HYPER SCADA SERVER INSTALLATION AND OPERATION MANUAL

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3 HYPER SCADA SERVER INSTALLATION AND OPERATION MANUAL Data Flow Systems, Inc. 605 N. John Rodes Blvd., Melbourne, FL Phone Fax

4 NOTICE Data Flow Systems, Inc. assumes no responsibility for any errors that may appear in this document, nor does it make any commitment to update the information contained herein. However, questions regarding the information contained in this document are welcomed. Data Flow Systems also reserves the right to make changes to the specifications of the Hyper SCADA Server, Hyper Server Module, Network Interface Module, Fiber Interface Module, Network Fiber Module, Network Switch Module, and the HT3 SCADA software and to the information contained in this document at any time without notice. DFS This document last revised: July 7, 2010

5 TABLE OF CONTENTS PREFACE...1 Purpose of this Manual... 1 Document Conventions... 1 Abbreviations Used in this Manual... 1 CHAPTER 1 : PRODUCT OVERVIEW...3 Hyper SCADA Server... 3 Description... 3 HSS HSS002-X... 4 User Interface... 6 SCADA System Options... 7 Hyper Server Module... 8 Overview... 8 Features of the HSM... 9 Backup Battery Power and Voltage Monitoring Heat Regulating Fan Network Modules Network Interface Modules Network Distribution Modules Network Module Applications CHAPTER 2 : BEFORE YOU BEGIN...17 Safety Precautions General Precautions Working Inside the HSS Protecting Against Electrostatic Discharge Using the HSS Site Selection...18 Receipt of Equipment Installation Overview CHAPTER 3 : MOUNTING AND AC WIRING INSTRUCTIONS...21 HSS Unpacking the HSS Mounting the HSS Wiring the Unit for AC Power HSS002-X Unpacking the HSS002-X Mounting the HSS002-X Installing the HSS002-X s Modules Wiring the HSS002-X for AC Power CHAPTER 4 : DEVICE WIRING INSTRUCTIONS...27 Dial Out / Dial In HSS HSS002-X i

6 Alarm Notification Options...30 Audio Device...30 Alarm Light, Alarm Horn, and Alarm Silence Button Options...32 CHAPTER 5 : NETWORK SETUP Overview...37 Functions of Network Modules in the HSS...38 Network Distribution and Isolation...38 Serial Tunneling...38 Power Distribution...38 Controlled by HSM...38 Reset Remotely...39 HSS Description...39 Network Distance Considerations...39 What You ll Need...40 Installation and Configuration Procedure...40 HSS002-1 Network Setup (Non-Redundant HSS002)...43 Description...43 Network Considerations/Vulnerabilities...43 What You ll Need (Minimums)...44 Installation and Configuration Procedure...45 HSS002-2 Network Setup (Redundant HSS002)...47 Description...47 Network Considerations...47 What You ll Need...48 Installation and Configuration Procedure...49 CHAPTER 6 : TELEMETRY SYSTEM SETUP Network RTUs (HSS002-X only)...53 Overview...53 Functions and Features...54 Installation and Configuration Procedure...56 Tunnel CTU...61 Overview...61 Functions and Features...62 Installation and Configuration Procedure...63 Serial Devices (HSS001)...68 CHAPTER 7 : WORKSTATION CONFIGURATION System Requirements...69 Workstation Configuration...69 Editing the Hosts File...70 Change Browser Settings...71 Install Plug-Ins and Java Policy File...72 Start HT CHAPTER 8 : CRITICAL DATA REDUNDANCY Configuring Remote System Backup...73 Procedure for Configuring Backup Site...73 Principles of Redundancy for an HSS Primary Server...75 Secondary Server...75 ii

7 IP Sharing Safe IP Address Switch Over Process HT3 Data Recovery CHAPTER 9 : SYSTEM TESTING & TROUBLESHOOTING...79 Troubleshooting Toolbox Access Network via Network Distribution Module Overview Installation and Configuration Procedure Potential Problems and Suggested Troubleshooting Steps My Network RTU is offline! My Tunnel CTU is not Polling! Obtaining a Console to a FIM Replacing the HSM APPENDIX A: TECHNICAL SPECIFICATIONS...87 Hyper SCADA Server HSS HSS Hyper Server Module Network Interface Module Fiber Interface Module FIM Network Fiber Module NFM Network Switch Module APPENDIX B: PIN DEFINITIONS...91 Hyper Server Module Pin Definitions Network Interface Module Pin Definitions* APPENDIX C: LED STATUS AND ERROR CODES...93 APPENDIX D: ADDRESSING MODULES...95 APPENDIX E: SUPPORT, SERVICE, AND WARRANTY INFORMATION...97 Support and Service Technical Product Assistance Return Authorization (RA) Procedure Warranty...99 Questions or Comments on This Manual INDEX iii

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9 PREFACE PURPOSE OF THIS MANUAL This manual is a reference guide for the Hyper SCADA Server (HSS). It describes procedures for installing, wiring, testing, and troubleshooting the HSS. This manual contains: Instructions for mounting and wiring the HSS Configuration option descriptions and setup instructions Instructions for implementing redundancy Information on how to test and troubleshoot the HSS Instructions for replacing the HSS Hyper Server Module (HSM) Technical data and specifications See the HT3 User Guide for detailed instructions on configuring, monitoring, and controlling your telemetry system. DOCUMENT CONVENTIONS The following conventions are used throughout this manual: Bulleted lists provide information, not procedural steps. Numbered lists provide sequential steps or hierarchal information. Italic type is used for emphasis. ABBREVIATIONS USED IN THIS MANUAL CIM Computer Interface Module CTU Central Terminal Unit FIM Fiber Interface Module HSM Hyper Server Module HSS Hyper SCADA Server MBP Modular Backplane NFM Network Fiber Module NIM Network Interface Module NSM Network Switch Module PSM Power Supply Module RIM Radio Interface Module RTU Remote Terminal Unit 1

10 HSS Installation and Operation Manual Notes 2

11 Chapter 1: PRODUCT OVERVIEW HYPER SCADA SERVER Description The Hyper SCADA Server (HSS) is a self-contained data collection and information server housed in a wall-mounted, lockable enclosure. The HSS is available in two models: HSS001 (baseline model; no redundancy) and the HSS002 (premium model with redundancy capabilities). The core of both units is the Hyper Server Module (HSM), which includes a CPU, two voice-grade modems for call-out (911) and call-in (411) functions, and the necessary network hardware. HSS001 The HSS001 is housed in a small 13 x13 x7 NEMA 4X fiberglass enclosure. In addition to the HSM, the HSS001 features a Power Supply Module (PSM), a Network Switch Module (NSM), backup battery, and Network Interface Module (NIM). The NIM provides two driver-configurable 9-pin serial ports. Using a process called serial tunneling that is provided by the NIM, the HSM is able to communicate with two serial-type devices, including Modbus devices. Features of the HSS x13 x7 NEMA 4X Fiberglass Enclosure Hyper Server Module Network Switch Module Network Interface Module (Serial Interface) HT3 SCADA Software Program MySQL Software Program Integrated 411 Information Call In Function Integrated 911 Voice Alarm Call Out Function RCA Audio Connector & Alarm Relay Terminal Integrated Uninterruptible Power Supply (UPS) Two Driver-Configurable 9-Pin Serial Ports 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols 3

12 SOURCE LOAD HSS Installation and Operation Manual HSS001 MODULAR BACKPLANE HSM001 NIM001 NSM001 PSM003 NETCARD 10/100B-TX MODEM MODEM SERIAL INTERFACE 10/100BASE-TX NETWORK SWITCH 100 WATT POWER SUPPLY TELEPHONE LINE 1 TELEPHONE LINE 2 AUDIO OUT ALARM TERMINALS SERIAL SERIAL PORT PORT COM 2 COM 1 BATTERY + - AC POWER INLET 115 VAC 60 HZ 2.6 AH BATTERY (INTEGRAL UPS) Figure 1-1, "HSS001 Block Diagram" HSS002-X The HSS002 features a 24 x30 x8 NEMA 4X steel enclosure. In addition to the HSM, the Hyper SCADA Server also features Network Switch Modules (NSM), Network Fiber Modules (NFM), Power Supply Modules (PSM), backup batteries, and surge suppressors. This combination of components provides a complete server with integral UPS function. The HSS can be ordered with or without redundancy. A redundant unit contains a second backplane in which an additional HSM, NSM, and PSM are installed. The acting redundant HSM can take over the functions of the primary unit should the primary fail. When this transition occurs, there is no loss of function or data; it is transparent to the end user except for an alarm that is generated. Features of the HSS x30 x8 NEMA 4X Steel Enclosure Accommodates Future Hot Standby Redundancy Hyper Server Module Network Switch Module HT3 SCADA Software Program Browser-Based HMI Software MySQL Software Program Integrated 411 Information Call In Function Integrated 911 Voice Alarm Call Out Function Integrated Uninterruptible Power Supply (UPS) 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols Optional Serial Interface Kit (Two 9-Pin Serial Ports) Optional Network Fiber Interface (Serial Tunneling) Optional RCA Audio & Alarm Relay Terminal Kit 4

13 Product Overview NEW NEMA 2 ENCLOSURE FIRST MBP001 BACKPLANE HSM001 SPARE SPARE NFM001 NSM001 PSM003 NETCARD 10/100B-TX MODEM MODEM FIBER/ 10BASE-T OR 10/100BASE-TX CONVERTER 10/100BASE-TX NETWORK SWITCH 100 WATT POWER SUPPLY TO CTU W/NIM This space reserved for future upgrade to redundancy 2-LINE SURGE PROTECTOR CAT5 NETWORK SURGE ARRESTOR TFS TFS FUSES FUSES TERMINALS 7.0 AH BATTERY CALL OUT LINE CALL IN/MAINTENANCE LINE TO CLIENT NETWORK Figure 1-2, "HSS002-1 Block Diagram" Features of the HSS x30 x8 NEMA 4X Steel Enclosure Includes Hot Standby Redundancy Dual Hyper Server Modules Dual 100W Power Supply Modules Network Switch Module HT3 SCADA Software Program MySQL Software Program Integrated 411 Information Call In Function Integrated 911 Voice Alarm Call Out Function Integrated Uninterruptible Power Supply (UPS) 10/100 Mbps Ethernet Interface Modbus & DFS Communication Protocols Optional Serial Interface Kit (Two 9-Pin Serial Ports) Optional Network Fiber Interface (Serial Tunneling) Optional RCA Audio & Alarm Relay Terminal Kit 5

14 HSS Installation and Operation Manual NEW NEMA 2 ENCLOSURE FIRST MBP001 BACKPLANE HSM001 SPARE SPARE NFM001 NSM001 PSM003 NETCARD 10/100B-TX MODEM FIBER 10BASE-T OR 10/100BASE-TX CONVERTER 10/100BASE-TX NETWORK SWITCH 100 WATT POWER SUPPLY MODEM TO CTU W/NIM POWER SUPPLY AND BUSS CONNECTOR SECOND MBP001 BACKPLANE HSM001 SPARE SPARE SPARE NSM001 PSM003 NETCARD 10/100B-TX MODEM 10/100BASE-TX NETWORK SWITCH 100 WATT POWER SUPPLY MODEM 2-LINE SURGE PROTECTOR CAT5 NETWORK SURGE ARRESTOR TFS TFS FUSES FUSES TERMINALS 7.0 AH BATTERY 7.0 AH BATTERY CALL OUT LINE CALL OUT/MAINTENANCE LINE TO CLIENT NETWORK Figure 1-3, "HSS002-2 Block Diagram" User Interface HT3, Data Flow Systems network-based SCADA software package, is installed on the HSM. HT3, which is compatible with most operating systems, allows for the monitor and control of remote, unmanned stations from a central location the HSS. Users access HT3 over a local area network from Windows-based workstations (Windows XP with SP2 or newer) using a Java-enabled Internet browser (Microsoft Internet Explorer 8.0 or newer). The only software required on the workstations is Internet Explorer 8.0 or newer, Java 1.5, and a Java policy file. The Java policy file gives HT3 s Java applets permission to write to specific directories on your computer. Connections to HT3 can be via either a local TCP/IP network or a PPP dial-up connection. Other options for accessing HT3 are HT3 Mobile and HT3 Public. HT3 Mobile is a streamlined version of HT3 optimized for today's smart phones. In HT3 Mobile, users will find all the essential tools needed for working in the field. The features provided in HT3 Mobile are alarms, screens, trends, and station status. HT3 Public is an option for displaying custom screens on a utility s website for public viewing. Public custom screens are view only; they don t include controls. Contact DFS for more information on adding HT3 Mobile and HT3 Public to your system. 6

15 Network RTU Network RTU Network RTU Network RTU Network RTU Product Overview SCADA System Options The HSS offers the flexibility of building your SCADA system around: Network RTUs Each Remote Terminal Unit, or station, features a Network Interface Module (NIM) or Fiber Interface Module (FIM) in place of a Radio Interface Module (RIM). All communication between the HSM and the station s I/O modules are via the network. Tunnel CTU The system s Central Terminal Unit features a FIM in addition to a RIM. The HSM communicates with remote, radio-based RTUs using a process called serial tunneling. Fiber provides isolation/protection from lightning strikes. Combination of Tunnel CTU connected to a system of Network RTUs. Network RTUs Network RTUs are used for in-plant, close-proximity systems. Each RTU has a Fiber Interface Module (FIM) in place of a Radio Interface Module (RIM). This allows the HSM to communicate directly with each station via a network connection. A network connection provides a more efficient means of transmitting and receiving data when compared to an RTU with a rubber duck antenna. For an overview of the FIM and its features, see Network Modules, p. 12. Figure 1-4, "HSS - Network RTUs Configuration" (below) shows how an HSS002 and a system of Network RTUs could be configured. NOTE: All modules in the HSS001 and HSS002 cabinets, except the NIM slot, communicate via CAT5 cable using the NSM as the hub. In an HSS, the backplane only supplies power to the modules; it is not a communications buss. Hyper SCADA Server (HSS002-1) H S M V O I D V O I D N F M N S M P S M DIN-RAIL MOUNTED NETWORK SURGE ARRESTOR CAT 5 CAT 5 Ethernet Network Workstation FIBER OPTIC CABLE RACK MOUNT MEDIA CONVERTER Workstation FIBER OPTIC CABLE RACK MOUNT SWITCH F I M P S M F I M P S M F I M P S M F I M P S M F I M P S M Figure 1-4, "HSS - Network RTUs Configuration" 7

16 HSS Installation and Operation Manual Tunnel CTU A Tunnel CTU is a Central Terminal Unit that contains both a Radio Interface Module (RIM) and a Fiber Interface Module (FIM). The FIM uses a process called serial tunneling to translate network data into a language (serial data) that the CTU s RIM can understand. This serial data can then be sent out to the system s radio-based RTUs. Figure 1-5, "HSS with Tunnel CTU" (below) shows how an HSS002 Tunnel CTU system could be configured. Hyper SCADA Server (HSS002-1) H S M V O I D V O I D N F M N S M P S M CAT5 CABLE Ethernet Network Workstation DIN-RAIL MOUNTED NETWORK SURGE ARRESTOR FIBER OPTIC CABLE Central Terminal Unit V O I D V O I D V O I D F I M R I M P S M Workstation REMOTE TERMINAL UNIT REMOTE TERMINAL UNIT REMOTE TERMINAL UNIT Figure 1-5, "HSS with Tunnel CTU" HYPER SERVER MODULE Overview The Hyper Server Module (HSM) is a Pentium-class computer housed on a DFS module card. The HSM uses the Linux operating system and runs HT3, DFS SCADA software that can be used to configure, control, and monitor all aspects of a water/wastewater system. User interfaces to the HSM are through a network via a standard web browser. The HSM communicates with the system s RTUs via a network interface. The HSM can communicate with up to 250 Network RTUs per NIM driver. It is capable of communicating with 100 fully-populated Network (FIM-based) RTUs with a total system poll rate of less than five seconds. The HSM can also simultaneously poll multiple DFS (radio) and/or Modbus RTUs through the network using Fiber Interface Modules (FIMs). 8

