DATRAN XL4 PLUS RTU USER GUIDE. Version 02

Transcription

1 DATRAN XL4 PLUS RTU USER GUIDE DATRAN XL4 PLUS RTU Version 02

2 Table of Contents DATRAN XL4 PLUS RTU... 1 Table of Contents... 2 Introduction... 4 Comparison to QTech XL4 RTU...4 Intended Audience...4 What s in this document...4 Hardware Features... 6 Front Panel...6 Side Panel...7 Configuration... 8 Precautions and Notes...8 Processor Board Configuration...9 Configuration Jumper Summary... 9 Module Address... 9 Real Time Clock System Reset Factory Default Status LEDs Q22 I/O Board Configuration Configuration Jumper Summary Power Supply /24V operation Auto Low Voltage Detection Programmable Low Battery Detection Internal Fuse Auxiliary Equipment power control Typical Power Supply Wiring I/O System Configuration System Status LEDs Communication Port Configuration RS485 Port RS232 Ports CNFG Port Ethernet Port USB Host Port Digital Inputs Digital Outputs Analog Inputs and Outputs Status LEDs Jumper Settings Analog Single Ended Input Analog Differential Input Analog Single Ended Output Device Specifications Communication Protocols Firmware Upgrade Process Upgrading the firmware from Q Reverting to Q04 firmware Upgrading RTU firmware that is already running Q04 Plus User Notes

3 Copyright 2017 to QTech Data Systems Limited Christchurch, New Zealand All rights reserved The circuit details and know how disclosed in this document are proprietary to QTech Data Systems Limited and shall remain the intellectual property of QTech Data Systems Limited. DISCLAIMER The information in this document is subject to change without notice and does not represent a commitment on any part of QTech Data Systems Limited. While the information contained herein is assumed to be accurate, QTech Data Systems Limited assumes no responsibility for any errors or omissions. Contact QTech Data Systems Limited 12 Midas Place, Middleton Christchurch 8024 New Zealand Phone: Fax: Revision History 01 November 2017 Initial Issue 02 September 2018 Added Firmware upgrade process, revised graphics. Fix to jumper settings for 4-20 ma operation updated error indicator meanings WARRANTY AND LIABILITY This document, the products described herein and all QTech products in general, are all subject to the terms and conditions of business made by QTech Data Systems Limited. For a copy of the company s terms and conditions including warranty policies please contact QTech. 3

4 Introduction The DATRAN XL4 Plus RTU comprises Q04 ARM processor with a Q22 IO board running Q04 Plus firmware, a real-time operating system (RTOS). It has a file-system configured for 8MB Flash memory, which is used for application and data storage. It is compatible with the QTech Workbench (2.0 or greater) configuration utility, QTech DLP Integrated Development Environment (IDE) and QTech s DATRAN VI SCADA software. The full datasheet for this product can be downloaded from the QTech Web site. Comparison to QTech XL4 RTU The DATRAN XL4 Plus RTU is a hardware and firmware upgrade of the DATRAN XL4 RTU. The flash memory in the XL4 Plus has increased to 8 MB from 4MB in the XL4. However, XL4 units can be upgraded to run the XL4 Plus firmware (Q04 Plus), without needing to modify hardware. The XL4 Plus RTU supersedes the XL4 RTU product. The XL4 Plus RTU is functionally backwards compatible with the XL4 RTU with a few exceptions notably: third party devices such as the MOXA interface are no longer required, the firmware upgrade programming procedure has changed, with the addition of a bootloader application to the XL4 Plus various methods such as module licensing have been simplified and improved. Please refer to the QTech application note: Guide to porting XL4 to XL4Plus for additional differences between the two products The XL4 Plus RTU has the same dimensions as the XL4 RTU and is therefore a drop-in replacement for the XL4 RTU. All connections and power requirements remain the same. Intended Audience This guide serves as an installation and reference guide for the XL4 Plus hardware. Users are also referred to the QTech Workbench User guide for information on configuring the software functionality of the device. This guide assumes that you have been trained as an Integrator/Installer and are familiar with QTech Data Systems Ltd (QTech) RTU products, their installation, and their terminology. What s in this document Throughout this document RTU is used to refer to a DATRAN XL4 Plus RTU or a DATRAN XL4 that has been upgraded to run the Q04 Plus firmware. This manual contains the following sections: An Introduction section describes the features of this model and introduces the interface elements. A Configuration section for the processor and I/O, board which describes hardware settings to apply during installation, for the various supported communication protocols and physical ports. A description of the power supply requirements for installation. A Configuration section describes in detail the input/output settings and communications port wiring requirements. 4

5 A summary of the supported device types that can be connected to the RTU. Firmware Upgrade procedures. The Reader should also refer to these additional sources of information: The DATRAN XL4 Plus RTU Quick Start Guide. The QTech Workbench User Guide version 2.0 or greater. Relevant application notes to provide guidance for specific configuration scenarios, detailing the configuration workflow steps. These can be obtained from the QTech web site. Additional information is available at 5

6 Hardware Features This section describes the layout of the Channels and ports on the XL4 Plus RTU. A typical RTU comprises two boards: a) Processor board b) Q22 I/O board. Please refer to the sections below for details on how to interpret, setup or connect each interface. Front Panel A B C D Feature A B C D Function Digital Outputs - 1-4, with status indicators lit when output goes low - +, 2 positions connected to supply for driving relays Digital Inputs - 1-8, with status indicators lit when input goes low. - G, 1 position connected to RTU ground. 8 System Led Indicators Analog Inputs/Outputs - 1-4, analog inputs only - 5,6 can be configured as inputs or outputs - +, 2 positions connected to RTU supply. - G, 1 position connected to RTU ground. 6

