dipswitch block SW4 as follows:
SW4
Input/Output under test
000
1
100
2
010
3
110
4
001
5
101
6
011
7
111
8
INPUT TEST –The test begins by pushing the button SW3. Each change in the status of the selected
input will be indicated by a short beep of the buzzer.
OUTPUT TEST –While being in INPUT TEST, push SW3 again, this will terminate the INPUT TEST
and will start the OUTPUT TEST. An "open" command will be sent to the selected output followed by a
single beep . Another push of SW3 generates a "close" command followed by a double beep .
Each push of SW3 will switch the solenoid between "open" and "close" positions.
To exit test mode change the position of SW4 or wait 1 minute and it will exit automatically.

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3.2 COMPACT RTUS
The compact RTUs can handle up to 2 outputs and 2 digital inputs or alternatively 1 analog
input can be requested in place of the two digital ones.
I/O test
The compact RTU does not have an address
switch; the address is set by communication
using special utility software and a special
communication interface as shown in the
following pictures.
The screen of the utility software includes
additional information about the RTU
including the number of available outputs
and inputs (analog or digital), the pulse
width and amplitude generated for opening
and closing solenoids, special parameters
defining the behavior of the unit in various
cases and tools for testing outputs, inputs,
push buttons, and the buzzer.
Reset
button
I/O test
button
Connection
point for the
2 wired line
Outputs
terminal
Digital
inputs
terminal
Analog
inputs
terminal
Jumper JP7
for
4-20 mA.
Plug for
communication
with the utility
software
I/O test
buttons

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3.2.1 THE LEDS AND THE BUZZER INDICATIONS
The LEDs and the buzzer indications of the compact RTU are similar to the modular RTU.
However there is a special ticking sound that can only be heard in the compact RTU which
has digital inputs defined.
3.2.2 TESTING INPUTS AND OUTPUTS OF THE COMPACT RTU
The unit is equipped with tools for testing the inputs and outputs under field conditions. There
are 2 I/O test buttons, when number 1 is pushed the first input and output are tested, when
number 2 is pushed the second input and output are tested.
INPUT TEST –The test begins by pushing the appropriate test button and it is indicated by a
long beep . Each change in the status of the selected input will generate a short beep of
the buzzer .
OUTPUT TEST –While being in INPUT TEST, push the appropriate test button again, this will terminate
the INPUT TEST and will start the OUTPUT TEST. An "open" command will be sent to the selected
output followed by a single beep . Another push of the test button generates a "close"
command followed by a double beep .
Each push of the appropriate test button will switch the solenoid between "open" and "close"
positions.
The system will exit test mode and return to normal activity after 60 seconds without touching
the buttons.
3.2.3 SELECTING THE DESIRED ANALOG INPUT TYPE
The system can handle analog inputs of 4-20 mA or 0-2.5 volts. Next to the terminal block
there is a jumper JP7 that when inserted as shown in the picture above makes the analog
input to accept 4-20 mA signals. When the jumper is removed the accepted signal will be 0-
2.5 v
3.3 TECHNICAL INFORMATION
The 2W interface
Power supply
12v DC 2.5 A
Minimal supply voltage
10.5v DC
Load free consumption
115-120 mA
Consumption contributed by each RTU
1.5 - 2.2 mA
Output voltage***
36v DC***
Main fuse
8A
Line fuses
2 x 1A
The 2W RTU
Typical supply voltage***
36v DC***
Minimal supply voltage***
20v DC***
Consumption measured by 2W tester
Test voltage 8v DC
14v DC
36v DC
Compact RTU
Economical RTU
0 mA
0 mA
-
0.75 mA
0.5 mA
0.75 mA
Output voltage
12-17v DC latch –pulse width 70 ms
Digital inputs
Dry contact
Analog inputs
4-20 mA or 0-2.5v externally energized
*** in normal operation mode the output voltage of the 2W interface is varying in a high
frequency and can not be measured by regular volt meters. The output voltage of 36v DC can
only measured under special test mode. To put the 2W interface in special test mode, set the
address switch to 000000 and press the RESET button.

