SCADAPack ES Hardware Manual

Transcription

1 SCADAPack ES Hardware Manual

2 2 SCADAPack ES Hardware Manual Table of Contents Part I SCADAPack ES Hardware 4 1 Technical... Support 4 2 Safety... Information 5 3 Introduction Hardware... Overview SCADAPack ES... Model Numbers External SCADAPack... ES Connections Isolation & Protection Processor Board Microprocessor... (CPU) & RAM Utility Port Compact... Flash, OS Flash, & Boot Monitor Flash Serial (RS-232,... RS-422, RS-485) Ports & Ethernet Ports I/O Board (Local... Physical I/O) Communication... Interfaces 19 5 Installation Mounting Field Wiring Grounding Pow er Supply... Requirements Auxiliary Pow... er Output Internal Fuses SCADAPack ES... Inputs/Outputs (I/O) Digital Inputs Counter Inputs Digital Outputs Analog Inputs Analog Outputs Series... I/O Expansion Pow er & Softw are... Requirements Inter Module Cables Installation Rules... and Recommendations Serial Communication Ports 0, 1 & Ports 3 & RJ-12 Modular... Connector Serial Communication... Cables Ethernet Communication Hex Sw itches... and Special Function Modes Battery Replacement SCADAPack E... Configurator 53 6 Startup... Modes Run Mode Service Mode Cold Boot Mode Other Startup... Modes 58

3 Contents SCADAPack ES... Remote I/O Sw itch Settings 60 7 SCADAPack... ES Diagnostics On Board Indication... LEDs I/O board LED... Enable Jumper Internal Analog... Points Internal Binary... Points Start-Up & Diagnostic... Display Session Command Line... Diagnostics Error Codes System Status... Codes DNP3 and PLC... Device Communication Errors & TCP/IP Errors Communication... Statistics 72 8 Calibration Overview Main Menu AI Menus Calibrate AI... Menu AO Menus Calibrate AO... Menu Calibrate Voltage... Monitor Calibration... Certificate Menu Calibration... Certificate Entering the... Operator Name Entering the... Calibration Equipment Entering the... Printed Circuit Board (PCB) Serial Numbers Supplementary... Test Data Menu Analog Input... Calibration Range Analog Output... Calibration Range 92 9 General... Maintenance Recommendations RTU Preventative... Maintenance Routine Recommendations Routine Maintenance... Schedule Specifications General Data Capaciity Pow er Supply Communications... Ports Digital Inputs Digital Outputs Counter Inputs Analog Inputs Analog Outputs Certifications

4 4 SCADAPack ES Hardware Manual I SCADAPack ES Hardware 2013 Control Microsystems Inc. All rights reserved. Printed in Canada. Version: The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage. 1 Technical Support Support related to any part of this documentation can be directed to one of the following support centers.

5 SCADAPack ES Hardware 5 Technical Support: The Americas Available Monday to Friday 8:00am 6:30pm Eastern Time Toll free within North America Direct Worldwide TechnicalSupport@controlmicrosystems.com Technical Support: Europe Available Monday to Friday 8:30am 5:30pm Central European Time Direct Worldwide +31 (71) euro-support@controlmicrosystems.com Technical Support: Asia Available Monday to Friday 8:00am 6:30pm Eastern Time (North America) Direct Worldwide TechnicalSupport@controlmicrosystems.com Technical Support: Australia Inside Australia au.help@schneider-electric.com 2 Safety Information Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists, which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

6 6 SCADAPack ES Hardware Manual DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. CAUTION CAUTION used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in equipment damage.. PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation, and has received safety training to recognize and avoid the hazards involved. BEFORE YOU BEGIN Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-of-operation guarding on a machine can result in serious injury to the operator of that machine. EQUIPMENT OPERATION HAZARD CAUTION Verify that all installation and set up procedures have been completed. Before operational tests are performed, remove all blocks or other temporary holding means used for shipment from all component devices.

7 SCADAPack ES Hardware 7 Remove tools, meters, and debris from equipment. Failure to follow these instructions can result in injury or equipment damage. Follow all start-up tests recommended in the equipment documentation. Store all equipment documentation for future references. Software testing must be done in both simulated and real environments. Verify that the completed system is free from all short circuits and grounds, except those grounds installed according to local regulations (according to the National Electrical Code in the U.S.A, for instance). If high-potential voltage testing is necessary, follow recommendations in equipment documentation to prevent accidental equipment damage. Before energizing equipment: Remove tools, meters, and debris from equipment. Close the equipment enclosure door. Remove ground from incoming power lines. Perform all start-up tests recommended by the manufacturer. OPERATION AND ADJUSTMENTS The following precautions are from the NEMA Standards Publication ICS (English version prevails): Regardless of the care exercised in the design and manufacture of equipment or in the selection and ratings of components, there are hazards that can be encountered if such equipment is improperly operated. It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always use the manufacturer s instructions as a guide for functional adjustments. Personnel who have access to these adjustments should be familiar with the equipment manufacturer s instructions and the machinery used with the electrical equipment. Only those operational adjustments actually required by the operator should be accessible to the operator. Access to other controls should be restricted to prevent unauthorized changes in operating characteristics.