7 Side Panel E F G H I J K L Feature E F G H I J K L Function USB type A Host Port for peripherals RS232-B - serial port used for specialised communication devices and peripherals. ETH - 10/100 MBit Ethernet port for Base Station and/or peripheral communications. CNFG - USB 2.0 type B for configuration, diagnostics, data/program and firmware exchange. Digital Outputs - 5-8, with status indicators lit when output goes low - +, 2 positions connected to supply for driving relays RS232-A - serial port used for specialised communication devices and peripherals. PWR - the power input (DC) connector and power control signal for auxiliary equipment - -V, Power Supply Negative - +V, Power Supply Positive, V - O/P, Control Signal Output. This allows the RTU to turn on devices when it is powered up. This was previously labelled C on older excel RTUs. RS485 - for Modbus or inter-module long distance, high speed communications 7

8 Configuration Precautions and Notes Power should be removed from the XL4 Plus by removing the power connector before setting up and making any adjustments to the processor or I/O PCB. Both PCB s incorporate static discharge sensitive devices. Normal Anti-Static Discharge precautions should be employed when setting up and making any adjustments. An anti-static wristband should be worn and the earth connection of this wristband should be connected to the terminal marked EARTH on the Q04 Plus Processor PCB or the Q22 I/O PCB. When re-installing the Q04 Plus Processor onto the associated motherboard, check to ensure that the Q04 Plus Processor is correctly seated on the motherboard s connectors. Make sure that the connectors are not misaligned. QTech Workbench software may be required in order to finalise the configuration of a port or channel. Tip: It is recommended that installers are equipped with a Laptop PC running Microsoft Windows and installed with QTech workbench, plus a Type A-B USB cable in order to configure additional RTU settings for example, communications protocols and RTU module address. In the jumper diagrams, the square pad on each jumper header is pin No 1. The pins are numbered 1, 2, and 3 away from pin 1. The jumper shorting links will only fit onto the jumper pins one way. Always check that they are seated properly. A jumper is closed when a jumper shorting link is installed on the jumper. A jumper is open when a jumper shorting link is removed/not installed. A two-way jumper has three pins so that the jumper shorting link can be installed one of two ways. Unused or open jumper shorting links may be installed on only one pin of the jumper Tip: A pair of fine pointed nosed pliers or tweezers can be used to remove and install the jumper shorting links. 8

9 Processor Board Configuration Various jumpers may be required to be fitted when installing the XL4 Plus RTU. The diagrams below show a photo and layout of the Q04 ARM Processor and can be used to locate and identify the various parts and jumpers detailed in the following sections. Processor layout Jumper and component positions Configuration Jumper Summary The following list describes the function of each of the configuration jumpers on the processor board: Jumper Function INIT When closed, this jumper will cause the RTU to execute power-up procedures depending on the state of the digital inputs. The jumper is normally open, and should be returned to the open position after performing a power up procedure. Contact QTech for application notes on the use of power-up procedures. 485TERM Close jumper A to provide a 120 ohm termination to the RS485 lines. Jumper B should not be installed and is provided for future RS422 termination options. BAT When open, this disables the real-time clock battery backup function. This allows the battery to be disconnected and preserved during long term storage of the module. This jumper is closed for normal operation, open for long term storage. ISP These jumpers are normally open. They must be closed when upgrading the bootloader firmware through the QTech Workshop software. The jumpers must then be opened again once the firmware update is completed. Contact QTech for a copy of the firmware upgrade application note. DEBUG This jumper is only used by QTech developers when developing software for the board. Important: powering up the unit with the INIT jumper fitted and with a digital input wiring harness in place may render the unit inoperable. To avoid this never connect a wiring harness to the unit whilst the INIT jumper is fitted. Module Address The Q04 Plus Address must be set using QTech Workbench. 9

10 Real Time Clock The real-time clock chip provides system day of the week, day of month, month, year, time in 12 or 24 hours format and am/pm. The real-time clock is battery backed up to maintain its operation during power down. A jumper labelled BAT on the module is provided to disable the real-time clock battery backup function. This allows the battery to be disconnected and preserved during long term storage of the module. This jumper is closed for normal operation, open for long term storage. System Reset The system reset circuitry ensures proper and reliable operation of the processor during power failure and power brown-outs. The Q04 ARM Processor does not include an externally accessible reset switch. If the module needs to be manually reset, simply remove the power for a few seconds and then reconnect it. Factory Default From time to time it may be necessary for you to reset the XL4 Plus back to factory defaults. There are two ways of doing this: 1. The factory default settings can be loaded back into the RTU using the Factory Default button in Q04 Plus Workbench. 2. There is a jumper on the RTU main processor board labelled INIT. It is normally open, but if the RTU is started up while the jumper is installed it will cause the RTU to restore the factory default settings. Use this method only if instructed to do so by QTech Staff. Important: The i/o connectors for the RTU must be disconnected prior to setting factory defaults. It is very important to remove the INIT jumper before reconnecting the connectors. Important immediately after rebooting or powering up the RTU the device will perform a file consistency check which may take up to 30s. Attempts to write configuration data to the RTU in this time will fail and the user should wait until the device is ready before updating the RTU configuration (this will be communicated by workbench). Status LEDs The status of the Q04 Plus is displayed on 5 LEDs on the top left of the PCB (they are not visible when the XL4 Plus case is in place). They can be used for diagnostic purposes during installation. The function of these LEDs is detailed below: Indicator PWR OK MSG A1 B1 Function This is a blue LED that shows that power is applied to the Q04 Plus. This is a green LED that shows the status of the central processing unit. The LED blinks slowly when the CPU is functioning correctly. The LED blinks 6 times quickly whenever a system reset has occurred. Any other condition of this LED indicates a malfunction of the CPU. This orange LED is unused. This orange LED is unused. This orange LED is unused. 10