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Appendix "A" –DECIMAL TO BINARY CONVERTION
In the following table a switch ON is marked by 1 and a switch OFF by 0.
Decimal address
Binary value set by the Dip Switch
Positions: 1 2 3 4 5 6
1
1 0 0 0 0 0
2
0 1 0 0 0 0
3
1 1 0 0 0 0
4
0 0 1 0 0 0
5
1 0 1 0 0 0
6
0 1 1 0 0 0
7
1 1 1 0 0 0
8
0 0 0 1 0 0
9
1 0 0 1 0 0
10
0 1 0 1 0 0
11
1 1 0 1 0 0
12
0 0 1 1 0 0
13
1 0 1 1 0 0
14
0 1 1 1 0 0
15
1 1 1 1 0 0
16
0 0 0 0 1 0
17
1 0 0 0 1 0
18
0 1 0 0 1 0
19
1 1 0 0 1 0
20
0 0 1 0 1 0
21
1 0 1 0 1 0
22
0 1 1 0 1 0
23
1 1 1 0 1 0
24
0 0 0 1 1 0
25
1 0 0 1 1 0
26
0 1 0 1 1 0
27
1 1 0 1 1 0
28
0 0 1 1 1 0
29
1 0 1 1 1 0
30
0 1 1 1 1 0
31
1 1 1 1 1 0
32
0 0 0 0 0 1
33
1 0 0 0 0 1
34
0 1 0 0 0 1
35
1 1 0 0 0 1
36
0 0 1 0 0 1
37
1 0 1 0 0 1
38
0 1 1 0 0 1
39
1 1 1 0 0 1
40
0 0 0 1 0 1
41
1 0 0 1 0 1
42
0 1 0 1 0 1
43
1 1 0 1 0 1
44
0 0 1 1 0 1
45
1 0 1 1 0 1
46
0 1 1 1 0 1
47
1 1 1 1 0 1
48
0 0 0 0 1 1
49
1 0 0 0 1 1
50
0 1 0 0 1 1
51
1 1 0 0 1 1
52
0 0 1 0 1 1
53
1 0 1 0 1 1
54
0 1 1 0 1 1
55
1 1 1 0 1 1
56
0 0 0 1 1 1
57
1 0 0 1 1 1
58
0 1 0 1 1 1
59
1 1 0 1 1 1
60
0 0 1 1 1 1

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Appendix "B" –ABOUT THE CABLE
ABOUT THE CABLE TO BE USED
Recommendations for the cable to be used with the 2 wired systems:
Never mix in one cable two lines of separate 2w channels.
Never mix in the same cable a 2 wired channel and an RS485 communication line.
Always maintain a distance of at least 20 cm between the cables of different 2W
channels and RS485 when laid in the ground.
The cable should be type NYY, which is double, coated and is suitable for being laid
underground.
Thickness 1.5 mm2
The cable capacity is of great importance, the lower the better. A capacity of 0.1 µF
per km is OK. The total capacity of the cables connected to the "interface 2W" should
not exceed 1 µF.
The resistance of the cable should be reasonably low, with no leakage between the
wires and between each wire to the ground. (see testing below).
The cable used for the "2 wired" system should not be used for other purposes such
as communication between the DREAM and other interfaces or between the DREAM
and the PC.
CABLE RESISTANCE TESTING
1. The cable must be tested for continuity of its wires, and for having good isolation
between the wires and between each wire and the ground.
2. Disconnect both ends of the cable under test (including from any RTU in the middle)
and make sure the wires are not touching each other.
3. Check the resistance between the wires. Use the highest range available on the
ohmmeter (tens or hundreds of KΩ). The resistance should be infinite or at least not
lower than 1 MΩ.
4. Check the resistance between each wire to the ground Use the highest range
available on the ohmmeter (tens or hundreds of KΩ). The resistance should be
infinite or at least not lower than 1 MΩ.
5. Make a short circuit between the wires at one end of the cable and test the resistance
between the wires at the other end. This time use the lowest range of your ohmmeter
(tens or hundreds of Ω). The resistance between a pair of wires increases with the
length of the wires and decreases with their thickness. For 1 Km distance and with a
pair of wires with 1.5 mm2cross section the resistance should be about 22Ω. The
formula for calculating the expected resistance of a pair of copper wires is the
following:
Resistance (in Ω) = 0.017 x Length (in meters)
Cross section (in mm2)