8 8 SCADAPack ES Hardware Manual 3 Introduction Figure 4.1: SCADAPack ES RTU The SCADAPack ES is an intelligent microprocessor based telemetry and control unit. The SCADAPack ES may operate Stand-alone providing data acquisition, process control and telemetry functions, or in conjunction with other SCADAPack E RTUs and peripherals such as PLC s. The SCADAPack ES features extensive communications capabilities including Ethernet interfaces and a powerful embedded micro-controller to provide the user with a sophisticated telemetry Remote Terminal Unit (RTU) in an Open Systems environment. Many operational facilities can be configured, depending on the required telemetry and control application. This manual describes the hardware aspects of the SCADAPack ES. Complete floating point PLC type operations are provided, which can be programmed in any of the five IEC programming languages. The SCADAPack ES supports hardware floating point capability for high performance. Open systems communication protocols such as DNP3 and MODBUS are provided, including TCP/IP, Open Modbus/TCP and Modbus RTU in TCP within the RTU s firmware. The SCADAPack ES has an extensive on-board I/O capability. The on-board switch mode power supply allows operation from a single external voltage supply (10 30 Vdc, depending on model purchased). The use of FLASH memory chips allows new firmware to be downloaded via the RTU interfaces, both

9 SCADAPack ES Hardware 9 locally and remotely, without removing the RTU from its enclosure, or removing the lid. RTU configurations are maintained in the on-board battery backed RAM and may be modified locally or remotely.

10 10 SCADAPack ES Hardware Manual 4 Hardware Overview This section presents a brief introduction to the major components of the SCADAPack ES The SCADAPack ES is an advanced Remote Telemetry Unit (RTU) combining a high speed processor, large memory capacity, analog and digital I/O, serial and Ethernet communications, IEC logic and a number of industry standard protocols in a single unit. The complete specifications of the SCADAPack ES RTU are in the Specifications 97 section of this manual. Generally Power Supply ports and I/O ports are protected against surge voltages and other conditions. However, if you need to remove the lid of the RTU for any reason, first observe the following warning. CAUTION The electronics inside the RTU can be destroyed by static electricity. If you need to remove the lid you need to wear a wrist strap. This wrist strap needs to be connected to the earth stud on the side of the unit. Not observing this simple step can cause total or intermittent loss of operation and will void the warranty. 4.1 SCADAPack ES Model Numbers Various models of SCADAPack ES units are available. Selected models are detailed in the following table. The model number, indicated on a sticker on the SCADAPack ES case, is in the format: P500-abcd-efgh-j Table 5.1: SCADAPack ES Model Numbers a b c d e Communication Serial Ports: 1. 3 RS232, 2 RS232//422/485, 2 Ethernet 10/100 BaseT, 1 Compact FLASH socket Processor/Memory: A. AMD Elan SC520 CPU - 32MB Operating System FLASH, 128MB volatile SDRAM, 2MB Battery Backed SRAM Protocol options: 0. Modbus, DNP 3, Modbus TCP, TCP/IP (included in all controllers) 1. IEC Master, Protection Relay Protocol (for data transmission with IEDs) 2. IEC Slave, Standard Telecontrol Tasks (allows a 101 Master to get data & send commands to the SCADAPack ES) 3. both IEC Master and IEC Slave protocol options Programming Environment & SCADA security 0. IEC : Executes two ISaGRAF kernels allowing two (2) control applications to run simultaneously 1. IEC with AGA-12 SCADA Encryption Security License Option: A. None B. Data Concentrator License

11 SCADAPack ES Hardware 11 C. DNP Multi-Master License D. Data Concentrator and DNP Multi-Master Licenses f g h j I/O configuration: DI DO AI AO A Fully populated I/O B Telemetry Processor E Partially populated I/O Power Supply: Vdc Wide Range Power input, no auxiliary power supply Vdc Wide Range Power input, auxiliary power supply with 5 Vdc output Vdc Wide Range Power input, auxiliary power supply with 10 Vdc output Vdc Wide Range Power input, auxiliary power supply with 24 Vdc output. Optional Agency Approvals: 1. None 2. Non-Incendive Electrical Equipment for Use in Class I, Division 2 Groups A, B, C and D Custom Options: None. (default range is 4-20mA) V. Analog Input range set for 1-5v C. Custom Analog Input Range (specify range)