17 Product Overview Two voice-grade modems, which double as data terminal modems, enable voice alarm callout, telemetry control and general status inquiries by phone and remote computer access via dial-up connection. Local voice alarm annunciation is available for use in a sound system (PA system, amplified speakers, or an amplifier plus speaker system). In addition, alarm horn and alarm light outputs are provided to accommodate large facilities where alarm announcements aren t always within earshot of personnel. Data backup for a non-redundant HSS is accomplished through the network by defining a client-computer backup location. In a redundant HSS, data redundancy is managed by the system as it continually copies data from the primary HSM to the redundant HSM. A redundant HSS can also be configured to backup to a designated Windows client computer in addition to its built-in redundancy process. Other features of the HSM are a manual CPU shutdown button, status LEDs that indicate CPU activity and system status, and several configuration straps at the card edge that provide system-level configuration options. Features of the HSM HT3 SCADA software Web browser-based user interface Two (2) on-board voice modems 10/100base-TX Ethernet Network Interface DFS Backplane interface Alarm horn driver with alarm silence input Alarm light driver Full system-backup capabilities Power-down button for manual CPU shutdown Status LEDs for CPU activity and system status Card-edge configuration straps for system-level configurations Power down and redundancy functions 9

18 HSS Installation and Operation Manual STATUS LEDs RESET/ POWERDOWN SWITCH VOICE MODEM RS-232 DRIVER SERIAL PORT 1 VOICE MODEM RS-232 DRIVER SERIAL PORT 2 10/100BASE-TX NETWORK PORT HYPER SERVER MODULE PRINTED CIRCUIT BOARD NET CARD RAM CPU HARD DISK DRIVE INTERFACE 10 GIGABYTE HARD DRIVE COOLING FAN PARALLEL PORT 30 SECOND TIMER AUDIO SIGNALS CPU WATCHDOG POWER SENSE POWER CONTROL AUXILIARY O/C OUTPUTS PHONE SIGNALS TRANSFORMER ISOLATION ALARM LIGHT & ALARM BELL O/C OUTPUTS ALARM SINENCE INPUT CPU ACTIVITY SLEDGE- HAMMER INPUT SLEDGE- HAMMER OUTPUT CONFIG JUMPERS RXD/ RESET SIGNAL REDUNDANT POWER CONNECTION Figure 1-6, "HSM Block Diagram" Backup Battery Each model of the Hyper SCADA Server is equipped with a backup battery (two batteries are provided in the HSS002-2). The backup battery enables the Hyper Server Module to survive short term power outages and safely shut down before a complete loss of battery power. Operating run times for a typical application running on battery power: HSS001 (single 2.6 AH battery) - approximately 24 minutes. HSS002-1 (single 7.0 AH battery) - approximately 60 minutes. HSS002-2 (two 7.0 AH batteries) approximately 26 minutes. The HSM monitors the battery voltage and will begin a safe shutdown if voltage drops to 11.1 volts. See Power and Voltage Monitoring, below, for more information. Power and Voltage Monitoring The HSM s onboard processor constantly monitors AC Power and DC Voltage. Parallel port bits on the HSM provide this data to HT3 s external points database. Because this information is stored in an accessible database, it can be monitored via custom screens and alarms. If AC power is removed from the HSS (black/brown out), the backup battery begins providing power to the backplane. If it has been configured in HT3, an alarm for the 10

19 Product Overview external point HSS AC Power will be generated. If AC power is not restored and battery voltage drops to 11.1 volts, the onboard processor sends a shut down signal that prompts HT3 to begin a safe shutdown of the HSM s operating system. When shutdown of the OS is finished, the onboard processor shuts down the HSM s microprocessor and hard drive. To be notified before shutdown that battery voltage is approaching a dangerous level, configure an alarm for the external point DC Voltage. The low level for the alarm must be set above the 11.1 volts threshold. If the low level is set at or below 11.1 volts, the HSM will shut down before the alarm can be generated. The onboard processor continues to monitor voltage after shutdown is complete. When battery voltage reaches 12.3 volts (as a result of AC power being restored and the battery being recharged), the processor restarts the HSM s microprocessor and hard drive. IMPORTANT: There is an option to restart the system manually before battery voltage reaches 12.3 volts. However this course of action is only recommended for emergencies. If the decision is made to manually restart the system, battery voltage must be greater than 11.1 volts. Heat Regulating Fan HSMs with 933MHz processors include a fan for regulating heat inside the device (the processor speed is listed on a label on the side of the HSM). This fan should always be running when the HSM is powered. If you discover that the fan is not running, you should notify Data Flow Systems Service Department as soon as possible to make arrangements to have the fan replaced. 11

20 HSS Installation and Operation Manual NETWORK MODULES DFS network modules are designed as generic, network-interface and -distribution platforms for use with TAC II telemetry systems. Network modules are typically used in conjunction with a Hyper SCADA Server (HSS)-based TAC II SCADA system. Four types of network modules are available, all of which are based on the same printedcircuit board. The network module type is determined by the auxiliary components that are mounted on the board CPU, media converter, and network. Network modules can be classified as either network interface modules or network distribution modules. Network interface modules (Network Interface Module and Fiber Interface Module) feature a DOS-based network CPU and provide a function called "serial tunneling." Serial tunneling is a process that converts serial data into network data for transmission over an Ethernet network. A network interface module, such as the FIM, can also replace a Radio Interface Module (RIM) in an RTU to provide Ethernet-based communication with the central site (Hyper SCADA Server). The Fiber Interface Module's Ethernet media converter protects the unit from transient voltage damage. Network distribution modules (Network Switch Module and Network Fiber Module) do not have processing capabilities (they do not come with the DOS-based network CPU). They are used strictly as a point of network distribution, or as a media converter (CAT5 to fiber optic) to protect network devices, such as the Hyper SCADA Server, from transient voltage damage. The network modules provide the means for rapid data retrieval by enabling the telemetry system s Remote Terminal Units (RTUs) to communicate over a network. In addition to an increased communication speed, the network modules higher sample rate also produces more accurate, near-real-time data retrieval. A card retainer interlock is included on all of the network modules. The interlock is a magnetic power up switch that prevents the network module (and all other modules powered by it) from being removed while powered up and drawing current. This interlock is only used if the network module is installed in the RIM slot of an RTU or CTU. If the network module is in an I/O module slot, the bypass is made by placing a jumper across pins 3 and 5. 12

21 Product Overview Network Interface Modules Network Interface Module (NIM) The Network Interface Module (NIM) is a DOS-based module designed as a generic, network-interface platform for use with TAC II telemetry systems. The NIM functions as an interface between a 10base-T Ethernet network and up to fifteen function modules of any combination. By communicating via a network instead of through traditional radios, the NIM is able to pass data quickly and reliably. DFS HT3 server can complete a systempolling loop in less than 5 seconds while communicating simultaneously with up to 100 NIM-based RTUs. The NIM plugs into the Radio Interface Module (RIM) slot of a Remote Terminal Unit (RTU) and provides the normal RIM functions of power supply, monitor, and control. The NIM can also be used with a RIM, a Computer Interface Module (CIM), or other NIMs. The NIM is capable of using serial tunneling a process by which serial communications over a network is achieved to communicate with RS232 devices, including Modbus devices. Features of the NIM DOS-based network CPU 250 addresses per communications link Uses standard TCP/IP for communication May be polled by multiple HT3 servers System polling time of 2-5 seconds Plug-and-play network configuration Serial tunneling to RS-232 devices LEDs on power, transmit data, network link, CPU failure, and test Two (2) configurable RS-232 ports RS-232 Service Port for system debugging Test mode switch for system debugging Battery back up during power failure Flash memory for field upgrades Program updates available from HT3 server No on-board adjustments, switches or straps (self configuring) Card retainer interlock that is bypassable and shareable Typical Application for the NIM Serial Tunneling Device The NIM uses serial tunneling, a process by which serial communications over a network is achieved, to communicate with RS-232 devices, including Modbus devices. 13

22 HSS Installation and Operation Manual Fiber Interface Module (FIM) The FIM is a network-interface platform for use with TAC II telemetry systems. It functions as an interface between a 10 or 10/100 Base T Ethernet network and up to fifteen (15) function modules of any combination. The FIM s Ethernet media converter, which protects the unit from transient voltage damage, is available in 10 Mbps and 10/100 Mbps speeds and can be ordered with support for either multi-mode or single mode fiber. Features of the FIM DOS-based network CPU 10 Mbps or 10/100 Mbps Ethernet media converter 250 addresses per communications link Uses standard TCP/IP protocol for communication May be polled by multiple HT3 servers System polling rate of 2-5 seconds Plug-and-play network configuration Serial tunneling to RS-232 devices 2 configurable RS-232 communication ports RS-232 service port and test mode switch for system debugging Battery back up during power failure Flash memory for field upgrades Program updates available from HT3 server LEDs for power, receive data, transmit data, network link, network traffic, COMM2, microprocessor fault, and test mode No on-board adjustments, switches, or straps (self-configuring) Card retainer interlock that is bypassable and shareable Typical Applications for the FIM Serial Tunneling Device in CTU When used in a CTU, the FIM uses serial tunneling to convert the RIM s serial TTL (radio) data into network data for transmission over fiber optic cable to the Hyper SCADA Server. Network Communication in RTU When used in a 200 Series RTU, the FIM replaces the RIM; communications with the central site is accomplished via Ethernet. The FIM will interface with up to 15 I/O modules of any combination. 14

23 Product Overview Available FIM Models The FIM is available in four models: FIM001-10: 10 Mbps; multi-mode fiber applications up to 2 km FIM001-10/100: 10/100 Mbps; multi-mode fiber applications up to 2 km FIM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-SM-10/100: 10/100 Mbps; single-mode fiber applications from 2-15 km Network Distribution Modules Network Fiber Module (NFM) The Network Fiber Module (NFM) is designed as a generic, network media converter for use with TAC II telemetry systems. The NFM interfaces between the Hyper Server Module (HSM) - a component of the Hyper Server Unit (HSU) - and one of the following two components: the client network or the telemetry network (RTUs or CTU). Each HSU features at least two NFMs. The NFM s main function is to provide the HSU s components with protection from transient voltage damage. The NFM can be ordered to interface with either a 10 Mbps or 100 Mbps network. Additionally, the Ethernet and Fast Ethernet converters can each be ordered to support either multi-mode or single mode fiber applications. Features of the NFM 10Mbps or 100Mbps Ethernet Media Converter LEDs on power, transmit data, network link, CPU failure, and test Monitors RTU power and DC bias Battery back up during power failure No on-board adjustments, switches or straps (self configuring) Card retainer interlock that is bypassable and shareable Typical Application for the NFM Hyper SCADA Server (HSS) Media Converter Plugs in module slot and provides transient voltage protection to the HSS s Hyper Server Module (HSM). One NFM interfaces between the HSM and the client network. A second NFM interfaces between the HSM and the telemetry system (RTUs or CTU). Available NFM Models NFM001: 10 Mbps; multi-mode fiber applications up to 2 km NFM001-F: 10/100 Mbps; multi-mode fiber applications up to 2 km NFM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-FSM: 10/100 Mbps; single-mode fiber applications from 2-15 km 15

24 HSS Installation and Operation Manual Network Switch Module (NSM) The Network Switch Module (NSM) is designed as a generic 5-port network switch for use with TAC II telemetry systems. The NSM features a 5-port 10/100 Fast Ethernet UTP switch that can be used to connect the telemetry network and the client network in an inplant monitor and control configuration. Features of the NSM 5-port 10/100 Fast Ethernet UTP switch LEDs on power, transmit data, network link, CPU failure, and test Monitors RTU power and DC bias Battery back up during power failure No on-board adjustments, switches or straps (self configuring) Card retainer interlock that is bypassable and shareable Typical Application for the NSM HSS (Hyper SCADA Server) Network Connectivity The Network Switch Module can be inserted in one of the HSS' module slots to provide a connection from the Hyper Server Module (HSM) to the client network and the telemetry system s RTUs and/or CTU. Temporary Network Connection: The NSM can also be placed in an RTU to provide a temporary network connection, for example, when programming a PLC. Network Module Applications Internally, the HSS uses the Network Switch Module (NSM) and the Network Fiber Module (NFM) to enable communications with telemetry hardware and users (client workstations), and to protect the unit from transient voltage damage and isolate it from signal noise. The Network Switch Module is a central distribution point for all of the HSS components, allowing the HSM to communicate with the local area network and the telemetry system. The Network Fiber Module provides a media conversion point (fiber optic to CAT5) within the HSS. Fiber optic cable (multi-mode or single mode depending on the distance to be covered) is used to protect the HSS components from transient voltage damage when connecting the HSS to the outside world. Fiber Interface Modules (FIM) can be used in both Network (FIM-based) RTUs and radiobased Tunnel CTUs. When the FIM is installed in the Radio Interface Module (RIM) slot of a Remote Terminal Unit (RTU), it provides the normal RIM functions of power supply, monitor, and control. In a Network RTU, the FIM functions as an interface between an Ethernet network and up to fifteen function modules of any combination. Using a FIM in a radio-based CTU (Tunnel CTU) allows data to be sent between a radio network and an Ethernet network. 16

25 Chapter 2: BEFORE YOU BEGIN SAFETY PRECAUTIONS Review the following statements before installing, servicing, or replacing any of the Hyper SCADA Server s (HSS) components. General Precautions Only trained and qualified personnel should install, service, or replace this equipment. Carefully read the installation and wiring instructions before connecting any of the HSS components to their power source. Do not work on the HSS, or connect or disconnect any of its cables during periods of lightning activity. To prevent overheating the HSS, do not operate it in an area that exceeds the maximum recommended temperature of 86 F (30 C). The recommended operating environment for the network interface and distribution modules is 0-40 C ( F) with a relative humidity of 5%-95% (noncondensing). Ensure that the unit is connected to earth ground during normal use. Working Inside the HSS Before working in the HSS where the removal of components is necessary, perform the following steps in the sequence indicated: 1. Power down all HSMs using the CPU Power (Down) button. 2. Turn off the main circuit breaker on the HSS. 3. Turn off the Power Supply Module s (PSM) circuit breaker. 4. IMPORTANT: Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. For example, there could be a relay on the DIN-rail that is connected to power from another source. 5. Ensure that any fiber-optic cables connected to the HSS will not become entangled in or caught on anything in the surrounding area. 6. Put on an electrostatic discharge wrist strap that is attached to ground before touching anything inside the enclosure. In addition, take note of these safety guidelines when appropriate: When disconnecting a cable, pull on its connector or on its strain-relief loop, not on the cable itself. Some cables have a connector with locking tabs; when disconnecting this type of cable, press in on the locking tabs before disconnecting the cable. When pulling connectors apart, keep them evenly aligned to avoid bending any connector pins. Also, before connecting a cable, make sure both connectors are correctly oriented and aligned. Handle components and boards with care. Don't touch the components or contacts on a board. Hold a board by its edges or by its metal mounting bracket. 17

26 HSS Installation and Operation Manual Extra care must be taken when handling any of the modules. Rough handling can damage them. Place modules on a clean and grounded surface after removal. When installing modules, use gentle pressure to slide them in the module slots. Insert them slowly; never use force. Protecting Against Electrostatic Discharge Static electricity can harm delicate components inside the HSS. To prevent static damage, put on an electrostatic discharge wrist strap before touching any of the HSS electronic components. In addition to the preceding precautions, the following steps can be taken to prevent damage from electrostatic discharge (ESD): When unpacking a static-sensitive component from its shipping carton, do not remove the component's antistatic packing material until ready to install the component in the HSS. Be sure to put on an electrostatic discharge wrist strap before unwrapping the antistatic packaging. When transporting a sensitive component, first place it in an antistatic container or packaging. Handle all sensitive components in a static-safe area. Place the equipment on a grounded surface. If possible, use antistatic floor pads and workbench pads. NOTE: Contact DFS if electrostatic discharge packaging is needed for return shipments. See Return Authorization (RA) Procedure, p. 97 for more information on returning equipment. Using the HSS When using the HSS, observe the following safety guidelines: To help prevent electric shock, wire the HSS and peripheral power cables into properly grounded power sources. Be sure nothing rests on the HSS cables and that the cables are not located where they can be stepped on or tripped over. Do not spill food or liquids on the HSS. If the HSS gets wet, see Appendix E: Support, Service, and Warranty Information, p. 97. Keep the HSS away from radiators and heat sources. SITE SELECTION When selecting a site for the HSS, keep the following in mind: The HSS must be located in an air-conditioned [5-30ºC (41-86ºF)], moisture-free [10-80% relative humidity (noncondensing)], office-type environment. The HSS main interface is through a network; there is no console interface. For this reason, the HSS must be connected to the existing local area network, either directly or via a network hub. Alternatively, a master workstation (single computer with necessary hardware and software) can be connected directly to the HSS. The HSS requires a 120V AC power supply. 18