11 Q22 I/O Board Configuration Various jumpers may be required to be fitted when configuring the I/O for the RTU. The diagrams below show a photo and layout of the DATRAN XL4 I/O board (Q22, revision D) and can be used to locate and identify the various parts and jumpers detailed in the following sections. Q22 I/O Board layout Jumper and component positions Configuration Jumper Summary The following list describes the function of each of the configuration jumpers on the Q22 I/O board: Jumper Function J1 This jumper selects the output voltage range for Analog output channel No. 6. Open is 0 to 5V/0 to 20mA output range whilst Closed is 0 to 10V output range. J2 This jumper selects the output voltage range for Analog output channel No 5. Open is 0 to 5V/0 to 20mA output range whilst Closed is 0 to 10V output range. J3 This 2-way jumper selects the output mode of Analog output channel No 6. Pins 1 & 2 closed is current output mode whilst 2 & 3 closed is voltage output mode. J4 This 2-way jumper selects the output mode of Analog output channel No 5. Pins 1 & 2 closed is current output mode whilst 2 & 3 closed is the voltage output mode. J5 This 2-way jumper selects the single ended input range of Analog input channel No. 2. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. J6 This 2-way jumper selects the single ended input mode of Analog input channel No. 2. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J7 This 2-way jumper selects the single ended input range of Analog input channel No. 1. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. J8 This 2-way jumper selects the single ended input mode of Analog input channel No. 1. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J9 This 2-way jumper selects the single ended input range of Analog input channel No. 3. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. J10 This 2-way jumper selects the single ended input mode of Analog input channel No. 3. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J11 This 2-way jumper selects the single ended input range of Analog input channel No. 4. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. 11

12 J12 This 2-way jumper selects the single ended input mode of Analog input channel No. 4. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J13 This 2-way jumper selects the single ended input range of Analog input channel No. 5. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. J14 This 2-way jumper selects the single ended input mode of Analog input channel No. 5. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J15 This 2-way jumper selects the single ended input range of Analog input channel No. 6. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. J16 This 2-way jumper selects the single ended input mode of Analog input channel No. 6. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. J17 This 2-way jumper selects the input mode of Analog input channels No s 1 & 2. Pins 1 & 2 closed is one differential input channel. Pins 2 & 3 closed is two single ended input channels. J18 This 2-way jumper selects the input mode of Analog input channels No s 3 & 4. Pins 1 & 2 closed is one differential input channel. Pins 2 & 3 closed is two single ended input channels. J19 This 2-way jumper selects the input/output mode of Analog channel 5. Pins 1 & 2 closed is output mode, whilst 2 & 3 closed is input mode. J20 This 2-way jumper selects the input/output mode of Analog channel 6. Pins 1 & 2 closed is output mode, whilst 2 & 3 closed is input mode. J21 This jumper selects the single ended/differential input mode for Analog input channels 1 & 2. Closed is single ended input for channel 1, whilst open is differential input for channels 1 & 2. J22 This jumper selects the single ended/differential input mode for Analog input channels 3 & 4. Closed is single ended input for channel 3, whilst open is differential input for channels 3 & 4. J23 This jumper selects the function of pin 8 on the RS232 B port. Pins 1 & 2 closed, pin 8 is +V supply. Pins 2 & 3 closed, pin 8 of the RS232 B port is Ring Indicate (RI). J24 Not fitted J25 Not fitted J26 Not fitted J27 This jumper selects the module s low battery/power supply detect voltage range. Closed is 10.5V low battery detection, open is 21V low battery detection. J28 This jumper selects the digital output channels over-current mode. Closed is channel turns OFF in over-current mode, whilst open is channels goes into current limit in over-current mode. 12

13 Power Supply The RTU can be supplied from 12-28V DC (battery operation is typically 12V or 24V). The RTU is factory configured for a nominal 12V DC supply, unless otherwise requested. When configured for 12V, the RTU will automatically shut itself down when the supply voltage drops to 10.5V. Specifications for the power supply, input and output levels and operating currents are as follows: Feature Value Units Notes Input Voltage range V dc 6 input channels labelled 1 through 6 and a ground connection labelled G. Each input is individually buffered. Quiescent current 200 ma At 12V 100 ma At 24V Output overcurrent protection 2 A Max. A Plug-in 2 amp TE5 fuse located on the Q22 protects the Module against reversed supply connection, over voltage supply and transient voltages. QTech part number for replacement fuses is FS-2AMPTE5 Output current 1.5 A Available at switched positive output on the + connectors Auto Low Voltage Detection: The RTU has a low battery (supply) detection circuit which automatically turns off the internal power supply of the RTU to prevent erratic operation of the Q22 Module and to prevent the battery from being totally discharged. RTU turns OFF RTU turns ON V V For 12V system RTU turns OFF RTU turns ON Software Controlled Low Battery Alarm: Alarm activates 11.5 Alarm deactivates 12.5 Alarm activates 23 Alarm deactivates 25 Pinout Pin Function -V Ground. The negative lead of the power supply +V Positive. The positive lead of the power supply O/P The switched positive output to auxiliary equipment V V V V V V For 24V system This alarm turns ON when the battery falls and turns OFF again when the battery rises. These thresholds can be configured in the Battery tab of QTech Workbench. For 12V system For 24V system 13