12 12 SCADAPack ES Hardware Manual 4.2 External SCADAPack ES Connections Table shows the external connections to a SCADAPack ES. Each port is labeled with polarity where appropriate. The following table shows each connector, the connector type, connector wiring polarity sensitivity and the description of the connector function. External connections for the SCADAPack ES are terminated on removable multi-part connectors for ease of wiring and maintenance. Some of connections are polarity sensitive: the analog input, analog output, digital input and the power supply input. The I/O terminals use 3.81mm (pitch) connectors. See the Specifications 97 for recommended wire sizes. Table 5.2: External Connections Connector Name Connector Type Polarity Sensitive Description PORT 0 RJ12 NA RS-232C PORT 1 RJ12 NA RS-232C PORT 2 RJ12 NA RS-232C, RS-422 / 485 PORT 3 RJ12 NA RS-232C, RS-422 / 485 PORT 4 RJ12 NA RS-232C ETHERNET 1 RJ45 NA UTP 10/100Base-T ETHERNET 2 RJ45 NA UTP 10/100Base-T DC-In Removable 3 position DC-Out Removable 3 position AI #1 to 12 Removable 2 position YES YES YES Power supply input (10 to 30Vdc) and chassis terminal. Power supply output (5, 10 or 24Vdc nom.) and chassis terminal. Analog input (4-20mA, 1-5V etc.) DI #1 to 32 Removable 4/5 position YES Digital input (1 common ground per 8 inputs) DO #1 to 16 Removable 3 position AO #1 to 4 Removable 4 position NO YES Digital output (relay, volt-free NO/NC contacts) Analog output (0-20mA, 4-20mA) I/O Bus IMC cable NO 5000 Series I/O Expansion Utility Slot NO Compact FLASH card slot

13 SCADAPack ES Hardware Isolation & Protection The SCADAPack ES RTU has been designed to provide extensive isolation from external connections as follows: Table 5.3: Isolation & Protection Connections Isolation Protection Digital Inputs Optical Current limiting resistor & Reverse polarity diode Digital Outputs Mechanical (relay) MOV Analog Inputs Optical (channel to channel AND channel to RTU) Fuse, zener diode and gas surge arrestor Analog Outputs Optical MOV External power supply DC-DC switch mode Fuse, MOV Serial Ports (Port 0, etc.) None ESD protected buffers Ethernet Ports Transformer ESD External I/O is isolated from the RTU logic and are protected against surge voltages and other conditions.

14 14 SCADAPack ES Hardware Manual 4.4 Processor Board The processor board executes the RTU firmware and provides the main communication interfaces for the SCADAPack ES. The following sections briefly describe the main components located on the processor board. Microprocessor (CPU) & RAM 15 Utility Port Compact Flash Socket, OS Flash, & Boot Monitor Flash 16 Serial (RS-232, RS-422, RS-485) Ports & Ethernet Ports 17

15 SCADAPack ES Hardware Microprocessor (CPU) & RAM Microprocessor (CPU) The CPU is an AMD Elan SC520 Embedded device operating at 100MHz. The CPU executes a preemptive multi-tasking operating system allowing the simultaneous, real-time, provision of: Communications protocols (DNP3, TCP/IP, IEC suite, Modbus, etc) Time stamped event processing Configuration management User application execution (ISaGRAF) RAM The battery backed RAM is used to store User Configuration (point definitions, port configurations etc) User defined sequence and control applications (ISaGRAF) Time stamped event data

16 16 SCADAPack ES Hardware Manual Utility Port Compact Flash, OS Flash, & Boot Monitor Flash Utility Port Compact Flash The Utility Port is a Compact Flash (CF) slot that provides extra non-volatile file-system storage using standard CF memory cards. The SCADAPack ES provides one External Compact Flash socket (UTILITY), and an option for an additional Internal Compact Flash Socket. These sockets can be used for supplementary file system storage (e.g. Compact FLASH memory cards). It is recommended that Compact Flash use the external Compact Flash socket, where possible. The external socket provides physical access for card connectors, exposure for antennas, etc. CAUTION The UTILITY port supports the insertion and removal of Compact Flash or utility cards on-line (hot-swap). However, the operation of the SCADAPack ES may be adversely affected by doing so, particularly removing cards that are in use by the SCADAPack ES. The UTILITY and optional internal Compact Flash interfaces support the following card types: 3.3V card types only supported up to 2GB memory capacity cards supported Operating System Flash The operating system flash stores the SCADAPack ES firmware. The firmware implements the communications protocols (DNP3, TCP/IP, Modbus etc), the Point Database (point configurations) and the ISaGRAF kernel (which runs the user-defined sequence and control applications). The use of flash memory chips allows new firmware to be down-loaded either locally (via serial port) and remotely (by file upload and command execution), without removing the RTU from its enclosure. Boot Monitor Flash The boot monitor firmware resides in a separate flash memory chip on the processor board. The boot monitor firmware is the first code executed by the CPU when power is applied to the RTU. The boot monitor configures the RTU hardware then verifies, loads, and executes the operating system firmware. The boot monitor also provides facilities for re-programming the operating system and boot monitor flash memory.