27 Before You Begin To utilize the call-in and call-out features, the HSS must have access to at least one telephone line. The HSS enclosure is a 23 x box with a continuous-hinged door. Allow enough space around the enclosure to ensure that the door has complete freedom of movement. RECEIPT OF EQUIPMENT When equipment is received, examine the outside of the carton for any damage incurred during shipment. Remove the packing list and the equipment from the shipping carton. Carefully inspect the equipment for damage. Resolve any damage with the local carrier. Report damages to Data Flow Systems ( ). Include the serial number of the unit and the extent of damage in your report. INSTALLATION OVERVIEW The table below outlines the steps required to get your HSS SDADA system up and running. Each step is followed by the chapter where detailed instructions can be found. Procedure Mount the unit Chapter Chapter 3: Mounting and AC Wiring Instructions Install modules (HSS002-X only) Wire AC power Wire call out/call in Wire alarm notification devices (optional) Configure HSS for networking Configure telemetry devices (RTUs, CTUs, Modbus) and connect to HSS Configure workstations Configure critical data redundancy Chapter 3: Mounting and AC Wiring Instructions Chapter 3: Mounting and AC Wiring Instructions Chapter 4: Device Wiring Instructions Chapter 4: Device Wiring Instructions Chapter 5: Network Setup Chapter 6: Telemetry System Setup Chapter 7: Workstation Configuration Chapter 8: Critical Data Redundancy 19

28 HSS Installation and Operation Manual Notes 20

29 Chapter 3: MOUNTING AND AC WIRING INSTRUCTIONS HSS001 Unpacking the HSS Carefully open the box in which the HSS001 was shipped and remove the unit. 2. Your HSS001 is shipped with the modules preinstalled in their appropriate slots with packing material placed between the modules to help prevent shipping damage. Before mounting the HSS001, open the enclosure's door and remove the packing material. 3. Visually inspect the enclosure and the modules. If any equipment appears damaged, read the information in the Return Authorization (RA) Procedure (p. 97) for instructions on having the equipment replaced or repaired. Mounting the HSS001 IMPORTANT: The HSS001 must be mounted to the wall in a vertical position to ensure proper airflow through the vents in the enclosure. These vents are used to help keep the unit and its components from overheating. Do not install the unit in a horizontal position or lay the unit down on its front, top, back, or sides. The HSS001 is designed to operate in an air conditioned, moisture-free, office-type environment [ F ( C)]. When selecting an installation site, make sure that it provides an acceptable environment. There are four mounting bosses on the back of the unit for attaching the brackets to the enclosure. Attach the four mounting brackets to the back of the HSS001 s enclosure using the supplied screws. Use all four brackets to ensure that the unit will be securely mounted. The mounting brackets may be aligned vertically or horizontally. After attaching the brackets to the enclosure, securely fasten the HSS001 to the wall in the desired location. Wiring the Unit for AC Power WARNING The HSS001 should only be installed and serviced by DFS personnel or other qualified technicians. The HSS001 must be installed in accordance with all national and local wiring rules. The rated voltage and current for the HSS001 are 120 VAC and 2 Amperes The HSS001 uses a 100-watt power supply module (PSM003) to provide 12V DC operating power to all the modules on its backplane and continuous charging to its backup battery. There is no wiring required for these functions; all connections are built into the backplane. 21

30 HSS Installation and Operation Manual The HSS includes a power cord that can be plugged into any standard grounding-type outlet. An optional power supply kit can be obtained for situations that require that you run your own conduit. IMPORTANT: When using the power cord included with the HSS, the power cord must be plugged into a grounded socket-outlet. The socket outlet must be installed near the HSS and be easily accessible. Use the optional power supply kit (part no ) when running your own conduit. This kit includes an IEC 320/C13 AC power plug assembly that features screw terminals. The power plug assembly is rated at 10 Amps/250 Volts. The rated voltage and current for the HSS001 are 120 VAC and 2 Amperes. HSS002-X Unpacking the HSS002-X IMPORTANT: When handling the HSS002-X's components, follow the instructions in "Protecting Against Electrostatic Discharge" (page 18). The HSS002-X enclosure and modules are shipped separately in two or more boxes. 1. Carefully open all boxes and locate the box that contains the enclosure. Remove the enclosure and visually inspect it. * 2. From the box that contains the modules, carefully remove each module from its packing and visually inspect it for shipping damage. * * If any equipment appears damaged, read the information in the Return Authorization (RA) Procedure (p. 97) for instructions on having the equipment replaced or repaired. Mounting the HSS002-X IMPORTANT: The HSS002-X is designed to be mounted to the wall in a vertical position. This ensures proper airflow throughout the enclosure and provides easy access to the internal devices. Do not install the unit in a horizontal position or lay the unit down on its front, top, back, or sides. The HSS002-X is designed to operate in an air conditioned, moisture-free, office-type environment [ F ( C)]. When selecting an installation site, make sure that it provides an acceptable environment. There are four mounting bosses on the back of the unit for attaching the brackets to the enclosure. Attach the four mounting brackets to the back of the HSS002-X s enclosure using the supplied screws. Use all four brackets to ensure that the unit will be securely mounted. The mounting brackets may be aligned vertically or horizontally. After attaching the brackets to the enclosure, securely fasten the HSS002-X to the wall in the desired location. 22

31 Mounting and AC Wiring Instructions Installing the HSS002-X s Modules Refer to the diagrams on the next page for correct placement of modules. Modules can be identified by their affixed labels. When inserting modules, line up the module's card edge connector with the slot and apply gentle pressure. Never force a module into a slot. If the module does not snap into place easily, realign the connector to the slot, and try inserting it again. HSS

32 HSS Installation and Operation Manual HSS

33 Mounting and AC Wiring Instructions Wiring the HSS002-X for AC Power WARNING The HSS should only be installed and serviced by DFS personnel or other qualified technicians. The HSS must be installed in accordance with all national and local wiring rules. Before starting this installation, verify that no power is coming into the HSS or to any device(s) wired to it. The HSS002-1 uses a 100-watt power supply module (PSM003) to provide 12V DC operating power to all the modules on its backplane and continuous charging to its backup battery. There is no wiring required for these functions; all connections are built into the backplane. An additional PSM003 is installed on the second backplane of the HSS Each PSM is primarily responsible for powering the modules on its own backplane, but is also wired to provide redundant power to the auxiliary backplane if it loses power. Each PSM must be wired directly to a 120V AC commercial power source using #16 AWG wire. A heavier gauge of wire or the installation of an interposing 10-amp breaker in the utility's control panel may be required in order to comply with local electrical codes. The procedure for wiring power is the same for both the HSS002-1 and the HSS Connections from the backplate to all of the DIN-rail mounted components, including the 10-amp breaker and the neutral terminal block used in this procedure, are prewired at the factory. Refer to the diagram below when wiring AC power. Note that the diagram shows only the right portion of the DIN rail. 1. Locate the hot (black) wire. Strip back approximately 1/4 of the wire s insulation and remove the excess. Connect this wire to the line side of the 10-amp breaker using the breaker s screw-type connection. 2. Locate the neutral (white) wire. Strip back approximately 1/4 of the wire s insulation and remove the excess. Connect this wire to pin 1 on the neutral terminal block using the block s Wago compression-type connector. 3. Locate the ground (green and yellow) wire. Strip back approximately ¼ inch of the wire s insulation, remove the excess, and terminate it with a #10 ring terminal. Connect the grounding wire to the HSS ground lug. H N LINE Pin 1 10 Ground Lug LOAD Figure 3-1, "HSS002-X AC Wiring" 25

34 HSS Installation and Operation Manual Notes 26

35 Chapter 4: DEVICE WIRING INSTRUCTIONS This chapter provides information on wiring the HSS to a call-out (911) and/or call-in (411) telephone line, and a sound system (PA system, amplified speaker, or combination amplifier and speaker). DIAL OUT / DIAL IN Each HSM features two voice modems, which enable dial in (411), dial out (911), and PPP dial-up, and allow alarm annunciation via a sound system (PA system, an amplified speaker, or an amplifier-plus-speaker system). The wiring method depends on the number of telephone lines available. (Is one line used for both call in and call out? Or, is one line dedicated to call in and a second line dedicated to call out?) When connecting the HSS to the telephone lines, basic precautions should be followed to reduce the risk of fire, electric shock, and personal injury. Safety Precautions Avoid working during an electrical storm. Do not install a telephone jack in a wet location unless the jack is specifically designed for wet locations. Never touch telephone wires or terminals that are not insulated unless the telephone line has been disconnected at the network interface. Use caution when installing or modifying telephone wiring. HSS001 NOTE: By default, HT3 SCADA software is configured for two phone lines. If only one phone line is used for both the call in and call out functions, HT3 s configuration must be changed. See Call In and Call Out: Configuring 911 & 411 in the HT3 User Guide for more information. One Telephone Line Setup (HSS001) Please note that if you are using only one line for both functions, call out (911) takes precedence. If you are calling in and an alarm occurs (one with call out enabled), the system will disconnect your call in order to place the 911 call. This setup requires a configuration change in HT3. See Call In and Call Out: Configuring 911 & 411 in the HT3 User Guide for instructions. 27

36 SOURCE LOAD SOURCE LOAD HSS Installation and Operation Manual Follow these instructions when using one line for both the Call Out and Call In functions. 1. From your telephone room or telephone wall jack, locate the telephone line's tip and ring wires and terminate them using an RJ11 modular plug. 2. Insert the plug into the LINE 2 jack. LINE 2 is prewired to the Line 2 termination points on the HSM s card edge. H S M TELEPHONE LINES 1 2 AUDIO OUT N I M ALARM TERMINALS SERIAL PORTS N S M COM2 COM1 P S M BATTERY TERMINALS +- AC POWER Battery CALL OUT (911) / CALL IN (411) LINE TO WALL JACK / TELEPHONE ROOM Two Telephone Line Setup (HSS001) Follow these instructions when using two separate telephone lines for the Call Out and Call In functions. 1. From your telephone room or telephone wall jack, locate line 1's and line 2's tip and ring wires. Terminate each line's tip and ring wires using an RJ11 modular telephone connector. 2. Plug the line that will handle call out (911 calls) in the LINE 1 jack. LINE 1 is prewired to the Line 1 termination points on the HSM s card edge. 3. Plug the line that will handle call in (411 calls) in the LINE 2 jack. LINE 2 is prewired to the Line 2 termination points on the HSM s card edge. H S M TELEPHONE LINES 1 2 AUDIO OUT N I M ALARM TERMINALS CALL IN (411) LINE CALL OUT (911) LINE SERIAL PORTS N S M COM2 COM1 BATTERY P S M BATTERY TERMINALS +- AC POWER TO WALL JACK / TELEPHONE ROOM 28

37 Device Wiring Instructions HSS002-X NOTE: By default, HT3 SCADA software is configured for two phone lines. If only one phone line is used for both the call in and call out functions, HT3 s configuration must be changed. See Call In and Call Out: Configuring 911 & 411 in the HT3 User Guide for more information. One Telephone Line Setup (HSS002-X) Follow these instructions when using one telephone line for both the Call Out and Call In functions. Refer to Figure 4-1, "Wiring HSS002-X for Call Out / Call In". Please note that if you are only using one line for both functions, call out (911) takes precedence. If you are calling in and an alarm occurs (one with call out enabled), the system will disconnect your call in order to place the 911 call. 1. From your telephone room or telephone wall jack, locate the telephone line s tip and ring wires and terminate them using an RJ11 or RJ12 modular plug. 2. Insert the plug into the LINE IN jack located on the HSS DIN rail. LINE IN is prewired to the Line 2 termination points on the HSM s card edge (pin7, Line 2 Tip and pin 5, Line 2 Ring). Two Telephone Line Setup (HSS002-X) Follow these instructions when using two separate telephone lines for the Call Out and Call In functions. Refer to Figure 4-1, "Wiring HSS002-X for Call Out / Call In". 1. From your telephone room or telephone wall jack, locate line 1 s and line 2 s tip and ring wires. Terminate each line s tip and ring wires using an RJ11 or RJ12 modular telephone connector. 2. Plug the line that will handle call in (411 calls) in the LINE IN jack that is located on the HSS DIN rail. LINE IN is prewired to the Line 2 termination points on the HSM s card edge (pin7, Line 2 Tip and pin 5, Line 2 Ring). 3. Plug the line that will handle call out (911 calls) in the LINE OUT jack that is located on the HSS DIN rail. LINE OUT is prewired to the Line 1 termination points on the HSM s card edge (pin 11, Line 1 Tip, pin 9, Line 1 Ring). DIN RAIL LINE OUT LINE IN DIN RAIL TO HSM (PREWIRED) TO HSM (PREWIRED) Figure 4-1, "Wiring HSS002-X for Call Out / Call In" 29

38 HSS Installation and Operation Manual ALARM NOTIFICATION OPTIONS The HSS offers several alarm notification options. Alarms are always displayed at client computers that are running the HT3 SCADA software. An Alarm LED is located on the Hyper Server Module (HSM). Alarms can be announced through an audio device. An external light can illuminate when an alarm occurs. A horn can sound when an alarm occurs. Audio Device Alarms can be announced at a client workstation that is running the HT3 SCADA software. For this to function, the client workstation must be capable of playing sound files, either through internal or external speakers. It is possible to have alarms announced at a remote site away from the workstation computer as well as locally. Alarms can be announced from an audio device, such as a PA system, an amplifier-plus-speaker system, or amplified speaker, in addition to being announced at a workstation. WARNING Before starting this installation, verify that no power is coming into the HSS or to any device(s) wired to it. Before connecting the HSS to an audio device: Ensure that the sound system has its own power source. Do not use the HSS to power the sound system. Before connecting the sound system to the HSS, turn off the sound system s power. This helps prevent damage to speakers as well as to any connected equipment. Connecting the HSS001 to an audio device The HSS001's RCA mono jack (Audio Out) may be used to connect an audio device, such as a PA system, an amplifier-plus-speaker system, or amplified speaker, to the HSS001. With this type of set up, alarm announcements can be heard remotely in addition to being heard locally at the workstations. Connecting the HSS002-X to an audio device Be sure to match the audio device s polarity (+ / ) to those of the HSS002-X s Hyper Server Module (Audio Output + and Audio Output -). If the polarities don t match, the sound may be distorted. Ensure that the audio device has its own power source and ground. Do not use the HSS002-X to power or ground the audio device. Refer to the figures on the next page for wiring illustrations. 30

39 Device Wiring Instructions HYPER SERVER MODULE PA SYSTEM / AMPLIFIED SPEAKERS / AMPLIFIER + SPEAKERS AUDIO CABLE AUDIO + AUDIO - PIN 3, AUDIO OUTPUT + PIN 1, AUDIO OUTPUT - Figure 4-2, "Audio Device Connected to HSS002-1" HYPER SERVER MODULE (1) AUDIO + 1 PIN 3, AUDIO OUTPUT + PIN 3, AUDIO OUTPUT - PA SYSTEM / AMPLIFIED SPEAKERS / AMPLIFIER + SPEAKERS AUDIO CABLE HYPER SERVER MODULE (2) 1 1K OHM 1/4 WATT RESISTOR AUDIO - 1 PIN 3, AUDIO OUTPUT + PIN 3, AUDIO OUTPUT - Figure 4-3, "Single-channel Audio Device Connected to HSS002-2" HYPER SERVER MODULE (1) RIGHT CHANNEL AUDIO - AUDIO + PIN 3, AUDIO OUTPUT + PIN 3, AUDIO OUTPUT - PA SYSTEM / AMPLIFIED SPEAKERS / AMPLIFIER + SPEAKERS HYPER SERVER MODULE (2) LEFT CHANNEL AUDIO - AUDIO + PIN 3, AUDIO OUTPUT + PIN 3, AUDIO OUTPUT - Figure 4-4, "Multi-channel Audio Device Connected to HSS002-2" 31