14 Location of J27 for 12/24V configuration Location of Q22 2A Fuse 12/24V operation Auto Low Voltage Detection When jumper J27 is fitted, the trip voltage is 10.5V and when jumper J27 is open the trip voltage is 21V. Jumper J27 is located at the lower middle side of the Q22 as viewed with the front display panel to the right and the Q04 Plus Processor removed. The power option for the RTU, as shipped, is marked on the case label. The jumper is fitted for 12V operation and removed for 24V operation. Programmable Low Battery Detection Additionally, the RTU has a software derived low voltage alarm. This alarm turns on when the battery voltage is less than 11.5/23.0 volts and turns off when the battery voltage is greater than 12.5/25 volts for 12/24 volts power supplies respectively. The alarm status is available to the DLP and at the DATRAN Base Station (via a Variable Status Poll). Internal Fuse The fuse is located at the lower right side of the Q22 I/O board as viewed with the front display panel to the right and the Q04 Plus Processor board removed. Always use the QTech recommended replacement part (FS-2AMPTE5). Auxiliary Equipment power control The O/P pin on the power connector is internally connected to the supply but switched so that if an under-voltage is detected on the supply rail the output will deactivate. This signal can be used to power down expansion modules and auxiliary equipment. QTech Q23 and Q26 expansion modules use the C input connected to the O/P output on the RTU to detect and power down if the signal is deactivated (low). 14

15 Typical Power Supply Wiring The following is a typical DC power connection for a DATRAN XL4 Plus RTU including expansion modules and radio power supply. 15

16 I/O System Configuration System Status LEDs There are 8 System Status LED s on the front panel of the RTU. The LEDs indicate the following status information: Indicator ON OK IP MU Rx KY TX ER Function This blue LED indicates that power is applied to the RTU. If power is connected and the LED is not on this could indicate that the supply voltage is low or that the Q22 fuse has blown This green LED fades slowly on and off at a slow regular interval to indicate that the Q04 Processor is running. The LED will flash 6 times rapidly whenever a system reset occurs. System resets occur at system power up or if the watch dog timer times out. This yellow LED flashes on for approximately 0.5 seconds every time a valid communications packet is received for this module address from another module on the RS485 bus. This yellow LED turns on when the mute gate in the radio connected to the RS232-B port opens showing the radio channel is busy. The module will not transmit data when MU (mute) LED is on. This yellow LED turns on whenever a valid data carrier is detected from the RS232-B port. This yellow LED turns on whenever the modem attached radio s transmitter on the RS232-B port is requested to be turned on. This yellow LED turns on whenever the RTU is transmitting data from the RS232-B port. This red LED is used to indicate if any of the seven error conditions are present. The LED will blink a certain number of times corresponding to that error condition. The LED pulses are separated by a 2 second period allowing multiple error codes to be indicated. The following is a list of the number of error light flashes for each of the error/fault codes: 1. Main battery failure. 2. Clock battery low. 3. Communications with Base Station has failed. 4. IPB communications failure. 5. One or more real digital outputs have failed. 6. One or more analog input is out of range. 7. The DLP is not loaded or is corrupted. 8. The Modbus Serial Master communications failure 10. Modbus TCP client communications failure 11. Qcomms Serial Master communications Failure 12. Qcomms TCP server communications failure Rapid continuous flash: Indicates that the RTU is not licenced to operate any protocols. QTech must be contacted to obtain a firmware licence. Tip: The XL4 RTU and XL4 Plus RTU look similar. The XL4 RTU uses a 1 second flash to indicate OK status, The XL4 Plus RTU uses a slow fade of the same LED to give the operator a quick visual indication that the RTU is running OK on XL4 Plus firmware. 16

17 Communication Port Configuration Follow these steps to complete initial configuration of communication ports. Complete specifications of the wiring interfaces are provided in the specifications section of this document. Additional settings may be required by configuring the device with QTech Workbench. RS485 Port The RS485 port is used for inter-module and Modbus long distance, high speed communications. Configure the following: 1. Termination impedance is built-in and can be set by jumper 485TERM on the Processor board. Close jumper A to provide a 120-ohm termination to the RS485 lines. Jumper B should not be installed and is provided for future RS422 termination options. 2. RS485 applications can be configured as a multi-drop network. In this case only the end RS485 transceivers should be terminated. A maximum of 32 devices are permitted for the multi-drop operation. 3. It is recommended that a surge protection device be fitted on any exposed cable runs, or runs exceeding 200 meters in length. Feature Value Units Notes Connector RJ12 Termination Impedance 120 Ω Built in. Multi-drop RS485 applications only the far end RS485 transceivers should be terminated Galvanic Isolation 2500 V Fan Out 32 Maximum of 32 devices in multi-drop Line length 1000 m Recommended to install surge protection devices on any exposed RS485 cable runs, or runs exceeding 200 meters in length Pinout Function Pin 1 Not Used Pin 2 Not Used (Yellow) Pin (Green) Pin (Red) Pin 5 Ground (Black) Pin 6 Not Used Note. RJ12 cable connector pin numbering Important: The connector used for the RS485 port looks similar to the one used on the Q03 product which has only 3 pins. Care must be taken! The connectors are NOT the same. Forcing a plug intended for a Q03 into a Q04 Plus can damage the socket. RS232 Ports The RTU contains two RS232 serial ports used for specialised communication devices and peripherals. These include PLC Interfaces, Cellular modems, Data Radios, modems etc. Configure the following: 1. The RS232-B port can be configured to provide an output voltage (+V) on pin 8. This is of specific use for the Q71 external 1200bps modem. Please refer to the Q71 Quick Start Guide for further details. Jumper J23 on the Q22 I/O board. 17