17 SCADAPack ES Hardware Serial (RS-232, RS-422, RS-485) Ports & Ethernet Ports Serial (RS-232, RS-422, RS-485) Ports The serial ports of the SCADAPack ES use standard RJ-12 connectors. The following options are software configurable, in various combinations, where supported for the serial port: Function Mode Baud Rate Data Mode DNP3, Modbus, Command Line, ISaGRAF etc RS-232/422/485, Hayes Modem, GPRS etc Standard data rates between 300bps to bps Data bits, Stop bits, and Parity Ports 2 and 3 support the software selection of RS-232, RS-422, or RS-485. Other ports only support RS-232. See Cold Boot Mode 57 for serial port default settings. Ethernet Ports The SCADAPack ES has two 10/100Base-T Ethernet Ports that can be used for TCP/IP communication and Remote I/O. The SCADAPack ES provides a range of TCP/IP services including FTP, TELNET, BOOTP, as well as providing other TCP/IP enabled protocols such as DNP3 and Modbus. The Ethernet Ports are disabled by default.

18 18 SCADAPack ES Hardware Manual 4.5 I/O Board (Local Physical I/O) The SCADAPack ES Model A includes an I/O board containing the following I/O: 32 digital inputs (including 8 dual function high speed counter inputs) 16 digital outputs 12 analog inputs 4 analog outputs Some SCADAPack ES models are shipped with less physical I/O. Refer to SCADAPack ES Model Numbers 10 for details. The Local I/O can be: locally controlled using ISaGRAF user application code. monitored & controlled from a remote site. transferred to an attached PLC for processing by that PLC. time-stamped and stored locally in files for later up-load to a SCADA Master. These operations are provided by the SCADAPack E operating system firmware. For more information see the SCADAPack E Technical Overview manual. The local I/O of the SCADAPack ES is located on a separate circuit board. I/O systems on this board are controlled by a local microprocessor. The processor and I/O boards are connected via four 40-pin connectors and communicate via dual port RAM. Both the microprocessors on the processor board and the I/O board continually monitor the status of each other, and if any problems are detected (e.g. loss of communications between the two boards), the hardware peripherals are powered down and the binary outputs are cleared. The microprocessor on the I/O board: Monitors the state/value of inputs Changes are time-stamped by the I/O board CPU and written to the processor board Performs basic filtering of analog inputs Performs basic de-bouncing of digital outputs Receives output control requests from the processor board and controls the corresponding outputs

19 SCADAPack ES Hardware Communication Interfaces The SCADAPack ES supports connection to a wide range of communication interfaces and services. The following communication ports and options are available: PORT 0 PORT 1 PORT 2 PORT 3 PORT 4 Ethernet 1 Ethernet 2 Compact FLASH I/O Bus RS-232 RS-232 RS-232, RS-422, RS-485 RS-232, RS-422, RS-485 RS-232 UTP (10/100Base-T) UTP (10/100Base-T) Memory card 5000 Series I/O module bus 5 Installation The following sections of the user manual describe specific aspects of installing the SCADAPack ES. SCADAPack ES units are factory configured and under normal conditions do not require removal or insertion of any peripherals or components. The configurations are stored in a combination of battery backed RAM and FLASH memory. The battery has a shelf life of ~8 years. Life of the battery may be increased past 8 years when the RTU is permanently connected to a power source. CAUTION The configuration information can be lost if the on-board battery goes flat, is disconnected, if the RTU is damaged, or if there has been a firmware upgrage.