40 HSS Installation and Operation Manual Alarm Light, Alarm Horn, and Alarm Silence Button Options The HSM features an Alarm LED that illuminates when an alarm condition occurs. It is also possible to add an external light in a location that is visible from all points in the plant. In addition to an external alarm light, an alarm horn that sounds when an alarm condition occurs can be connected. The alarm horn features an optional alarm silence button (HSS002-X only). WARNING Before wiring any of the HSS alarm options, verify that no power is coming into the HSS or to any device(s) wired to it. HSS001 Alarm Options The HSS001 includes alarm terminals (source and load) that can be used to connect an external light or horn. The alarm terminals are rated for 125 VAC/60 VDC max./.5 ma max. An alarm silence button is not included. You can wire an external relay to function as an alarm silence button if this feature is necessary. HSS002-X Alarm Light Before wiring an alarm light, ensure that: Each set of contacts on the relay is rated for the voltage and current it is switching. The coil is rated for the +12VDC with which the HSS is driving it. The alarm light has its own power source and ground. Do not use the HSS to power or ground the external light. Refer to the diagram below when wiring an alarm light to the HSS A wiring diagram for the HSS002-2 is provided on the next page. HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL EXTERNAL LIGHT POWER SOURCE COMMON PIN 16, ALARM LIGHT OUT - SIDE OF COIL NO NEUTRAL RETURN +12 VDC POWER DISTRIBUTION BLOCK Figure 4-5, "HSS002-1 Alarm Light Wiring" 32

41 Device Wiring Instructions HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL COMMON ALARM LIGHT POWER SOURCE NO PIN 16, ALARM LIGHT OUT - SIDE OF COIL +12 VDC POWER DISTRIBUTION BLOCK (1) HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL COMMON PIN 16, ALARM LIGHT OUT - SIDE OF COIL NO NEUTRAL RETURN +12 VDC POWER DISTRIBUTION BLOCK (1) Figure 4-6, "HSS002-2 Alarm Light Wiring" HSS002-X Alarm Horn Before wiring an alarm horn, ensure that: Each set of contacts on the relay is rated for the voltage and current it is switching. The coil is rated for the +12VDC with which the HSS is driving it. The alarm light has its own power source and ground. Do not use the HSS to power or ground the external light. Refer to the diagram below when wiring an alarm horn to the HSS A wiring diagram for the HSS002-2 is provided on the next page. 33

42 HSS Installation and Operation Manual HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL COMMON ALARM HORN POWER SOURCE PIN 14, ALARM HORN OUT - SIDE OF COIL NO NEUTRAL RETURN +12VDC POWER DISTRIBUTION BLOCK Figure 4-7, "HSS002-1 Alarm Horn Wiring" HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL COMMON ALARM HORN POWER SOURCE NO PIN 14, ALARM HORN OUT - SIDE OF COIL +12VDC POWER DISTRIBUTION BLOCK (1) HYPER SERVER MODULE PIN 42, SYSTEM DC + + SIDE OF COIL COMMON PIN 14, ALARM HORN OUT - SIDE OF COIL NO NEUTRAL RETURN +12VDC POWER DISTRIBUTION BLOCK (2) Figure 4-8, "HSS002-2 Alarm Horn Wiring" 34

43 Device Wiring Instructions HSS002-X Alarm Silence Button This feature is available on the HSS002 only. Before wiring an alarm silence button, ensure that: Contacts on the relay are rated for the voltage and current it is switching. The coil is rated for 43.6 ma at 12VDC, and the contact is rated for 8 amps at 250VAC / 8 amps at 30VDC. The alarm silence button has its own power source and ground. Do not use the HSS to power or ground the alarm silence. Refer to Figure 4-9, "HSS002-1 Alarm Silence Button Wiring" and Figure 4-10, "HSS002-2 Alarm Silence Button Wiring", below. HYPER SERVER MODULE PIN 40, SYSTEM DC GROUND COMMON POWER SUPPLY + PIN 18, ALARM SILENCE INPUT NO NC POWER SUPPLY - Figure 4-9, "HSS002-1 Alarm Silence Button Wiring" HYPER SERVER MODULE (1) PIN 40, SYSTEM DC GROUND COMMON POWER SUPPLY + PIN 18, ALARM SILENCE INPUT HYPER SERVER MODULE (2) NO NC POWER SUPPLY - PIN 18, ALARM SILENCE INPUT DC GROUND DISTRIBUTION BLOCK Figure 4-10, "HSS002-2 Alarm Silence Button Wiring" 35

44 HSS Installation and Operation Manual Notes 36

45 FIM PSM FIM PSM VOID VOID VOID FIM RIM PSM Chapter 5: NETWORK SETUP OVERVIEW The Hyper Server Module (HSM) itself has no console interface, although a keyboard and monitor can be connected for troubleshooting. In order for workstations to access the HSM and the HT3 SCADA software, the HSS must be connected to an Ethernet network via a network switch, hub, or directly to a stand-alone master workstation. All client computers must be able to access the same network the HSM uses. The term master workstation is used to describe a computer that is connected directly to the HSS NSM instead of a LAN switch/hub. This dedicated workstation is necessary when the HSS is not a part of an existing client local area network. When the HSS is connected via a component of an Ethernet network, users access it from client computers. The diagram below illustrates one way in which a redundant HSS can be used in a SCADA system using both a CTU and a system of network-based RTUs. HSS FIBER CABLE CTU HSM UNSUSED UNSUSED NFM HSM UNSUSED NFM NFM NSM PSM NSM PSM RTU100 SERVICE PORT CAT5 CABLE TO NETWORK / PCs FIBER CABLES NETWORK SURGE ARRESTOR RTU200 Figure 5-1, "Typical HSS002-2 Configuration with Redundancy" 37

46 HSS Installation and Operation Manual FUNCTIONS OF NETWORK MODULES IN THE HSS Network Distribution and Isolation A Network Switch Module (NSM) is installed in the RIM or NSM slot of the HSS backplane (HSS001 and HSS002-1). In a redundant unit (HSS002-2), two NSMs are installed: one in each backplane. The NSMs provide a central network distribution point for the Hyper Server Modules installed in the HSS. The HSS002-X features a NFM that fiber-optically isolates the HSM(s) from the telemetry system s CTU or network-based RTUs. All of the network distribution modules communicate via Ethernet to the Hyper Server Module. The HSS buss supplies power to each module. Serial Tunneling The Network Interface Module (NIM) or the Fiber Interface Module (FIM) in the HSS001 can act as an interface between the serial devices connected to the HSS and the network. The HSS001 s two serial ports (COM1 and COM2) are connected to the NIM. This allows the serial devices to pass their data to network devices through a process called serial tunneling. In serial tunneling, the HSM bundles serial data into network packets and forwards it to the NIM. When the NIM sees an incoming packet, it switches to serial tunnel mode, extracts the serial data, and sends the data out the appropriate COM port. When a serial device sends data to one of the NIM s COM ports, the NIM bundles the data into network packets and forwards them to the HSM. NOTE: COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Both COM1 and COM2 are used only as a stand-alone serial tunnel; there is no buss communication. COM1: Pin 2=RXD, Pin 4=TXD, Pin 6=GND, Pin 11=RTS, Pin 13=CTS COM2: Pin 8=RXD, Pin 10=TXD, Pin 12=GND, Pin 14=RTS, Pin 16=CTS Power Distribution The skeleton board for each module, which is used as the base of all network modules (NIM, FIM, NSM, and NFM), provides power to the attached network hardware (switches or converters). The network distribution modules, because they are wired to the HSS backplane(s), obtain power from the backplane and benefit from the HSS battery backup function. Controlled by HSM The Network Switch Module (NSM) monitors the HSM s Power Supply Module (PSM) and reports status to the HSM. It also initiates a PSM shutdown when requested by the HSM. The HSM instructs the network distribution module to cycle power to its network hardware if communication problems are experienced. 38

47 Network Setup Reset Remotely The microprocessors on both types of network distribution modules are programmed to monitor the TX data line of the HSS bus. If communication problems are experienced, the modules can be remotely reset via software on the HSM. It is possible to toggle the TX data line to either reset the network hardware on the network distribution modules, or shut down the power supply in order to perform a battery test. HT3 s System Control Panel provides the ability to perform these functions from any configured Windows workstation. See Using System Troubleshooting and Maintenance Tools in the HT3 User Guide for more information. HSS001 Description The HSS001 contains a single backplane with the following modules installed: Hyper Server Module, Network Switch Module, and Power Supply Module. It also includes one of the following: Network Interface Module, Network Fiber Module, or Fiber Interface Module. The HSS001 also includes two 9-pin serial ports for connecting serial-type devices (including Modbus devices), a 2.6 AH backup battery, two telephone line input jacks, one RCA mono jack, and alarm terminals (for connecting an alarm light/horn). Critical data is backed up nightly to a Windows workstation. For more information on Critical Data Redundancy, see the HT3 User Guide. Network Distance Considerations When planning an installation, consider the following when selecting the type of fiber-optic cable (multi-mode or single-mode) and the type of media converters: Will the HSS be connected to an existing local area network (LAN) or directly to a master workstation? If the HSS is to be connected to an existing LAN, what is the speed of the network? If the HSS is to be connected to a master workstation, what is the speed of the media converters used in the HSS? What is the distance between the HSS and the telemetry system connection point (the CTU or the media converter) to which the system s Network RTUs are connected? What is the distance between the HSS and the LAN/master workstation? Is the master workstation/lan situated in a different location than the HSS (for example, in a different building) Cable Selection Multi-mode fiber-optic cable covers distances up to 2 km (~1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~9.3 miles). 39

48 HSS Installation and Operation Manual Converter Selection The converter used on the Fiber Interface Module (FIM) and the Network Fiber Module (NFM) is a 10Mbps Ethernet Media Converter. This converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU or Network RTUs. The type of media converter used is solely based on application. Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be a 10/100Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length). What You ll Need Two (2) Free/unused IP addresses - one for the HSM and one for the NIM/FIM CAT5 cables terminated with RJ-45 connectors Telephone cable terminated with RJ-11 connectors Computer with Windows operating system installed Keyboard and monitor (for connecting to the HSM when configuring its IP address) Installation and Configuration Procedure Step 1: Configure the NIM s IP Address The HSS001's NIM acts as an interface between the serial devices connected to the HSS001 and the network. The NIM is referred to as a "tunneling device," because its function is to pass - or tunnel - serial data through a network. The NIM requires a valid IP address. IMPORTANT: (1) The NIM cannot be addressed greater than 250. (2) The ground (G) switch must remain in the ON position. (3) The BRAIN switch, when set to the OFF position, allows for an IP address to be configured when using a NIM/FIM. Set the BRAIN switch to ON when using a network distribution module (i.e., NFM). 40

49 Network Setup The NIM features automatic IP addressing. It obtains the first three octets of its network address from an HSM broadcast (a network service called NIM Broadcast). The last octet comes from the NIM Tunneling IP Address block (located in the HSS001 to the left of the NIM). The last octet is configured by placing each of the DIP switches on the address block in either the ON or OFF position. The address is calculated by adding up the bits that are OFF. The example at right shows the NIM addressed at 208. The 128, 64, and 16 switches have been placed in the OFF position ( = 208). See Appendix D: Addressing Modules for more information on module addressing. G BRAIN NIM TUNNELING IP ADDRESS O N O F F When the NIM boots up, it receives a broadcast from the HSM that says, "This is your subnet." The NIM reads its subnet, mates it with the tunnel address, and begins to talk at that IP address. Step 2: Make Network Connection This section provides information on making connections inside the HSS001. See Chapter 6: Telemetry System Setup for information on connecting the HSS001 to the telemetry system s serial devices. If the HSS001 is to be connected to an existing network (via a hub, switch, router), follow the instructions given for Option 1: Client Network. If there is no network available and the HSS001 is being connected directly to a workstation, follow the directions in Option 2: Dedicated Workstation. The diagrams on the next page show connections for two versions of the HSS001 one with a NIM installed in the second slot; one with a FIM installed. For both versions, connection to the workstation/network is identical. The only difference is in how the NSM is connected to the NIM/FIM. The HSS includes a NIM when using the unit s COM ports to connect to serial-type devices [see Serial Devices (HSS001), page 68]. The HSS requires a NFM/FIM when the unit is connected to a Tunnel CTU (see Tunnel CTU, page 61). Option 1: Client Network When connecting the HSS to a client network via a device such as a hub, switch, or router, connect port 1 (one) on the NSM to a port on the other device. Option 2: Dedicated Workstation When connecting the HSS to a dedicated workstation (stand-alone PC), connect port 1 (one) on the NSM to a port on the computer's network card. 41

50 HSS Installation and Operation Manual HSS001 with FIM HSS001 with NIM Step 3: Configure the HSM s Static IP Address 1. Connect a PS-2 keyboard and monitor to the HSM. Ports for connecting a keyboard and monitor are easily accessible and clearly marked. 2. Restore power to the unit. A. Turn on the PSM. B. Connect the battery. The HSS is now activated. 3. It is not necessary to power up the HSM; it will automatically power up when it senses power has been applied. LED sequence during power up is as follows: C. The ACT LED is constant. The SDN LED blinks slowly and then more quickly. +CPU and +5V LEDS are constant and remain constant during and after power up. D. The SDN LED goes off and the ACT LED is constant. 42

51 Network Setup E. The ACT LED begins to blink indicating that the HSM is fully powered. 4. When the HSM is fully powered and booted up, a login prompt appears on the monitor. Enter mgr for the login and htiimgr for the password. 5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the IP address of the HSM). Follow the on-screen prompts. HSS002-1 NETWORK SETUP (NON-REDUNDANT HSS002) Description A non-redundant HSS002 contains a single backplane with the following modules installed: Hyper Server Module, two Network Fiber Modules, Network Switch Module, and Power Supply Module. It also includes one 7.0 AH backup battery and DIN-rail mounted surge protection devices for connecting phone and audio lines. Critical data is backed up nightly to a networked drive or a Windows workstation. For more information on Critical Data Redundancy, see the HT3 User Guide. Network Considerations/Vulnerabilities When planning an installation, consider the type of fiber-optic cable (multi-mode or singlemode) and the type of media converters needed (see technical specifications beginning on page 88). Consider the following when evaluating network vulnerabilities: Will the HSS be connected to an existing local area network (LAN) or directly to a dedicated/master workstation? If the HSS is to be connected to an existing LAN, what is the subnet mask and speed of the network? If the HSS is to be connected to a master workstation, determine if that workstation has access to the internet. If so, determine vulnerabilities (possibility of hacker attacks) on the HSS Apache web server. Also determine the speed of the media converters used in the HSS. What is the distance between the HSS and the telemetry system connection point, such as the CTU of the media converter for each of the system s Network RTUs? What is the distance between the HSS and the LAN distribution device (switch, router) or the master workstation? Is the master workstation/lan situated in a separate area from the HSS (for example, in a different building) Additional NFMs Required in HSS If the distance between the HSS and the LAN/master workstation is greater than the maximum Ethernet distance (100 meters or 328 feet), or if the LAN/master workstation is in a different location than the HSS (for example, a different building), additional NFMs may be required in the HSS. Fiber optic cable is used to isolate components from lightning strikes. Therefore a media converter (available on the NFM/FIM) may be required for network RTUs or additional CTUs. 43