18 2. Port protocols and communication settings for each peripheral must be configured using the QTech Workbench configuration software. Refer to specifications section for additional port setting parameters configured by QTech Workbench. 3. In electrically noisy environments it is necessary to use screened data cable and keep the cable length as short as possible. In general, the RS232 serial port can be extended up to a maximum of 15 metres. Cable lengths exceeding this distance communications may result in unreliable performance. The RS232 serial port connectors are both 8 way RJ45 connectors. One is located on the Q04 Plus processor board, labelled RS232-A, while the other is located on the Q22 I/O board, labelled RS232-B. Feature Value Units Notes Connector RJ45 Line length 15 m RS232 serial port can be extended up to a maximum of 15 metres. Beyond this distance communications will be unreliable. Pinout Function Pin 1 DTR Pin 2 RTS Pin 3 CTS Pin 4 Ground Pin 5 RXD Pin 6 TXD Pin 7 DCD Note. RJ45 cable connector pin numbering Pin 8 RI CNFG Port A Type B USB port is used for on-line configuration, diagnostics and data/program exchange. The port is labelled CNFG on the side panel. This port is also used for In-system programming of the firmware. Configure the following: 1. No special configuration is required for general use. 2. In system programming to upgrade the bootloader firmware of the RTU requires both the ISP jumpers to be fitted on the processor board and the device connected via this port to QTech workbench running on a PC. Upgrades to bootloader firmware occur rarely and the upgrade process is covered in a separate application note available from QTech. 3. Port protocols and communication settings for each peripheral must be configured using the QTech Workbench configuration software via this port. 4. Maximum cable length is 5 meters. Ethernet Port The port labelled ETH on the side panel is a standard 10/100-base-T ethernet port with auto polarity reversing (no crossover cables required for peer to peer connections). It can be configured for Base Station or peripheral communications via such protocols as QComms, DNP3, Modbus Slave/Master, etc. The Ethernet socket has a green and an orange LED. The orange LED is the Link LED and turns on when a good link is established then flashes off for Ethernet traffic. The green LED is the Speed LED and turns on for 100 MBit connections and off for 10 MBit connections. Configure the following: 18

19 1. Port protocols and communication settings for each peripheral must be configured using the QTech Workbench configuration software (see the specifications at the end of this manual for the settings). 2. Maximum cable length is approximately 30m. Feature Value Units Notes Connector RJ45 Type 10/100 Mbit Indicators 2 The Ethernet socket has a green and an orange LED. The orange LED is the Link LED and turns on when a good link is established then flashes off for Ethernet traffic. The green LED is the Speed LED and turns on for 100 MBit connections and off for 10 MBit connections. Pinout Function Pin 1 Tx + Pin 2 Tx - Pin 3 Rx + Pin 4 Unused Pin 5 Unused Pin 6 Rx - Pin 7 Unused Note. RJ45 cable connector pin numbering Pin 8 Unused USB Host Port The port labelled USB is a USB-2 Type A Host Port and provides a method of connecting standard and specialised USB Devices peripherals to the Processor board. These USB peripheral devices may include USB Pen Drives, USB Mass Storage devices; QTech supplied programming and configuration devices. Configure the following: 1. No special configuration is required for general use. 2. Firmware upgrades to the RTU application firmware use a USB memory stick (formatted as FAT32) inserted into the socket. Firmware upgrades do not require jumpers to be fitted. 3. Please refer to QTech supplied application notes for performing firmware upgrades. 19

20 Digital Inputs The DATRAN XL4 Plus has 8 digital input channels labelled 1 through 8 and a ground connection labelled G. The digital input channels can be connected to a range of devices including relays, mechanical switches, solid-state switches, or transistors. The state of each digital input is indicated with a corresponding green status LED. The LED associated with each digital input will light up when the input is Active/On/Closed. Inputs have an internal pull-up resistor that will pull the input terminal to the power supply + when the input is open circuit (the OFF state). The pull up/pull down convention is different for some PLCs. If required, the active state of I/O can be inverted in the RTU DLP control program or the PLC. To turn a digital input ON, connect the input (via a set of contacts if necessary) to the common G terminal on the Digital Input terminal block. All G terminals on the RTU are tied internally to the -V terminal on the power supply connector. Important: Care should be taken to avoid earth loops by ensuring that the system ground (common) is connected to earth in one place only. When turning an input ON, the external device must ground the appropriate terminal for at least 100ms for the state to be detected in a DLP running on the RTU. When turning an input OFF, the external device must open circuit the appropriate terminal or hold it at the supply voltage, for at least 100ms for the new state to be detected. Shorter pulses can be detected by setting a digital input to pulse counting mode. The minimum pulse width in this mode is 20ms. This feature is configured in QTech Workbench. Digital input channel 8 can also be configured as a high-speed pulse counter, allowing pulses as narrow as 0.05 ms (40 khz) to be counted. This feature is configured in QTech Workbench. Typical configuration of the inputs is as follows: Digital inputs High Speed Counter 20

21 Feature Value Units Notes Number of channels 8 8 digital input channels labelled 1 through 8 and a ground connection labelled G. Each input is individually opto-isolated but has a common ground. Indicator 1 Per channel The state of each digital input is indicated with a corresponding green status LED. ON indicates the input is grounded. Input current 1 ma Min required 2.5 ma ON state current, typically, when supply is 12V 5 ma ON state current, typically, when supply is 24V Input resistance 4K7 Ω maximum allowable ON state resistance of the external switching supply, supply) Input Low pass filter 34 khz Filter cutoff (3dB() frequency Input overvoltage protection Vsupply (+V) Clamped to 1.5V over supply voltage for surges <250mA Input Pulse width 100 ms Min for inputs ms Min for input 8 Please contact QTech for application specific details. Source Resistance 5K Ω Max when supply is 12V 10K Ω Max when supply is 24V Digital input change of state 100 ms Normal operation on any channel detection (min) Input as a pulse counter, 20 ms When channel is configured as a pulse minimum pulse width High speed pulse counter, minimum pulse width counter 0.05 ms Channel 8 only when configured as a high speed pulse counter. Important: The input voltage on any digital input channel should not be permitted to go above the power supply voltage. 21