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Appendix "C" –TESTING PROCEDURE
TESTING PROCEDURE OF THE 2W SYSTEM
The 2W interface has three main functions:
1. Supplying energy to all the RTUs in the system.
2. Scanning all the RTUs second by second.
3. Exchanging information with the DREAM second by second.
The 2 wired cable originating from the 2W interface and arriving to all the RTUs, carries both
the energy and the communication to the RTUs. Due to the variable nature of the signal
carried by the 2W line, it cannot be measured by a voltmeter, not as a DC voltage and not as
an AC voltage. The testing procedure described herewith helps us to overcome this obstacle
and enables us to differentiate between a normal system and a system with problems.
Putting the 2W interface into SPECIAL TEST MODE: set the address switch of the
interface to 000000 and press the RESET button of the interface. As a result the red led
indicating the communication between the DREAM and the interface stops blinking and
remains constantly ON.
Checking the supply voltage: test the supply of 12v DC to the interface.
Checking the output voltage of the interface: check the existence of 36v DC at the
terminals where the 2 wired line is connected to the interface.
Measuring the “load free” consumption of the interface: disconnect the 2 wired line from
the interface. Connect an Ampere meter in the range of 200 or 500 mA between the positive
12v wire feeding the system and the +12v terminal on the interface board where the wire is
supposed to be connected. This way we are measuring the consumption of the interface
itself. It should be around 115-120 mA.
Measuring the contribution of the cable to the consumption of the interface: unplug all
the RTUs from the 2 wired line and reconnect the 2 wired line back to the interface. At this
stage the measured consumption of the interface may increase due to possible leakage of the
cable. The consumption contributed by the cable depends on it’s length, thickness of the
wires and the quality of the coating of the wires. Up to 20-30 mA may be considered
reasonable.
Measuring the contribution of the RTUs to the consumption of the interface: The
contribution of each RTU to the consumption of the interface should be about 1.5-2.2 mA.
Plug the RTUs back to the 2 wired line one by one and make sure that the consumption
grows by 2.2 x N, where N represents the number of RTUs in the system. If the consumption
is significantly higher it means that some of the RTUs are consuming too much.
Measuring the consumption of the RTUs in the field: the consumption of each RTU can
be measured in the field by the “2W tester” or by a regular Ampere meter. For measuring by
the tester, see the instructions of the tester’s manual. For measuring by an Ampere meter,
the interface 2W must be in “SPECIAL TEST MODE” (see above), in this case the interface is
feeding the line with 36v DC. However a voltage drop along the cable down to 20v DC is still
acceptable. The individual consumption of the RTU can be measured by inserting the Ampere
meter (range of 10-20 mA) in series with one of the 2W wires. A normal result will be 0.75 mA
for the modular RTU and 0.5 mA for the compact RTU.
Exiting SPECIAL TEST MODE : In order to return to normal operation mode set the address
switch of the 2w interface to it’s correct address and push it’s RESET button. As a result the
red led indicating the communication between the DREAM and the interface will start blinking,
a short blink each second.


Remote
P2N2
DREAM ++2W
P.S. AC/DC
P.S. ++
P N +12 V-
+12 V-
Rechargable
battery
12V
7 Ah 12V
P N +12 V-
+12 V-
Rechargable
battery
12V
7 Ah 12V
Int 2W.
P N +12 V-
Rechargable
battery
12V
7 Ah 12V
+12V-
Int 2W.
N1
N1 N2
P.S. ++ Int 2W.
N2 N3
Wiring of a DREAM system which is powered by AC and which contains
multiple 2 wired interfaces
PN P N
+12 V-
To DR .
Remote I/OTo Int .2 W
Repeater
PN P N
+12 V-
To DR .
Remote I/OTo Int .2 W
Repeater
Appendix "D" –MULTIPLE INTERFACES WIRING