52 HSS Installation and Operation Manual Cable Selection Multi-mode fiber-optic cable covers distances up to 2 km (~1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~9.3 miles). Converter Selection The converter used on the Fiber Interface Module (FIM) and the Network Fiber Module (NFM) is a 10Mbps Ethernet Media Converter. This converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU or Network RTUs. The type of media converter used is solely based on application. Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be 10/100 Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length). What You ll Need (Minimums) Two free, or unused, static IP addresses. One for the HSM. The other for the CTU. These IP addresses must be on the same network. HSS with Hyper Server Module (HSM), Power Supply Module (PSM), Network Switch Module (NSM), and Network Fiber Module (NFM) installed. (Refer to the specifications for the Network Fiber Module provided on page 90 in Appendix A: Technical Specifications when selecting an NFM.) NIM/FIM for Tunnel CTU or Network RTUs (NOTE: Network RTUs require desktop-style or rack mount fiber-optic media converters between them and the HSS). Local area network or master workstation. (NOTE: Each may require appropriate fiber-optic media converters between them and the HSS) Configuration jumpers (black #16 stranded wire can be used for making jumpers). Three CAT 5 patch cables terminated with RJ-45 connectors. One CAT5 cable of sufficient length to cover the distance from the HSS to the local area network or master workstation. One fiber-optic cable of sufficient length to cover the distance between the HSS and the telemetry system connection point (the Tunnel CTU or the media converter to which the system s Network RTUs are connected). In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters. PS-2 keyboard and monitor. This will be connected to the HSM after all components are installed in the HSS and will be used to configure the HSM s IP address. Electrostatic discharge wrist strap (this must be worn while working inside the unit). 44

53 Network Setup Installation and Configuration Procedure This section provides information on making connections inside the HSS002-X. See Chapter 6: Telemetry System Setup for information on connecting the HSS002-X to the telemetry system (Tunnel CTU or Network RTUs). See Figure 5-4, "HSS Jumper and Address Settings" (p. 52) to view a diagram of the HSS address and jumper settings. Refer to HSS002-1 Internal Wiring (below) when wiring the HSS Figure 5-2, "HSS002-1 Internal Wiring" Please follow normal Ethernet wiring practices when installing the HSS. Step 1: Prepare the Unit 1. Safely power down the HSS. A. Press the power down button on the HSM, the shutdown LED (SDN) begins to flash indicating that the shut down process has begun. B. SDN then goes constant indicating that services to the HSM have been turned off. C. After a few moments, the CPU power LED (+CPU) goes out indicating that it is now safe to remove power. D. Disconnect the battery. E. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. 2. Ensure that all module address blocks, except the RIM slot s address block, have been removed. 3. For the network module installed in the RIM/NSM slot (usually a network switch 45

54 HSS Installation and Operation Manual module), ensure that all of the address block s DIP switches are in the ON, or closed, position. 4. Ensure that each of the HSS remaining network distribution modules is addressed at 256. This is accomplished by placing a jumper across pins 43 and 25 (with no J(X) switch installed). Step 2: Make Ethernet Connections 1. Connect the HSM to port 4 on the NSM using a CAT 5 patch cable that has been terminated with RJ-45 connectors. Connect the NFM to port 3 of the NSM. 2. Connect the DIN-rail mounted network surge arrestor to port 1 (one) of the NSM. 3. From the surge arrestor, make a connection to the local area network or to the master workstation using CAT5 cable. [IMPORTANT: To minimize signal interference, avoid installing CAT5 cable near florescent lighting or other AC conduit.] 4. Connect the NFM to the telemetry system connection point. Connection is through a fiber-optic cable that is attached to the NFM s media converter (TX and RX connectors). Step 3: Configure the HSM s IP Address 1. Connect a PS-2 keyboard and a VGA monitor to the HSM. Ports for connecting a keyboard and monitor are easily accessible and clearly marked. 2. Restore power to the unit. A. Turn on the PSM. B. Connect the battery. The HSS is now activated. 3. It is not necessary to use the HSM s CPU Power (Up) button. The HSM will automatically power up when it senses power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly. +CPU and +5V LEDS are constant and remain constant during and after power up. B. The SDN LED goes off and the ACT LED is constant. C. The ACT LED begins to blink indicating that the HSM is fully powered. 4. When the HSM is fully powered and booted up, a login prompt appears on the monitor. Enter mgr for the login and htiimgr for the password. 5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the IP address of the HSM). Enter Y or N to confirm IP change. Step 4: Reboot the HSM. 1. Press the power down button on the HSM and watch the HSM's LEDs. When the +CPU LED goes off, the HSM is fully powered down. After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed. 2. After 10 seconds have passed, press the power up button on the HSM and watch the HSM's LEDs. When the ACT LED begins to blink, the HSM is fully powered up. We recommend that you keep the keyboard and monitor attached to the HSM until you verify that you can communicate with the HSM from a Windows workstation. 46

55 Network Setup HSS002-2 NETWORK SETUP (REDUNDANT HSS002) Description A redundant HSS features two backplanes and two 7.0 AH backup batteries. The top backplane is fully populated: it contains a HSM, a Network Fiber Module, a Network Switch Module, and a Power Supply Module. The bottom backplane features an additional HSM, NSM, and PSM. The HSS also contains DIN-rail mounted devices for connecting network, telephone, and audio lines. The telephone and audio lines are used for call out (911) and call in (411), and voice alarm notification. Connection between the two HSMs, the external telemetry system and local area network, is via the HSS two Network Switch Modules. Refer to Figure 5-3, "HSS002-2 Internal Wiring", page 49, to see a diagram of these connections. Either HSM can act as the primary server. The primary HSM is responsible for controlling the telemetry system and collecting data. Critical data is continually copied to the redundant HSM that monitors the Primary HSM s functions. If the primary HSM were to fail, the redundant HSM would automatically take over the primary server role with no loss of data or function. Network Considerations When planning an installation, consider the following when selecting the type of fiber-optic cable (multi-mode or single-mode) and the type of media converters: Will the HSS be connected to an existing local area network (LAN) or directly to a master workstation? If the HSS is to be connected to an existing LAN, what is the speed of the network? What is the distance between the HSS and the telemetry system connection point (the CTU or the media converter to which the system s Network RTUs are connected)? What is the distance between the HSS and the entry point to the LAN? Is the LAN/master workstation situated in a different location than the HSS (for example, in a different building) Additional NFM Required in HSS If the distance between the HSS and the LAN/master workstation is greater than 100 meters (328 feet), or if the LAN/master workstation is in a location away from the HSS (for example, a different building), an additional NFM must be installed in the HSS. Fiber optic cable must be used to connect this NFM, via a media converter, to the LAN/master workstation. Cable Selection Also see Converter Selection. Multi-mode fiber-optic cable covers distances up to 2 km (~ 1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~ 9.3 miles). 47

56 HSS Installation and Operation Manual Converter Selection The converter used on the Fiber Interface Module (FIM) and the Network Fiber Module (NFM) is a 10Mbps Ethernet Media Converter. This converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU or Network RTUs. The type of media converter used is solely based on application. Most Ethernet networks and workstations today are capable of 100 Mbps, so the most common media converter used to connect the HSS to an existing network or to the "Master" workstation will be 10/100Mbps auto-negotiating converter. The distance between the HSS and the network or Master workstation will determine which model must be used. It will be very common to have different model media converters in the HSS (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length). What You ll Need A minimum of four free, or unused, static IP addresses. One for each of the HSMs, one to act as the Shared IP, and one for the CTU Tunnel. These IP addresses must be on the same network. See Principles of Redundancy for an HSS002-2 in Chapter 8: Critical Data Redundancy for more information on the Shared IP. A Safe IP address. This IP address is always "up" and is on the same network as the HSS. See Principles of Redundancy for an HSS002-2 in Chapter 8: Critical Data Redundancy for more information on the Safe IP. HSS with two Hyper Server Modules (HSM), two Power Supply Modules (PSM), two Network Switch Modules (NSM), and one Network Fiber Module (NFM) installed. (Refer to the specifications for the Network Fiber Module provided on page 90 in Appendix A: Technical Specifications when selecting an NFM.) Tunnel CTU or Network RTUs (Network RTUs require desktop-style or rackmount fiber-optic media converter between them and the HSS and a separate static IP address for each). Local area network or master workstation. Each requires appropriate fiber-optic media converter between it and the HSS. Configuration jumpers (black #16 stranded wire can be used for making jumpers). Five CAT 5 patch cables terminate with RJ-45 connectors. One CAT5 cable of sufficient length to cover the distance from the HSS to the local area network or master workstation. One fiber-optic cable of sufficient length to cover the distance between the HSS and the telemetry system connection point (the Tunnel CTU or the media converter to which the system s Network RTUs are connected). In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters. Electrostatic discharge wrist strap (this must be worn while working inside the unit). 48

57 Network Setup Installation and Configuration Procedure This section provides information on making connections inside the HSS. See Chapter 6: Telemetry System Setup for information on connecting the HSS to the telemetry system (CTU or Network RTUs). See Figure 5-4, "HSS Jumper and Address Settings" (p. 52) to view a diagram of the HSS' address and jumper settings. NOTE: The instructions below refer to the two Hyper Server Modules as HSM1 and HSM2; the two Network Switch Modules are referred to as NSM1 and NSM2. HSM1 and NSM1 are installed in the top backplane; HSM2 and NSM2 are installed on the lower backplane. The two Network Fiber Modules that are installed on the top backplane are referred to as NFM1 and NFM2. Refer to Figure 5-3, "HSS002-2 Internal Wiring" (below) when wiring the HSS Figure 5-3, "HSS002-2 Internal Wiring" 49

58 HSS Installation and Operation Manual Please follow normal Ethernet wiring practices when installing the HSS. Step 1: Prepare the Unit 1. Safely power down the HSS. A. Press the power down button on the HSM, the shutdown LED (SDN) begins to flash indicating that the shut down process has begun. B. SDN then goes constant indicating that services to the HSM have been turned off. C. After a few moments, the CPU power LED (+CPU) goes out indicating that it is now safe to remove power. D. Disconnect the battery. E. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. 2. Ensure that all module address blocks, except the two RIM slot address blocks, have been removed. 3. Ensure that a jumper has been placed across pins 3 and 5 on each NSM and. Placing a jumper across these pins allows the modules to bypass the startup plate. 4. For the network modules installed in the top and bottom RIM slots (usually network switch modules), ensure that all of the address block s DIP switches are in the ON, or closed, position. 5. Ensure that each of the HSS remaining network distribution modules is addressed at 256. This is accomplished by placing a jumper across pins 43 and 25. See Appendix D: Addressing Modules for more information on module addressing Step 2: Make Ethernet Connections See note at end of this section. 1. Use a CAT 5 patch cable to connect each HSM to port 4 of its corresponding NSM (HSM1 NSM1; HSM2 NSM2). This connection provides each HSM with a link to the local area (client) network and the telemetry system. 2. Connect the NFM to port 3 of NSM1 using a CAT 5 patch cable terminated with RJ-45 connectors. 3. Connect port 1 (one) on NSM2 to port 2 (two) of NSM1. This connection provides the communications link between the two HSMs, which allows them to pass data back and forth and switch primary and redundant roles. 4. Connection port 1 (one) on NSM1 to the DIN-rail mounted network surge arrestor. 5. From the surge arrestor, make a connection to the local area network or to the master workstation using CAT5 cable. [IMPORTANT: To minimize signal interference, avoid installing CAT5 cable near florescent lighting or other AC conduit.] 6. Connect the NFM to the telemetry system connection point. Connection is through a fiber-optic cable that is attached to the NFM s media converter (TX and RX connectors). 50

59 Network Setup Step 3: Configure the HSMs IP Addresses NOTE: A Class C IP subnet mask ( ) is used by default. If a different subnet mask is required, contact the DFS Service department for specific instructions. 1. Connect the keyboard and monitor to the upper HSM (HSM installed on the top backplane). Ports for connecting a keyboard and monitor are easily accessible and clearly marked. 2. Restore power to the HSS. A. Turn on both PSMs. B. Connect both batteries. The HSS is now activated. 3. It is not necessary to power up the HSM; it will automatically power up when it senses power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly. +CPU and +5V LEDS are constant and remain constant during and after power up. B. The SDN LED goes off and the ACT LED is constant. C. The ACT LED begins to blink indicating that the HSM is fully powered. 4. When the HSM is fully powered and booted up, a login prompt appears on the monitor. Enter mgr for the login and htiimgr for the password. 5. At the command prompt, type change_ip xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the IP address of the HSM). 6. Disconnect the keyboard and monitor from the upper HSM and connect them to the lower HSM. The login prompt should be displayed on the monitor. (NOTE: If the login prompt is not displayed, press the space bar to refresh the video display.) 7. Repeat steps 4 and 5 to configure the lower HSM s IP address. Step 4: Reboot the HSMs Reboot the HSMs one at a time. The order in which the HSMs are rebooted is not important. 1. Press the power down button on the HSM and watch the HSM's LEDs. When the +CPU LED goes off, the HSM is fully powered down. After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed. 2. After 10 seconds have passed, press the power up button on the HSM and watch the HSM's LEDs. When the ACT LED begins to blink, the HSM is fully powered up. We recommend that you keep the keyboard and monitor attached to one of the HSMs until you verify that you can communicate with the HSS from a Windows workstation. Specific instructions for configuring a redundant servicer can be found in separate documents. Contact Data Flow Systems Service department for more information. 51

60 HSS Installation and Operation Manual Figure 5-4, "HSS Jumper and Address Settings" 52

61 Chapter 6: TELEMETRY SYSTEM SETUP There are many options for configuring an HSS-based telemetry system. These options depend on the type of system the HSS will be communicating with a system of Network RTUs or a Tunnel CTU? The following sections describe a few of these different system configurations and provide basic instructions on how to connect them to the HSS. Your configuration may differ based on your system s needs and your existing network structure. NETWORK RTUS (HSS002-X ONLY) Overview In this configuration, data is passed between an Ethernet client network or a stand-alone workstation, and a system of Network (FIM-based) Remote Terminal Units (RTUs). Each RTU contains a Fiber Interface Module (FIM) that is responsible for communications between the primary HSM and the station's function modules. The Network RTUs connect to the HSS via a rack-mount media converter. NOTE: Although the diagram below shows a non-redundant HSS, connections for both the HSS002-1 and HSS002-2 are identical when connecting to a system of Network RTUs. For an HSS002-2, assume that the illustration only shows the unit s top backplane. Hyper SCADA Server (HSS002-1) H S M V O I D V O I D N F M U N S M P S M DIN-rail mounted Network Surge Arrestor CAT 5 CAT 5 Ethernet Network Workstation Fiber Optic Cable Rack Mount Media Converter Workstation Fiber Optic Cable Rack Mount Switch Network RTU F I M P S M Network RTU F I M P S M Network RTU F I M P S M Network RTU F I M P S M Network RTU F I M P S M Figure 6-1, "Illustration of Network RTU System" 53

62 HSS Installation and Operation Manual In a Network RTU, a Fiber Interface Module (FIM) is installed in the Radio Interface Module (RIM) slot of the RTU. No connector changes are necessary; the FIM and the RIM are keyed the same. The RTU must be addressed between 1 (one) and 250. If the RTU is being converted from a RIM-based to a FIM-based unit, the RTU must be readdressed if it is currently addressed between 255 and 512. Communication between the HT3 system and the RTU s function modules takes place over a network via an HT3 NIM driver. This provides high-speed communication and a more efficient polling loop for in-plant configurations. In this configuration, the Network RTUs and the HSS must be on the same local area network. The FIM supports and can communicate with or 1200-baud modules. To obtain the most efficient polling rate, we recommend that 9600-baud modules be used. Functions and Features Reduced Polling Time Polling time is greatly reduced when a FIM replaces a RIM in an in-plant RTU that was using a rubber duck antenna. The polling rate of any external (out-of-plant) RTUs is also improved, because the amount of information being processed via radio has been reduced. Similar I/O The I/O of the RIM and the FIM are basically the same. The only difference is that the FIM has additional termination points to enable RS-232 communications. Serial Tunneling The DOS-based network CPU on FIMs provides network communication logic that allows each module to communicate over a network as if it were a radio. This function is referred to as serial tunneling. Serial tunneling via COM1 and COM2 allows the FIM to communicate with RS-232 devices, including Modbus devices. COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Both COM1 and COM2 are used only as a stand-alone serial tunnels; there is no buss communication. COM1: Pin 2=RXD, Pin 4=TXD, Pin 6=GND, Pin 11=RTS, Pin 13=CTS COM2: Pin 8=RXD, Pin 10=TXD, Pin 12=GND, Pin 14=RTS, Pin 16=CTS. 54