22 Digital Outputs The DATRAN XL4 Plus has 8 digital output channels physically separated into two banks. The first bank contains digital output channels 1 to 4, and is located on the front panel. The second bank contains digital output channels 5 to 8, and is located on the side panel. The first bank of the digital outputs has 4 status LEDs to indicate the state of the corresponding digital output channel. When turning an output ON, the RTU switches the specific digital output channel to ground. In the OFF state, a digital output channel is open circuit. The digital outputs also contain two voltage supply terminals labelled + on each bank. These make the internal switched positive voltage rail available externally. These outputs can be used to source current to drive a relay coil, for example. The supply (+) terminal will deactivate if the RTU undervoltage protection is activated (Typically at a supply voltage of 10.5V for 12V operation). When switching inductive loads, it is recommended good practice that such loads be fitted with their own fly back or free-wheeling diode. Important: Relays and other control devices should always be wired to be failsafe. Always ensure that any equipment attached to relays goes into a safe state when the relay or controlling device is removed or not powered. Set the total load to limit continuous switching current to at 1 amp maximum. The RTU internal 2-amp fuse may operate if too many channels are active at this current. The over-current protection will activate if the current being sourced through a given channel exceeds nominally 4 A. The channel will be turned OFF and remain OFF until the over-current fault clears. This default behaviour can be changed by removing J28. An over-current fault will put the channel into 500mA current-limit mode until the over-current fault clears. Jumper J28 is located at the centre lower right-hand side of the Q22 PCB. J28 Location Output Protection and Open Circuit Detection status information can be reported by flashing the status LEDs. This feature only applies to bank 1 of the digital outputs. 22

23 Typical Configuration of the Outputs is as follows: Digital output relay control Internal Circuit details Feature Value Units Notes Number of channels 8 8 digital output channels labelled 1 through 8 in two banks. Two voltage supply terminals labelled + per bank. Indicator 1 Per channel Channel 1-4 only, indicates ON state Output current (continuous) 1 A Continuous Max per channel. limited to 2A total for all channels by internal fuse. Output current (peak) 3 A For ms before overcurrent protection will trip. Output resistance 1 Ω Typical Output overvoltage protection 65 V Output voltage is clamped at 65 volts to help reduce the effects of voltage spikes when switching inductive loads. Output current limit 500 ma By removing jumper J28 an over-current fault will put the channel into currentlimit mode of 500mA until such time as the over-current fault clears (provided thermal shut down has not occurred also) Output over temperature protection 170 C High Internal temperature of the output driver circuit will trip thermal shutdown. Open Circuit Detection Current 50 ua Load detection for each digital output channel when they are in the OFF state. Output Protection and Open Circuit Detection status Status LED will flash. This feature can be selectively enabled for each channel. Applies to bank 1 of the digital outputs. 23

24 Analog Inputs and Outputs The RTU has six analog I/O channels which can be reconfigured to provide inputs or outputs, either single ended or differential. Available modes of operation are shown in the table below. Modes are configured by jumper settings. The connector is on the front panel. Analogue I/O port mode settings Channel No Single Ended Input Differential Input Single Ended Output In addition to the analog channels the terminal labelled G is a system ground connection. For Single Ended channels, the I/O signal is referenced to this ground terminal. As with any analog measurement system, care must be taken to correctly earth the equipment to prevent earth loops. Four input ranges are supported: 4-20 ma input (default factory setting) 0-20 ma input 0-5V input 0-10V input Status LEDs Each analog channel has a status LED to indicate the state of the channel. Each status LED shows the following channel status: OFF: Indicates that the analog input is at 0V, 0mA, or less than 4mA, depending on the mode configured. ON: Indicates that the analog input is within the specified voltage or current range, depending on the mode configured. FLASHING: Indicates that the analog input is at full scale or higher dependent upon the mode configured. The terminals labelled + are connected to the internal switched positive supply rail. These can be used to source power to instrumentation. The analog input channels are sampled by a 10-bit analog to digital converter (ADC). The analog output channels are driven from an 8-bit pulse width modulation (PWM) output from the Processor. 24

25 Jumper Settings Configuration jumpers are located on the Q22 I/O board. Analog Input jumpers are in the region near connector P1. On each jumper, the square pad denotes pin 1. The pins are numbered 1, 2, and 3 away from pin 1. Analog I/O jumper locations Refer to the jumper configuration summary in the section marked Q22 I/O board configuration for details of the individual jumper settings. 25

26 Analog Single Ended Input Single Ended analog inputs provide a high impedance unity gain buffer input to the RTU. Note that some jumpers are required to be fitted in order to convert two channels used as a single differential input to separate single ended channels. Single ended inputs are referenced to the RTU ground. Inputs are diode clamped and input voltages should not exceed the specified maximum. The following tables show the jumper configurations of each channel when configured as single-ended Inputs: Range Channel 1 Channel 2 Channel 3 J7 J8 J21 J5 J6 J17 J21 J9 J10 J ma CLOSE CLOSE CLOSE 0-20 ma CLOSE CLOSE CLOSE 0 5 V 2-3 OPEN CLOSE 2-3 OPEN CLOSE CLOSE 2-3 OPEN CLOSE 0-10 V CLOSE CLOSE CLOSE Range Channel 4 Channel 5 Channel 6 J11 J12 J18 J22 J13 J14 J19 J15 J16 J ma CLOSE ma CLOSE V 2-3 OPEN 2-3 CLOSE 2-3 OPEN OPEN V CLOSE Tip: When an Analog channel is to be configured for 4 to 20mA input, configure the jumpers for 0 to 20mA input. Then use QTech Workbench to configure the channel as 4 to 20mA. Example wiring conventions are shown below: 0-5V single ended input 0-10V single ended input 0-20 and 4-20 ma single ended input 26

27 Single Ended analog input specifications: Feature Value Units Notes Number of channels 6 6 input channels labelled 1 through 6 and a ground connection labelled G. Each input is individually buffered. Input resistance >100K Ω 0 5V 20K Ω 0 10V 250 Ω 0 20mA a voltage drop of 5 volts at 20mA is created in multidrop current loop. 250 Ω 4 20mA a voltage drop of 5 volts at 20mA is created in multidrop current loop Input voltage range 15 V Max 0 V Min Input overvoltage protection Vsupply (+V) Clamped to 1.5V outside supply voltage for surges <200mA 27

28 Analog Differential Input Analog input channels 1 & 2 and/or 3 & 4 can be configured together to form two separate differential input channels. When configured as differential inputs analog input channels 1 and/or 3 are the positive inputs and analog input channels 2 and/or 4 are the negative inputs. Differential analog inputs provide a buffered input to the RTU. Note that some jumpers are required to be left open (not fitted) in order to use two channels used as a single differential input. Single ended inputs are referenced to the RTU ground. Inputs are diode clamped and input voltages should not exceed the specified maximum. The following tables show the jumper configurations of each channel when configured as differential Inputs: Range Channel 1&2 Channel 3&4 J7 J8 J17 J21 J9 J10 J18 J ma OPEN OPEN 0-20 ma OPEN OPEN 0 5 V 2-3 OPEN 1-2 OPEN 2-3 OPEN 1-2 OPEN 0-10 V OPEN OPEN Tip: When an Analog channel is to be configured for 4 to 20mA input, configure the jumpers for 0 to 20mA input. Then use QTech Workbench to configure the channel as 4 to 20mA. Example Wiring diagrams for differential inputs. 0-5V differential input 0-10V differential input 0-20 and 4-20 ma differential input 28

29 Differential analog input specifications: Feature Value Units Notes Number of channels 2 Analog input channels 1 & 2 and/or 3 & 4 can be configured together to form two separate differential input channels. Common mode Input voltage 10 V Max range 0 V Min Input overvoltage protection 0 Vsupply (+V) Clamped to 1.5V outside supply voltage for surges <200mA 29

30 Analog Single Ended Output Only channels 5 and 6 can be configured as outputs. For devices requiring single ended analog outputs connect them to the terminals as follows Single ended output means that the output voltage or current is referenced to ground. That is, the negative side of the output is at ground potential (the G terminal on the ANALOG I/O port). The following tables show the jumper configurations of each channel when configured as single ended outputs: Range Channel 5 Channel 6 J2 J4 J19 J1 J3 J ma OPEN OPEN ma OPEN OPEN V OPEN OPEN V CLOSE CLOSE Tip: When an Analog channel is to be configured for 4 to 20mA input, configure the jumpers for 0 to 20mA input. Then use QTech Workbench to configure the channel as 4 to 20mA. Differential analog output specifications: Feature Value Units Notes Number of channels 2 Analog output channels 5 & 6 can be configured to be output channels. Output Current 100 ma Max Permitted load impedance 50 Ω Max for the 0 5V range 100 Ω Max for the 0 10V range Input overvoltage protection 0 Vsupply (+V) Clamped to 1.5V outside supply voltage for surges <200mA 30

31 Device Specifications Communication Protocols Protocols and port parameters must be set up using the QTech Workbench software application. QTech supports a range of communication devices that can be configured for use with the RTU. Each device may require specific settings as indicated in the table below. RS232 Ports (A and B) Device type Protocol Baud rate Parity Flow Control Raw serial interface QTech-Qcomms N,O,E RTS/CTS, None PLC DF1, Modbus N,O,E RTS/CTS, None Modbus Device(RTU as Slave) Modbus: (ASCII/RTU) N,O,E RTS/CTS, None Modbus Device (RTU as master) Modbus: (ASCII/RTU) N,O,E RTS/CTS, None Q bps radio modem QTech-QComms 1200 N,O,E None Tait TM8xxx radio QTech-QComms 2400,14400,19200 N None CM910 cellular modem QTech-QComms 9600 N RTS/CTS, None DNP3 Master (RTU as a slave) DNP N,O,E RTS/CTS, None RS485 Device type Protocol Baud rate PLC Modbus (19200 default) Q23, Q26 expansion module QTech-IPB 9600 Modbus Device(RTU as Slave) Modbus: (ASCII/RTU) Modbus Device (RTU as master) Modbus: (ASCII/RTU) Ethernet Device type PLC Modbus Device (RTU as client or server) DNP3 Master (RTU as a slave) Protocol Modbus (TCP) Modbus: (TCP) DNP3 31

32 Firmware Upgrade Process DATRAN XL4 Plus RTU uses a new RTU configuration file paradigm which is only compatible with versions of Workbench version or later. For currently deployed RTUs the recommended approach is to use Workbench to undertake the firmware upgrade then upgrade Workbench if necessary to version or later in order to configure the RTU. The upgrade process preserves critical settings such as calibration data of analogue i/o and the electronic serial number (ESN) of the RTU. Important. The licensing information in the XL4 (running Q04 firmware) is destroyed during the upgrade process. Please record the license information and the ESN serial number of the device prior to upgrade, so that if issues arise QTech support can assist. The XL4 Plus RTU firmware (Q04 Plus) also features the ability to perform self-tests at boot time (when the RTU is powered up). Provided herein is a brief overview of tests that you may wish to run to check the operation of your RTU. Workbench can be downloaded from the QTech web site Please read the Workbench User guide for installation Instructions. A procedure for rolling back the firmware is also provided. Equipment required: Workbench XL4 or XL4 Plus RTU USB Cable (type A-B) XL4 Power supply and cable Q04 Plus Bootloader firmware (.hex) file (locate in a folder on the PC) USB drive (formatted as FAT) containing Q04 Plus Application firmware file and MD5 validation file (.elf +.md5) (optional) DIP switch jig for setting digital inputs on and off (not supplied) (optional) LAN patch cable if access to a local area network running DHCP services is available The firmware application file, bootloader file and message digest checksum file (MD5) are distributed by QTech. 32