63 Telemetry System Setup Program Updates The DOS-based program on the FIM can be remotely updated through a driverinitiated download. This is accomplished through the Module Patching tool included with HT3. See the HT3 User Guide for more information. The module s on-board processor is in-socket programmable. The processor controls the power going to the CPU and any network hardware (for example, converters or switches) mounted on the module. Automatic IP Addressing The NIM/FIM features automatic IP addressing. The modules obtain their network address from the NIM driver and the station address strap. The first three octets of the address come from the driver; the last octet comes from the address strap. This assumes a class C subnet mask. If you need a different subnet mask, contact DFS Service department for assistance. When the NIM/FIM module boots up, it receives a broadcast from the NIM driver that contains its subnet. The FIM reads its subnet, mates it with the station address, and begins to talk at that IP address. [IMPORTANT: The NIM/FIM cannot be addressed greater than 250. If the RIM that is being replaced was addressed greater than 250, you must readdress the module slot at 250 or less.] Power Monitoring Functions Monitors RTU Power and DC Bias from the Power Supply Module (PSM). Powers the buss through the startup plate (magnetic switch on front plate). Shuts down the PSM for battery test. Powers network hardware (one-port media converter or four-port switch). Cycles power to network hardware and the CPU if communications stop for more than two minutes. This is done continuously until communications resume. Test Mode When a network interface module (FIM or NIM) is placed in test mode, its service port shows traffic to function modules. This information can be viewed using WinRTU Test s Inject or Antenna forms. WinRTU Test s Module, Module Config, and ROM Patch forms can be used to communicate with function modules. To place a network interface module in test mode: 1. Power down the RTU by disconnecting the battery and then powering down the PSM. 2. On the network interface module, press and hold the test button while powering up the PSM. Press and hold the test button until the network interface module s transmit and receive LEDs start flashing and its Test LED comes on. 3. When the Test LED comes on and remains constant, the module is in test mode. To exit test mode, power down the network interface module and then power up without pressing the test button. 55

64 HSS Installation and Operation Manual Installation and Configuration Procedure Network Considerations The Fiber Interface Module (FIM) has an RJ-45 Ethernet jack and is designed to communicate over a 10base-T Ethernet network. If your local area network is a 100mbs network and you will be distributing the network from the RTU, the media converter on the FIM can be upgraded to a 10/100Mbps auto-negotiating model (FIM001-10/100). When installing a network interface module in an RTU, it is highly recommended that the RTU be isolated from the rest of the network utilizing fiber optic cable. The Fiber Interface Module (FIM) was designed for this purpose; the FIM has an attached media converter for converting twisted pair copper to fiber. IMPORTANT: When dealing with a large number of networked RTU's, it isn t financially practical to try to bring all networking into the HSS. For this reason, a centralized location is needed to convert the fiber back to copper and to connect the RTU(s) to the Hyper SCADA Server. It is recommended that the fiber from all the RTUs be run to a common location (for example, a server or telephone room) in which a large media converter has been installed. This larger unit, which typically mounts into a network hardware rack, would have a single power supply and 8-12 fiber to CAT5 converters. In addition, this central location would require a larger switch to accommodate each converted fiber and must provide access to the HSS and the local area (client). A UPS must be used to provide battery back up for all this network hardware. When planning an installation, consider the following when selecting the type of fiberoptic cable (multi-mode or single-mode) and the type of media converters: Speed of the local area network Distance between the HSS and rack-mount media converter to which the system s Network RTUs are connected Cable Selection Multi-mode fiber-optic cable covers distances up to 2 km (~ 1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~ 9.3 miles). Converter Selection The standard converter used on the Fiber Interface Module (FIM) is a 10Mbps Ethernet Media Converter that accepts multi-mode fiber. The FIM s converter can be upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the Network RTUs. Additionally, both the FIM and the NFM can be ordered with converters that accept single-mode fiber (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length). 56

65 G Telemetry System Setup Baud Rate Considerations To have the FIM communicate at its fastest speed, all of the station s I/O modules must be able to communicate at 9600 baud. I/O modules that meet this requirement are the AMM002, ACM002, DMM002, and all versions of the DCM003. If any one module at the station communicates at 1200 baud, the entire station can only communicate at that speed. The exception to this is when the station contains a PLC (PLCs communicate at 9600 baud; function modules communicate with the rest of the system through the PLC). In this situation, the communication speed of the I/O modules that are downstream from the PLC is irrelevant. What you will need: One Fiber Interface Module (FIM). One Network Switch Module (NSM) (optional; only required if using 10/100Mbps auto-negotiating converters.) One CAT 5 patch cable terminated with RJ-45 connectors. Fiber-optic cable of sufficient length to cover the distance from the RTU to the connection to the local area (client) network. In most circumstances, multi-mode cable can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode cable and appropriate converters. Electrostatic discharge wrist strap (this must be worn while working inside the RTU). NOTE: These instructions provide details on converting an existing radio-based RTU to a network-based RTU. If you are creating an original network-based RTU, disregard references to removing the RIM and readdressing the station. 1. Remove power from the RTU. 2. Remove the RIM. Note that the RTU s module address blocks do not require any changes unless the address is above Install a FIM in the RTU s RIM slot. The FIM requires no jumpers. 4. Address the FIM if required. The FIM must be addressed less than 250 (1-250). The station must be readdressed if it originally contained a RIM that was addressed between 256 and 512. This address is the node portion of the Network RTU s IP address. The address is calculated by adding up the bits that are OPEN, or OFF. The figure at right is an example of how to set the station address for a network RTU. It shows the setting for addressing a FIM at 208. The 128, 64, and 16 switches have been placed in the OPEN position ( = 208). See Appendix D: Addressing Modules for more information on module addressing. Open Closed Station Address Figure 6-2, "FIM Addressed at 208" NOTE: Modular RTU only 256 bit is inverted. 57

66 HSS Installation and Operation Manual 5. Connect the FIM s media converter to its DOS-based network CPU using a CAT 5 patch cable terminated with RJ-45 connectors. 6. (Optional) If your configuration requires use of 10/100Mbsp auto-negotiating media converters, install a NSM in any unused module slot in the RTU. Jumpers must be placed between pins 3 and 5 and also between pins 43 and 25 on the NSM. Punch out the module address for the NSM s corresponding module slot. Using CAT5 cable, connect the FIM s media converter to the NSM; Also connect the FIM itself to the NSM. 7. Connect the RTU to the local area (client) network (refer to the drawings on the next page). Using 10Mbps media converters: Connection to the network is through a fiberoptic cable that is attached to the FIM s media converter (TX and RX connectors). In most circumstances, multi-mode fiber can be used. If the distance to be covered is greater than 2 km, it will be necessary to use single-mode fiber and appropriate converters. Using 10/100Mbps auto-negotiating media converters: Connection to the network is through a CAT5 cable connected to the NSM. 8. Restore power to the RTU. 9. Add and configure a NIM driver in HT3. For instructions on adding a NIM driver, see the HT3 User Guide. 10. Configure this station in HT3. (NOTE: If this is an RTU that is being converted from radio to network communications, you can copy the existing station and its related module and point configurations from the DFS driver to the newly created NIM driver. You can then delete the station from the DFS driver.) For instructions on configuring stations, see the HT3 User Guide. 58

67 FUNCTION MODULE FUNCTION MODULE FUNCTION MODULE FIBER INTERFACE MODULE FIM001 FIBER OPTIC CONV. F/O POWER SUPPLY MODULE FUNCTION MODULE FUNCTION MODULE FUNCTION MODULE FUNCTION MODULE FIBER INTERFACE MODULE FIM001 FIBER OPTIC CONV. F/O POWER SUPPLY MODULE Telemetry System Setup NETWORK RTU (10Mbps Converter) CAT5 CAT5 FIBER NETWORK Figure 6-3, "Network RTU (10Mbps Converters)" NETWORK RTU (10/100Mbps Converter) NETWORK SWITCH MODULE CAT5 CAT5 CAT5 CAT5 CAT5 FIBER OPTIC LOCAL AREA NETWORK FIBER NETWORK / HYPER SCADA SERVER Figure 6-4, "Network RTU (10/100 Mbps Converters)" 59

68 HSS Installation and Operation Manual Figure 6-5, "Network RTU Address Settings" 60

69 Telemetry System Setup TUNNEL CTU Overview In this configuration (HSS Tunnel CTU), data is passed between a local area (client) network (or a master workstation) and a Tunnel CTU. A Tunnel CTU is a radio-based CTU that uses a Fiber Interface Module for serial tunneling - a process that enables serial (radio) data to be sent over a network. An HSS-Tunnel CTU system uses a CTU that includes both a FIM and a RIM. Communications are sent to the FIM via the network. The FIM translates the network data into serial (radio) data and passes this information to the CTU s RIM, which then transmits it to radio-based RTUs. A Tunnel CTU requires that a radio-type driver instead of a NIM driver be configured. Network interface modules provide a serial tunnel (COM1) from the client network to the local RIM s bus. An optional second tunnel (COM2) is provided to the card connector. See "Two Serial Tunnels" on the next page for more information. (IMPORTANT: There is no test mode function when the FIM s second serial tunnel port is used.) Hyper SCADA Server (HSS002-1) H S M V O I D V O I D N F M U N S M P S M Category 5 Cable Category 5 Cable Ethernet Network Workstation DIN-rail mounted Network Surge Arrestor Fiber Optic Cable Central Terminal Unit V O I D V O I D V O I D F I M R I M P S M Workstation Remote Terminal Unit Remote Terminal Unit Remote Terminal Unit Figure 6-6, "Illustration of Tunnel CTU System" 61

70 HSS Installation and Operation Manual Functions and Features Installs in CIM Slot If an existing system is being upgraded to the Hyper SCADA Server, the CTU s Computer Interface Module (CIM) must be replaced with a FIM. The illustrations below show the placement of the FIM in a CTU. If the CTU is a 202 box, the FIM must be placed in the far left module slot (opposite end from the PSM). For a 204 box, place the FIM directly beside the RIM. When replacing a CIM with a FIM, remove all CIM jumpers. Place a jumper across pins 15 and 21 on the FIM and configure the FIM with a valid station address (information provided in the section Installation and Configuration Procedure beginning on page 63). Figure 6-7, "CTU in 202 or 204 Box" Drivers The operation of this setup is identical to a radio system, and supports both DFS and Modbus radio drivers. A NIM driver is not applicable when a FIM is being used as a tunneling device. Two Serial Tunnels The first serial tunnel (COM1) goes over the CTU s buss to the Radio Interface Module (RIM). This tunnel enables the transfer of data between the network and the radio. The driver s Tunnel IP Address would be configured in HT3 as x.xxx.xxx.aaa.1, where xxx.xxx.xxx defines the subnet of the network interface module, AAA represents the network interface module s station address, and 1 represents the COM port number the RIM is connected to. For example, for a CTU with an IP address of with a default connection using COM port 1 of a FIM addressed at 247, you would configure a DFS Driver in HT3. The driver s CTU Tunnel IP Address would be

71 Telemetry System Setup When used as a stand-alone tunnel device (not with DFS RTU equipment), COM1 provides five-wire RS-232 serial communications, including RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. The network interface modules also provide an optional second serial tunnel (COM2). This second tunnel enables one network interface module to poll two different types of devices. The COM2 port is used only as a stand-alone serial tunnel; there is no buss communication. COM2 also includes RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. (NOTE: The test port is disabled if the second serial tunnel port is used.) For example, the first tunnel can be communicating through COM1 to a DFS RIM, while the second tunnel is communicating through COM2 to a Modbus PLC. In this example, a second radio driver (Modbus driver) would have to be configured for the second device. In HT3, the Tunnel IP Addresses for both drivers would be identical except for the last octet, which represents the COM port number. The second driver s address would be xxx.xxx.xxx.aaa.2, indicating that it is communicating via the second COM port. Following our example above, this device would require that a Modbus driver be configured with a Tunnel IP Address of See the HT3 User Guide for more information on configuring drivers.. Service Port and Test Mode With a tunneling network interface module, Test mode does not supply a function. In this configuration, where the first serial port (tunnel 1) is being used for tunneling, the service port automatically shows tunnel 1 s traffic. Tunnel 1 s traffic can be viewed using the WinRTU Test software provided by DFS. Connect a laptop to the network interface module s service port and use WinRTU Test s Inject or Antenna form to view the communication traffic. Note: If the second serial port (optional tunnel 2) is being used, there is no service port function. Installation and Configuration Procedure Network Considerations When planning an installation, consider the following when selecting the type of fiberoptic cable (multi-mode or single-mode) and the type of media converters: Speed of the local area network. Distance between the HSS and the CTU. Cable Selection Multi-mode fiber-optic cable covers distances up to 2 km (~ 1.2 miles). Single-mode fiber-optic cable covers distances up to 15 km (~ 9.3 miles). Converter Selection The standard converter used on the Fiber Interface Module (FIM) is a 10Mbps Ethernet Media Converter that accepts multi-mode fiber. The converter can be 63

72 HSS Installation and Operation Manual upgraded to a 10/100Mbps auto-negotiating converter for those customers who are running a fast network and need to distribute the network from the CTU. Additionally, the FIM can be ordered with converters that accept single-mode fiber (refer to the specifications in Appendix A: Technical Specifications when selecting a converter for important information on operating environment and fiber length). What you ll need: One Fiber Interface Module (FIM). (See Appendix A: Technical Specifications - Fiber Interface Module on page 89 when selecting a Fiber Interface Module.) (Optional) One Network Switch Module (NSM) (required only if using 10/100Mbps auto-negotiating media converters). CAT 5 patch cable terminated with RJ-45 connectors (one cable required if using 10Mbps converters; two cables required if using 10/100Mbps converters). Fiber-optic cable (multi-mode or single-mode depending on required fiber distance) of sufficient length to cover the distance from the Tunnel CTU to the Hyper SCADA Server or HT3 central computer. Configuration jumpers (black #16 stranded wire can be used for making jumpers). Electrostatic discharge wrist strap (this must be worn while working inside the CTU). These instructions provide details on converting an existing CIM-based CTU. If you are creating an original Tunnel (FIM-based) CTU, disregard references to removing the CIM. Wiring diagrams are provided beginning on page 66 to assist you with set up. See Figure 6-12, "Tunnel CTU Jumper and Address Settings" on page 67 to view a diagram of jumper and address settings for the Tunnel CTU. Note: If your system requires use of the 10/100 auto-negotiating media converter and the additional Network Switch Module, you must use the 204 CTU box. 1. Power down the unit. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. 2. Remove the CIM and all CIM jumpers. 3. Insert the FIM in the vacated CIM slot. The first three module slots are unused if using a 204 box; the second module slot is unused if using a 202 box. See Figure 6-7, "CTU in 202 or 204 Box" on page (Optional; this step only required when using 10/100Mbps auto-negotiating converters). Insert the NSM in a vacant module slot. Jumpers must be placed between pins 3 and 5 and also between pins 43 and 25 on the NSM. Punch out the module address for the NSM s corresponding module slot. 5. Swap the buss to the RIM by placing a jumper across pins 15 and 21 of the FIM. 6. Bypass the startup plate by placing a jumper across pins 3 and 5 on both the FIM and the RIM. 7. Configure the FIM with a valid station address. Place a jumper across the appropriate pins to set the FIM at the desired address. [IMPORTANT: The address cannot already be in use by any other network device, including other network RTUs or CTUs.) See Figure 6-8, "FIM Addressing Examples" (below). Note that only pins 27-43, which are 64

73 G Telemetry System Setup used for addressing the FIM, are drawn; the entire card is not shown. See Appendix D: Addressing Modules for more information on module addressing Figure 6-8, "FIM Addressing Examples" 8. The RIM maintains a CTU address 0 or See Figure 6-9, "RIM Addressed at 254" (below). More information on module addressing can be found in Appendix D: Addressing Modules. If your system uses an FTU (Forward Telemetry Unit), note that the FTU station address does not have to be configured in HT3, but it is recommended for easier troubleshooting. An FTU contains two RIMs (one RIM addressed as a station, usually to communicate with the central site and the other RIM addressed as a CTU to communicate with all the remote sites. Open Station Address Closed Figure 6-9, "RIM Addressed at 254" 9. Remove the module address block between the FIM and the last unused module slot. In a 204 box, the module address block between the first and second unused slots may be removed or left as is. ( continued on next page) 65

74 FIBER INTERFACE MODULE FIBER OPTIC CONV. F/O RADIO INTERFACE MODULE POWER SUPPLY MODULE FIBER INTERFACE MODULE FIBER OPTIC CONV. F/O UNUSED MODULE SLOT RADIO INTERFACE MODULE POWER SUPPLY MODULE HSS Installation and Operation Manual 10. Select the appropriate step below depending on the type of media converter you are using: 10Mbps converters: Connect the FIM s media converter to its DOS-based network CPU using a CAT 5 patch cable terminated with RJ-45 connectors. 10/100Mbps converters: Use CAT5 cable to connect the FIM s DOS-based network CPU to a port on the NSM; use a second CAT5 cable to connect the FIM s media converter to a port on the NSM. 11. Connect the CTU to the network or directly to the HSS. Connection to the network/hss is through a fiber-optic cable attached to the FIM s media converter (TX and RX connectors). In most circumstances, multi-mode fiber can be used. If the distance to be covered is greater than 2 km, single-mode fiber and different converter types must be used. 12. Restore power to the CTU. 13. Add and configure a DFS RTU driver in HT3. The CTU Tunnel IP Address field must show the IP address of the FIM. For instructions on configuring drivers, see the HT3 User Guide. TUNNEL CTU (10Mbps Converter) CAT5 CAT5 CAT5 CABLE FIBER OPTIC CABLE TO FIBER NETWORK / HYPER SCADA SERVER Figure 6-10, "Tunnel CTU with 10Mbps Converter" TUNNEL CTU (10/100Mbps Converter) CAT5 CAT5 CAT5 CABLE NETWORK SWITCH MODULE CAT5 CABLE CAT5 CABLE TO LOCAL AREA NETWORK FIBER OPTIC CABLE TO FIBER NETWORK / HYPER SCADA SERVER Figure 6-11, "Tunnel CTU with 10/100Mbps Converter" 66

75 Telemetry System Setup Figure 6-12, "Tunnel CTU Jumper and Address Settings" 67

76 HSS Installation and Operation Manual SERIAL DEVICES (HSS001) The Hyper SCADA Server (HSS001) features two ports (COM1 and COM2) for connecting serial-type devices, including Modbus devices. These ports are connected to the HSS' NIM, which allows the serial devices to pass their data to network devices. This is accomplished through a process called serial tunneling. In serial tunneling, the HSM bundles serial data into network packets and forwards it to the NIM. When the NIM sees an incoming packet, it switches to serial tunnel mode, extracts the serial data, and sends the data out the appropriate COM port. When a serial device sends data to one of the NIM s COM ports, the NIM bundles the data into network packets and forwards them to the HSM. Both the HSM and the NIM are capable of bundling serial data into network packets, and disassembling these packets and extracting their data when they are received. COM1 and COM2 include RTS and CTS to support connections to equipment (such as radios and modems) that require hardware handshaking. Additionally, both COM1 and COM2 are used only as a stand-alone serial tunnels; there is no buss communication. COM1: Pin 2=RXD, Pin 4=TXD, Pin 6=GND, Pin 11=RTS, Pin 13=CTS COM2: Pin 8=RXD, Pin 10=TXD, Pin 12=GND, Pin 14=RTS, Pin 16=CTS H S M N I M N S M P S M COM2 COM TELEPHONE LINES AUDIO OUT SOURCE LOAD BATTERY AC POWER TO SERIAL DEVICE 1 TO SERIAL DEVICE 2 Figure 6-13, "HSS001 Connected to Serial Devices" 68

77 Chapter 7: WORKSTATION CONFIGURATION After the Hyper SCADA Server (HSS) has been installed, and the telemetry system has been wired and configured, the client workstations that will be accessing the HT3 SCADA software must be configured. Since the HSS itself does not include a console interface (monitor, keyboard, and mouse), client computers on the network, or a master workstation connected directly to the HSS, are used to access HT3 via its browser-based interface. Although more than one client workstation can be used to access HT3, we recommend that one computer be designated as the primary workstation. This workstation would be used to maintain a constant connection to HT3, and would be used for recording voice alarms and playing alarm announcements. The primary workstation is also used as a backup location for the HSS. Information on critical data redundancy is provided in Chapter 8: Critical Data Redundancy and in the HT3 User Guide in the section titled Configuring Your System: Critical Data Redundancy. Each computer that will be used to access HT3 must meet specific system requirements and be set up to connect to the HSS. SYSTEM REQUIREMENTS All computers that will be using the HT3 SCADA software must meet the following requirements: Windows XP with SP2, or newer IE 8.0 or newer Java 1.5 *A microphone for recording voice alarm announcements is optional. WORKSTATION CONFIGURATION The instructions below provide details on how to configure a Windows workstation to communicate with the HSM. Workstations communicate with the HSM via HT3, Data Flow Systems network-based SCADA software. HT3 monitors and controls in-plant, as well as remote, unmanned stations from a central telemetry server the Hyper Server Module (HSM). HT3 is installed on the HSM; users access HT3 from Windows-based workstations using a Java-enabled Internet browser. The only software installed on each workstation is Internet Explorer 8.0 or newer, a Java Policy file, and Java 1.5. After starting HT3, you can learn more about the software by reading the release notes (select About HT3 from the HT3 Help menu). To read descriptions of the software s functions and instructions on their use, select HT3 Online Help from the HT3 Help menu. 69

78 HSS Installation and Operation Manual Configuration consists of the following steps: Take the following steps to configure a Windows workstation to access HT3: 1. Edit the Hosts file 2. Change Browser settings 3. Install plug-ins and Java Policy File 4. Start HT3 Editing the Hosts File The hosts file allows you to associate a name (for example, ht3) with an IP address. Editing the hosts file as described below is necessary to allow HT3's applications, such as Screen Builder and Logic Builder, to save files on the workstation (a Java Policy file is also required). Adding an entry for HT3 to the hosts file also allows you to use the host name instead of an IP address to connect to your Hyper SCADA Server through HT3. Note to Users Upgrading from HyperTAC II: You do not need to edit the hosts files of existing workstations. HT3's Java Policy file also recognizes the host name hypertacii used by existing HyperTAC II systems. 1. On the Windows taskbar, click the Start button, and then click Run. 2. In the Run box, type one of the following (depending on your OS level) and click OK: For Windows XP and newer, type edit c:\windows\system32\drivers\etc\hosts For Windows 2000 / NT, type edit c:\winnt\system32\drivers\etc\hosts. 3. In the hosts file, place your cursor on a line below the file's comments - lines preceded by a pound sign (#) - and do the following: A. Type xxx.xxx.xxx.xxx (where xxx.xxx.xxx.xxx represents the Hyper SCADA Server's IP address) B. Press the Tab key C. Type ht3 4. Select Save As from the File menu. Verify that the name hosts appears in the File Name field and click OK. 70

79 Workstation Configuration Test Connection to Hyper SCADA Server After the host file has been edited and saved, use the ping command to verify that your workstation can connect to the Hyper SCADA Server using the assigned host name. 1. On the Windows taskbar, click the Start button, and then click Run. 2. Type ping ht3 in the Run dialog box and click OK. 3. A DOS window appears on screen and indicates if a reply has been received from the Hyper SCADA Server. Change Browser Settings Several changes must be made to Internet Explorer's security settings before you can successfully run HT3. 1. Start Internet Explorer. 2. Select Internet Options from the Tools menu. 3. Click the Security tab and select the Local intranet zone. 4. Click Custom Level In the Security Settings dialog box, enable the following: All of the options listed under ActiveX controls and plug-ins All of the options listed under Cookies 6. Click OK at the Security Settings dialog box. 7. Click OK at the Internet Options dialog box. 71

80 HSS Installation and Operation Manual Install Plug-Ins and Java Policy File 1. Start Internet Explorer. 2. In Internet Explorer's Address box, type hypertac (the host name assigned to your Hyper SCADA Server). 3. If the necessary plug-ins are not already installed, the HT3 Plug-Ins page is loaded. (Note: If the HT3 Plug-Ins page does not automatically load, type in Internet Explorer's Address box.) 4. Follow the instructions on the page to install the required HT3 files and plug-ins.. Start HT3 1. When installation of the plug-ins and the Java policy file is complete, type hypertac in Internet Explorer's Address box. 2. On the HT3 login page, enter your Login and Password and click OK. 3. Bookmark HT3 in your browser or create a shortcut to HT3 on your Windows desktop. 72

81 Chapter 8: CRITICAL DATA REDUNDANCY CONFIGURING REMOTE SYSTEM BACKUP HT3 features an automated backup routine that protects your system from critical data loss. Data is copied and stored locally in a designated backup folder on the Hyper Server Module (HSM). As an additional protection against data loss, a Windows workstation can be configured as a remote backup location. A remote backup site protects you from loss of data in the event of an HSM hardware failure (the HSM itself stops functioning). The designated backup workstation should be equipped with a hard drive large enough to hold all of the system's backup data and must be configured as a remote backup location. See Configuring Remote System Backup, below for instructions on configuring a remote backup site. HT3 performs an automated backup procedure daily at a few minutes after midnight. The system first makes a local copy of the data (stored on the Hyper Server Module). It then attempts to locate the remote backup computer. For remote backup to occur, the designated Windows workstation must be on and running. It is recommended that all power management be disabled (i.e., the network card is not allowed to sleep). If HT3 does not find the remote location, it skips the creation of a remote copy. It will not attempt another remote backup until the following midnight. An entry is made in the current day's Access Log to indicate if the previous day's backup succeeded or failed. When the system performs a backup, all of the configuration databases, and the logs and journals for the previous day are backed up. The configuration databases are kept for one week in directories named for each day of the week (e.g., Monday's data is placed in a backup directory named Mon). Logs and journals are backed up daily and kept until the hard drive reaches full capacity. Data is archived and condensed based on the purge settings configured in HT3 (see Critical Data Redundancy: Configuring Purge Schedules in the HT3 User Guide). When the amount of hard drive space used approaches 100 percent, HT3 deletes the oldest logs and journals. If you need to keep older data (configurations, logs, journals), copy it to external media prior to it being deleted. For example, data can be copied to a folder on the backup Windows workstation or to a flash drive. If you need to restore backed up data, contact DFS Service Department. Procedure for Configuring Backup Site NOTE: We recommend that the remote Windows backup machine have at least 5 gigabytes of free disk space. 1. If the backup directory is to be on a Windows NT/2000, or Windows XP or newer machine, it is recommended that a new user account be created on the machine. 2. Create a backup folder, or directory, on the Windows workstation that has been designated as the remote backup. 73

82 HSS Installation and Operation Manual 3. Share the backup folder. (Refer to your Windows Help for information on sharing folders.) Windows 98 / ME: A. Select Full for Access Type. B. Enter HSS for the Shared as name. C. Enter a password in the Full Access Password box. Windows 2000 / NT, or Windows XP or newer A. Change the share name of the folder to HSS. B. Set all shared folder permissions to Full Control. C. Give the user account created in step one, above, Full access to the shared folder. 4. Login to HT3 and open the System Backup tool by clicking Configure on the HT3 main menu and then clicking Backup on the Configure submenu. 5. Configure the following: Enable Remote Backup - Select this option to turn on automated backup. Remote Machine Name - Enter the IP address of the Windows workstation that has been designated the remote backup location. Remote Share Name - Enter the share name of the backup folder. This should be HSS. Remote User Name - Enter the name of the user account created in step 1, above (Windows 2000/NT or Windows XP or newer machines only). Remote Share Password Windows 98/ME: Enter the Full Access Password assigned to the shared backup folder. Windows 2000/NT or Windows XP or newer: Enter the password of the user account created in step one, above. 6. Verify that all of the above information is correct and click Ok. 74

83 Critical Data Redundancy PRINCIPLES OF REDUNDANCY FOR AN HSS002-2 A redundant system uses an HSS002-2, which is a Hyper SCADA Server (HSS) with two Hyper Server Modules (HSMs). The goal of redundancy is to allow the two HSMs to operate as one. One HSM acts as primary and runs HT3 and the MySQL database server. The other HSM runs in secondary mode and monitors the primary HSM. Implementing redundancy requires that you have three (3) unused IP addresses on the same class network: one for each HSM and one designated as the shared IP. The primary HSM always uses a shared IP address as well as a dedicated IP address. If the secondary HSM senses a loss of telemetry from the primary HSM, the secondary HSM reboots the primary, assumes the shared IP address, and begins to run the HT3 and MySQL servers. The roles of primary and secondary are not dependent upon the HSM's configured IP address or the backplane in which the HSM is installed. Either can operate as the primary or secondary server. You can determine the current role of an HSM (primary or secondary) by viewing the flashing pattern of the HSM's ACT LED. Single Flash A single flash indicates that the HSM is the primary server. Double Flash A double flash indicates that the HSM is the secondary server. The sections below provide an overview of redundancy. For more information on configuring HT3 for a redundant system, see Onfiguring Your System: Critical Data Redundancy in the HT3 User Guide. Primary Server The HSM acting as the primary server runs the HT3 SCADA software, including infoserver, all drivers, web server, MySQL server, and the remote file distribution (rdist) process. The function of the remote file distribution (rdist) process is to backup/copy specific data between two hard drives over a network. In the Hyper SCADA Server, the primary server is responsible for backing up all configuration data to the secondary server. The remote file distribution (rdist) process takes place every 10 minutes, and keeps the secondary up to date in case a switch over (redundancy takeover) is required. The primary also performs normal routines including backups to the remote windows computer and system purges. A single-flashing ACT LED on the HSM indicates that it is the acting primary server. Secondary Server The HSM acting as the secondary server only runs the client portion of remote file distribution process. The secondary server accepts distributed files from the primary, continuously checks for proper network connectivity, and checks for telemetry responses from the primary server. A double-flashing ACT LED on the HSM indicates that it is the acting secondary server. 75

84 HSS Installation and Operation Manual IP Sharing Redundancy uses a function called IP sharing that allows two or more network devices to communicate at one shared IP while retaining their own unique address. In the HSS002-2 application, the primary HSM "masquerades" as the shared IP address. Additionally, client computers are configured to communicate with the primary HSM using the shared IP (not the configured address). NOTE: Both HSMs can be accessed via their configured IP. The acting primary HSM can be accessed using either its configured IP or the shared IP. This may be useful during troubleshooting or when doing system maintenance. IP sharing makes redundancy virtually transparent to devices on the network, because they communicate with the primary HSM at the shared IP address not its configured address. When the primary and secondary HSMs switch roles, the new primary begins masquerading as the shared IP; there is no need to reconfigure clients to communicate with the new primary HSM. With a redundant server, all clients should access the server using the shared IP address and not the configured IP address for either HSM. Clients should set up their hosts file to associate the name hypertac with the shared IP address. Safe IP Address A Safe IP is the IP address of a device that is always up and is on the same network as the HSS. The secondary HSM uses this IP to determine if it should take over as primary after not getting a response from the acting primary. When it pings the Safe IP, it is trying to determine where the communication problem originated: with the primary HSM or with itself. If a gateway is configured on the HSM, it should be used as the Safe IP address. Examples of other Safe IPs are the addresses of routers, print servers, and voice-over-dsl devices. A workstation computer, although valid, is not the best selection since it can be easily turned off. A workstation computer can be used if no other devices are available, but it is important that it remain on at all times. Switch Over Process In a redundant system, the secondary HSM listens to the telemetry signal coming from the primary HSM. If the secondary does not detect telemetry from the primary for a period of 210 seconds, it initiates a takeover. If there is a response from the Safe IP, the secondary uses the hardware sledgehammer function to reboot the primary. While the primary HSM is rebooting, the secondary HSM will switch to primary mode, start all servers, and begin to masquerade the shared IP address. As the original primary reboots, it notices the partner HSM running as primary and enters secondary mode. Alternatively, if the secondary HSM does not get a response from the Safe IP, the problem may be with the secondary HSM itself. In this case, no switch over takes place, the timers are reset, and the secondary begins listening for the primary again. The secondary will not take over the primary role if it cannot successfully ping the Safe IP address. 76