33 Upgrading the firmware from Q04 Step Procedure Note 1 Power on the XL4 and connect Workbench (WB) via USB Select DATRAN XL4 RTU from the workbench device type menu. Click connect to connect to the RTU if necessary. 2 Ensure that any RTU Datalogging data on the RTU has been retrieved as it will be erased by this process 3 Check that Workbench can read a valid serial number form the RTU. The presence of the 4 numbers in ASCII is one of the things that the Bootloader uses for detecting that RTU was previously running the old (Q04) firmware. 4 (optional step) Check the analogue calibration factors in Workbench. The Bootloader will read and convert these into values stored in a JSON format configuration file on the RTU. 5 Close or disconnect Workbench, depower the RTU, unscrew and remove the RTU case cover, and insert the two ISP jumpers. Later the values in the config file can be checked and differ from that noted in WB at this stage the unit may need recalibrating. 6 Power up the RTU and run Workbench (No need to connect just select device type as XL4 if needed) within Workbench. 33

34 Step Procedure Note 7 Go to the Firmware upgrade section of Workbench, browse to the bootloader firmware file, select it then press Program to flash the RTU with the selected file. At this stage if successful workbench will display a message and the RTU will flash the ERR led to indicate that the bootloader cannot yet find the application to boot. If the process fails at this step then: remove the ISP jumpers, cycle the power on the RTU, close then reopen Workbench, select device type as XL4 if necessary, in Workbench, Press Connect. Insert the ISP jumpers, repeat the instructions at the start of this section (7). 8 Close Workbench and remove the ISP jumpers. 9 (optional) At this point the user can use the bootloader to check the FLASH and SDRAM integrity. These actions are triggered by first having inserted the INIT jumper (aka factory default jumper), plus a combination of RDI switches: ALWAYS REMOVE THE INIT JUMPER AFTER CONDUCTING SELF TESTS Activating a test will illuminate the corresponding LED on the digital input (RDI) bank. If the test/action Passed then the corresponding RDO LED will be lit after the test/action. When tests are executing the bank of status LEDs will flash in sequence to show the test is in progress. Grounding the input (assert low) selects the test. a. RDI1 Test SDRAM Switch jig A switch jig is not required if you simply wire a RDI to the ground pin (G) on the RTU. Contact QTech if serial number becomes corrupted. Always remove the INIT jumper after performing self-tests otherwise self-test functions may be inadvertently conducted 34

35 Step Procedure Note b. RDI2 Test FLASH when the digital input harness is reconnected and the device c. RDI3 Test USB Memory Stick repowered. d. RDI7 Erase the FLASH e. RDI8 Erase the NVRAM - Set the desired switch settings (INIT jumper inserted) - repower the RTU to initiate tests. - When tests are complete the ERR led will flash. - Execute the SDRAM and FLASH tests (optional) - Do not erase the FLASH at this point as it will be reformatted anyway. - Do not erase the NVRAM, as that will make the RTU lose its serial number and calibration factors. This is not advised unless those values are subsequently found to be corrupted. 10 Turn all digital inputs off (negate) and/or remove switch jig. Remove the INIT jumper 11 Insert the USB drive containing the application firmware into the USB port on the RTU. The firmware must be stored in the root folder of the USB drive. The USB drive must be formatted as FAT32. Repower the RTU to commence programming. The bootloader will indicate that it is flashing (programming) the application firmware by illuminating the display board LEDs (in a scanning sequence). Note that the Bootloader may need to reformat the FLASH, which can take several seconds (approx. 10s). There is no LED activity during this time, so be patient and don t repower the RTU during this time. 12 Visually Check LED operation. The CPU OK LED will fade on /off The ERR led will indicate any additional fault codes. (This is normal because at this stage a DLP will not be loaded so DO NOT REMOVE POWER FROM THE XL4 DURING THE PROGRAMMING PROCESS. The Status LEDs will flash in sequence to indicate programming is in progress. Note. If you have trouble upgrading the application with a large USB drive (e.g. 32 GB or more) try using a smaller USB 2.0 8GB drive or similar, formatted FAT32. If successfully flashed the Application should boot the indication of this is that the CPU OK LED fades on and off (instead of blocking as per Q04 firmware). If there was a fault then the CPU LED will be off, with the ERR LED indicating an error code. 35

36 Step Procedure Note this will be the most likely error code being shown). MU led will be on. If the ERR led flashes rapidly continuously this indicates that there may be an issue with the vsaliditiy of the RTU licenses to run some tasks, connect to workbench to verify the required licenses and contact QTech support if necessary. 13 Remove the USB Drive. Do not leave it in otherwise the next time the RTU reboots it will attempt to re-flash the firmware. 14 Note down the name of the XL4 usually in the form Q04-xxxx or XL4-xxxx (e.g. XL4-1008) (usually printed on a sticker on the processor board) The name can be used for additional checks. Replace the XL4 case cover and screw together. 15 From this point on you must install and operate Workbench or later in order to configure the device. 16 Re-Connect the USB cable to the RTU and PC. Power on the RTU. Open Workbench. By default, it selects the XL4 Plus RTU device type to configure but if not then select Datran XL4 Plus RTU from the device type menu. The device type is displayed at the top of the window. Click Connect Select the Overview category from the category tree on the left side of the window. Verify the serial number of your RTU is displayed. IMPORTANT immediately after rebooting or powering up the RTU the device will perform a file consistency check which may take up to 30s. Attempts to write configuration data to the RTU in this time will fail and the user should wait until the device is ready before updating the RTU configuration (this will be communicated by workbench) 17. The unit is now ready for further configuration. You can switch to using the latest version of QTech Workbench to configure the unit at this point. Refer to the Workbench user guide or additional application notes for specific details on how to configure the RTU. 36