85 Critical Data Redundancy HT3 DATA RECOVERY If you need to restore backed up data, contact DFS Service Department. 77

86 HSS Installation and Operation Manual Notes 78

87 Chapter 9: SYSTEM TESTING & TROUBLESHOOTING TROUBLESHOOTING TOOLBOX The following items are necessary for troubleshooting a network interface module (NIM or FIM)-based system: Laptop computer with serial port and Ethernet adapter RIM/NIM communication cable HyperTerminal, or similar terminal program A Network Switch Module (NSM) is optional, but is useful for obtaining a connection to the network. Becoming a client on the network enables you to perform tasks such as: Pinging the server to verify ability to connect Accessing HT3 from a remote location A NSM can be installed in any unused module slot of an RTU. For more information on this, see Access Network via Network Distribution Module, below. NOTE: The following paragraphs refer only to Fiber Interface Modules (FIMs), but the same information also applies to the Network Interface Module (NIM). ACCESS NETWORK VIA NETWORK DISTRIBUTION MODULE Overview This setup is typically used in conjunction with a Hyper SCADA Server (HSS) to provide a point of distribution for networking. A Network Switch Module (NSM) or Network Fiber Module (NFM) is installed in any unwired module slot of a network-based Remote Terminal Unit (Network RTU) to provide additional network switch ports or media conversion. This configuration is useful for troubleshooting purposes, or to use a NSM to provide a network connection for a laptop computer that is being used to program a PLC. Installs in Module Slot In this application, the NSM or NFM is not placed in the RTU s RIM slot. It is inserted in any other unused module slot, and it must be addressed at 256. To address the module at 256, place a jumper between card connector pins 43 and 25. The NSM or NFM must be addressed at 256 to identify it as a network distribution module (network module without a DOS-based network CPU). Power Distribution The skeleton board used as the base of all network modules provides power to the attached network hardware (switch or media converter). The NSM or NFM, because it is wired to the RTU s backplane, obtains power from the RTU and benefits from the RTU s battery backup function. 79

88 HSS Installation and Operation Manual Service Port The service port on network distribution modules provides no function. Installation and Configuration Procedure What you ll need: Network Switch Module (NSM) or Network Fiber Module (NFM). Configuration Jumpers (black #16 stranded wire can be used for making jumpers). CAT 5 patch cable terminated with RJ-45 connectors and/or fiber-optic cable (depending on the application). Electrostatic discharge wrist strap (this must be worn while working inside the unit). Refer to Figure 9-1, "Jumper and Address Settings for Network Hardware in RTU" (next page) for a wiring and configuration diagram. (NOTE: This configuration does not require changes to any HT3 configurations.) 1. Power down the RTU. Ensure that any other power sources coming into the enclosure are turned off. Even if the circuit breakers for the enclosure and the PSM have been turned off, dangerous voltages may still be present in the enclosure. 2. Insert a NSM or NFM in any empty or unused module slot in the RTU. (IMPORTANT: If the slot contained a module at one time and any field wiring remains, the field wiring must be removed. Failure to remove any field wiring terminated to the module slot could result in damage to the NSM/NFM, the backplane, or the installer.) 3. The NSM or NFM must be addressed at 256 to identify it as a network distribution module (network module without a DOS-based network CPU). To address the NSM or NFM at 256, place a jumper across pins 43 and 25. See Appendix D: Addressing Modules for more information on module addressing. 4. Bypass the startup plate by placing a jumper across pins 3 and 5 on the NSM / NFM. 5. Use the patch cable and/or fiber-optic cable to make network connection. 6. Restore power to the RTU. NOTE: If the NSM/NFM was installed for temporary use, remove all jumpers after removing the NSM/NFM. 80

89 System Testing & Troubleshooting Figure 9-1, "Jumper and Address Settings for Network Hardware in RTU" 81

90 HSS Installation and Operation Manual POTENTIAL PROBLEMS AND SUGGESTED TROUBLESHOOTING STEPS My Network RTU is offline! If you find that your network RTU is offline, verify the following: Physically check Is the FIM powered? Is the FIM s media converter powered? Is the media converter fiber linked? Verify by obtaining a console to the FIM (see procedure on next page) Is the FIM addressed < 250? Is the FIM s DOS-based CPU booting? Is the FIM seeing its station address? Is the FIM getting a network address from HT3 Verify through HT3 Has a NIM driver been configured and is it polling? Has the station been configured under the NIM driver and is it being polled? My Tunnel CTU is not Polling! If you find that your tunnel CTU is not polling, verify the following: Physically check Is the FIM powered? Is the FIM s media converter powered? Is the media converter fiber linked? Is there a jumper placed across pins 15 and 23 on the FIM? Is the RIM addressed as a CTU (0 or )? Verify by obtaining a console to the FIM (see procedure on next page) Is the FIM addressed < 250? Is the FIM s DOS-based CPU booting? Is the FIM seeing its station address? Is the FIM getting a network address from HT3? Verify through HT3 Has a NIM driver been configured to poll the correct NIM address? 82

91 System Testing & Troubleshooting OBTAINING A CONSOLE TO A FIM Connecting a laptop computer to a FIM enables you to: Verify that the FIM s CPU is functional Determine the version of DOS code that the FIM is running Determine the version of firmware running on the FIM s processor Determine the station address to which the FIM is set Determine the network address, or subnet, that is being broadcast by HT3 Determine the settings (baud rate, data bits, parity, stop bits) of the NIM driver under which the FIM has been configured NOTES: A console cannot be accessed if both serial ports on the FIM are being used for tunneling. This is not the test mode operation of the FIM that is used to monitor buss communication. Test mode does not require setting the console to noquiet and is designed to function with WinRTU Test at O 2. To obtain a console: 1. Connect the laptop s serial port to the FIM s service port using a RIM/NIM cable. 2. Configure your terminal program (HyperTerminal or a similar program) to connect directly to the FIM s serial port at N 1 3. Press Ctrl + C while powering up the FIM. 4. Type noquiet 5. Type reboot The following information is provided (see screenshot on the next page): The initial boot screen verifies that the FIM s CPU is functional Version of DOS code running on the FIM s CPU Version of firmware running on the FIM s processor Station address at which the FIM is set Network address (subnet) that is being broadcast by HT3 Baud rate, data bits, parity setting, and stop bits (in that order) required to access the console of the FIM s DOS CPU. IMPORTANT: When you have finished the troubleshooting session, you must return the FIM to quiet mode to re-enable the FIM s second serial tunnel. 83

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93 System Testing & Troubleshooting REPLACING THE HSM IMPORTANT: This should only be done by DFS-authorized personnel or under their direct supervision. You must have an HSM preconfigured with your system s settings and data before beginning this procedure. NOTES: Step 7, below, instructs you to connect a keyboard and monitor to the HSM. If your HSM was preconfigured at the factory and you do not need to configure its IP address, disregard step 7. After the HSM has been powered down, it cannot be restarted for 10 seconds. All inputs are ignored until 10 seconds have passed 1. Press the power down button on the HSM, the shutdown LED (SDN) begins to flash indicating that the shut down process has begun. 2. SDN then goes constant indicating that services to the HSM have been turned off. 3. After a few moments, the CPU power LED (+CPU) goes out indicating that it is now safe to remove power. 4. Disconnect the battery. 5. Turn off the PSM. The HSS is now deactivated. 6. Remove the HSM and install a new HSM. 7. Connect a keyboard and monitor to the HSM. Ports for connecting a keyboard and monitor to the HSM are easily accessible and clearly marked. 8. Turn on the PSM. 9. Reconnect the battery. The HSS is now activated. 10. It is not necessary to power up the HSM; it will automatically power up when it senses power has been applied. LED sequence during power up is as follows: A. The ACT LED is constant. The SDN LED blinks slowly and then more quickly. +CPU and +5V LEDS are constant and remain constant during and after power up. B. The SDN LED goes off and the ACT LED is constant. C. The ACT LED begins to blink indicating that the HSM is fully powered. 85

94 HSS Installation and Operation Manual Notes 86

95 Appendix A: TECHNICAL SPECIFICATIONS HYPER SCADA SERVER HSS001 Model Number HSS001 Part Number DFS Enclosure Size 13 W x 13 H x 7 D Board Size 5.25" x 6.88" Supply Voltage 115 VAC - 60 Hz Power Consumption 100 Watts Environment F (5-30 C), moisture-free Network Interface 10/100base-TX Network Protocol TCP/IP Dial-up Connection PPP Communication Protocols DFS TAC II, DFP (DFS new high speed protocol), Modbus ASCII, Modbus RTU, Modbus TCP HSS002 Model Number HSS002-1 (one MBP); HSS002-2 (two MBPs) Part Number DFS Enclosure Size 24 W x 30 H x 8 D Board Size 5.25" x 6.88" Supply Voltage 115 VAC, 60 Hz Supply Current 200 Watts Environment F (5-30 C), moisture-free Network Interface 10/100base-TX Network Protocol TCP/IP Dial-up Connection PPP Communication Protocols DFS TAC II, DFP (DFS new high speed protocol), Modbus ASCII, Modbus RTU, Modbus TCP 87

96 HSS Installation and Operation Manual HYPER SERVER MODULE Model Number HSM001 Part Number DFS Board Size 5.25" x 6.85" Supply Voltage 11.8 to 13.4 VDC Supply Current 1.5 Amps Network Interface 10/100base-TX NETWORK INTERFACE MODULE Model Number Part Number NIM001 DFS Board Size 5.25 X 6.88" Service Port Circuit Protection Power Requirements Network Interface Network Protocol Serial Interfaces CPU RS-232 (ASCII) Transorb 12 to 14 VDC; 579 ma 10base-T TCP/IP (UDP Datagram) Two external serial interfaces with four modes of operation. Interfaces are configurable at the connector. DOS-based network CPU Environment 0-40 C ( F) with a relative humidity of 5%-95% (noncondensing) 88

97 Technical Specifications FIBER INTERFACE MODULE FIM001 Model Number FIM001 Part Number DFS Board Size 5.25 X 6.88" Service Port RS-232 (ASCII) Circuit Protection Transorb Power Requirements 12 to 14 VDC; 653 ma Network Interface 10base-T or 10/100base T (determined by model selected) Network Protocol Serial Interfaces CPU Media Converter LEDs TCP/IP (UDP Datagram) Two (2) external serial interfaces with four (4) modes of operation. Interfaces are configurable at the connector. DOS-based network CPU 10Mbps Ethernet media converter or 10/100Mbps auto-negotiating Ethernet media converter (determined by model selected) Power, receive data, transmit data, network link, network traffic, COMM2, microprocessor fault, test mode Environment 0-40 C ( F) with a relative humidity of 5%-95% (noncondensing) Models FIM001-10: 10 Mbps; multi-mode fiber applications up to 2 km FIM001-10/100: 10/100 Mbps; multi-mode fiber applications up to 2 km FIM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-SM-10/100: 10/100 Mbps; single-mode fiber applications from 2-15 km 89

98 HSS Installation and Operation Manual NETWORK FIBER MODULE NFM001 Model Number NFM001 Part Number DFS Board Size 5.25 X 6.88" Circuit Protection Transorb Power Requirements 12 to 14 VDC; 280 ma Network Interface: 10base-T Network Protocol: TCP/IP (UDP Datagram) Media Converter: 10Mbps Ethernet media converter or 10/100Mbps auto-negotiating Ethernet media converter (determined by model selected) Environment: 0-40 C ( F) with a relative humidity of 5%-95% (noncondensing) Models NFM001: 10 Mbps; multi-mode fiber applications up to 2 km NFM001-F: 10/100 Mbps; multi-mode fiber applications up to 2 km NFM001-SM: 10 Mbps; single-mode fiber applications from 2-15 km FIM001-FSM: 10/100 Mbps; single-mode fiber applications from 2-15 km NETWORK SWITCH MODULE Model Number NSM001 Part Number DFS Board Size 5.25 X 6.88" Circuit Protection Transorb Power Requirements 12 to 14 VDC; 790 ma Network Interface 10base-T Network Protocol TCP/IP (UDP Datagram) Network Switch 10/100 Mbps Fast Ethernet 5-port UTP switch 90

99 Appendix B: PIN DEFINITIONS HYPER SERVER MODULE PIN DEFINITIONS Name Pin Name CONFIGURATION GROUND SYSTEM DC+ CONFIGURATION BIT SYSTEM GROUND CONFIGURATION BIT REDUNDANT DC+ CONFIGURATION BIT UNUSED UNUSED UNUSED UNUSED A/C POWER UNUSED NIM POWER DOWN UNUSED UNUSED UNUSED UNUSED UNUSED I/O +V UNUSED TRANSIENT GROUND UNUSED I/O GROUND UNUSED ALARM SILENCE INPUT UNUSED ALARM LIGHT OUTPUT UNUSED ALARM BELL OUTPUT UNUSED CPU ACTIVITY OUTPUT LINE 1 TIP (Default call out) SLEDGEHAMMER INPUT LINE 1 RING (Default call out) 9 8 SLEDGEHAMMER OUTPUT LINE 2 TIP (Default call in/maintenance) 7 6 OUTPUT 1 LINE 2 RING (Default call in/maintenance) 5 4 OUTPUT 2 AUDIO OUTPUT OUTPUT 3 AUDIO OUTPUT

100 HSS Installation and Operation Manual NETWORK INTERFACE MODULE PIN DEFINITIONS* Name Pin Name STATION ADDRESS GROUND SYSTEM V+ =key= STATON ADDRESS BIT SYSTEM GROUND STATION ADDRESS BIT POWER DOWN STATION ADDRESS BIT REQUEST TO SEND STATION ADDRESS BIT CLEAR TO SEND STATION ADDRESS BIT RECEIVE DATA STATION ADDRESS BIT TRANSMIT DATA STATION ADDRESS BIT (PSM) POWER SUPPLY V+ STATION ADDRESS BIT (PSM) POWER SUPPLY GROUND STATION ADDRESS BIT (PSM) POWER SUPPLY CONTROL PROGRAM STRAP PROGRAM STRAP (PSM) / RTU POWER OK PROGRAM STRAP (PSM) / BIAS OK PROGRAM STRAP CTS 2 PROGRAM STRAP GROUND RTS CTS GND 2 =key= 232 RTS TXD 2 BATTERY GROUND RXD 2 BATTERY V GND 1 / POWER UP TXD 1 REDUNDANT POWER SUPPLY GROUND RXD 1 =key= REDUNDANT POWER SUPPLY V+ 1 * These pin definitions apply to all versions of the network modules (NIM, FIM, NSM, and NFM) 92

101 Appendix C: LED STATUS AND ERROR CODES SDWN Shutdown ACT Activity SOUT Sledgehammer out +CPU CPU voltage +5V Module voltage HORN Alarm horn LIGHT Alarm light OUT1 Reserved for future use OUT2 Reserved for future use OUT3 Reserved for future use RXD1 Receive Data (COM 1; Line 1) TXD1 Transmit Data (COM 1; Line 1) RXD2 Receive Data (COM 2; Line 2) TXD2 Transmit Data (COM 2; Line 2) SDWN Indicates the shutdown or startup status of the primary server (HSM). Solid on Power has been removed from the server and the server is no longer responsive. Initial slow single blink that accelerates Server is starting up. (IMPORTANT: Server cannot be shut down until the LED stops blinking.) Initial fast double blink that decelerates Server is in the process of shutting down. (IMPORTANT: Server cannot be restarted while the LED is blinking or within 10 (ten) seconds after the blinking has stopped.) ACT Heartbeat monitor provided by the server via HSUport to confirm that processes are running. If there is a pause greater than 30 seconds between blinks, the CPU s firmware assumes the server has seized and issues a cold boot by shutting down the system and restarting it. (NOTE: The SDWN indicator will function as normal.) SOUT Indicates that the redundant HSM (if present) is disabled or is in the process of being disabled. The sledgehammer (disable) process is controlled by HSUport and HT3. +CPU Indicates that voltage is being applied to the server s microprocessor. +5V Indicates that +5V is being applied to the module (HSM). If the LED is not lit, the module is not receiving adequate voltage. HORN Indicates that the alarm horn is active (sounding off). 93