20 20 SCADAPack ES Hardware Manual 5.1 Mounting Refer to Figure for the locations of the 4 mounting holes for the SCADAPack ES. WARNING The Class 1, Division 2 for Hazardous Locations version of the SCADAPack ES has a cover with integrated connector retention. Check that when replacing the cover that all connectors have been secured and that connector removal is not possible " 8mm " 286mm 1.083" 27.5mm 4.055" 103mm Figure 6.1 : SCADAPack ES Mounting and Dimensions

21 SCADAPack ES Hardware Field Wiring The following drawing shows the locations of the field wiring connections, LED indicators and the fuses and jumper links that are accessible to the user in the I/O board. The following sections describe the I/O points and provide some example wiring. DI DI DI DI DO 9 DO 10 DO 11 DO 12 DO 13 DO 14 DO 15 DO 16 AI 7 AI 8 AI 9 AI 10 AI 11 AI 12 AOUT 3 AOUT 4 Ethernet Port 1 Ethernet Port 2 Fuses FS7 to FS12 J14 J16 J18 J20 J22 J24 DC I/P DC O/P HEX SW1 Port 4 J1 - LEDs enabled position shown HEX SW2 LED 1 LED 2 Port 0 Port 1 Port 2 Utility J2 J4 J6 J8 J10 J12 RX TX Port 3 Run Fuses FS1 to FS6 DI 1-4 DI 5-8 DI 9-12 DI DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 AI 1 AI 2 AI 3 AI 4 AI 5 AI 6 AOUT AOUT 1 2 Figure 6.2: Layout

22 22 SCADAPack ES Hardware Manual 5.3 Grounding CAUTION The SCADAPack ES case includes an Earth connection stud located adjacent to the power connector terminal block. This Protective Conductor stud needs to be connected to Earth. The earth connection stud on the RTU s case and the earth connection on the RTU s power supply terminal block should be connected to a clean earth point in the cabinet in which the RTU is installed. Each piece of equipment (or multiple units) should be connected to the same earth point in a star configuration. The DC resistance between each item and the earth point should be < 0.1 ohms.

23 SCADAPack ES Hardware Power Supply Requirements The SCADAPack ES is powered through a 3 terminal connector, labeled I/P on the module cover. The RTU is designed for a 10-30VDC operating voltages. The input power supply must be a filtered DC supply. An auxiliary DC power output (labeled O/P on the module cover) is optionally available for operation of external equipment, such as modems or Vision operator interfaces. Refer to the SCADAPack ES Model Numbers 10 and Specifications 97 sections in this manual for the voltage output and the ratings of the auxiliary DC output. The SCADAPack ES is typically powered from a 12VDC power supply, battery, or 24VDC power supply. Refer to the Specifications 97 section for the input voltage limits and power requirements. The power requirements will be determined by the number of relays energized, the loading on the auxiliary power outputs and the number of analog outputs. The power required will range from as low as 6 W to as high as 18.8W at 12V with every relay energized, the auxiliary supply output fully loaded and the analog outputs in use. WARNING SELV (Safety or Separated Extra Low Voltage) power supplies are required on the power input and I/O points. Power supplies with Vac inputs that comply with safety standard IEC/EN generally have SELV outputs. Check with the manufacturer or the agency certification listing to confirm that they have SELV outputs. The following Vac input, 24VDC output power supplies have SELV outputs: Idec PS5R series (7.5 to 240W) Weidmuller CP SNT 24W 24V 1A Phoenix MINI-SYS-PS AC/24DC/1.5

24 24 SCADAPack ES Hardware Manual FS1 FS2 DC Input Power FS3 FS4 + Fuse + Power supply or Battery Chassis connection suitable for cable shield CPU Board + DC Auxiliary Output + Auxiliary load Chassis connection suitable for cable shield Figure 6.3: Power Supply Wiring and Fuses

25 SCADAPack ES Hardware Auxiliary Power Output The SCADAPack ES has an Auxiliary Output available on a 3 terminal connector, labeled O/P on the module cover. The RTU is manufactured with several optional versions of the Auxiliary Output as shown in the table below. Refer to the SCADAPack ES Model Numbers 10 and Specifications 97 sections in this manual for the voltage output and the ratings of the auxiliary DC output. Table 6.1: Auxiliary Output Description 5VDC None 24VDC 10VDC Comments 5VDC (1A) is available at connector O/P. The same 5VDC is also connected to the expansion I/O connector. No voltage is available at connector O/P. 5VDC (100mA max.) is available on the expansion I/O connector. 24VDC (200mA) is available at connector O/P. 5VDC (100mA max.) is available on the expansion I/O connector. 10VDC (500mA) is available at connector O/P. 5VDC (100mA max.) is available on the expansion I/O connector. The output capacity needs to be de-rated at high temperatures. Refer to the Specifications 97 section of this manual. CAUTION A SCADAPack ES with 5000 Series I/O modules or Vision display installed needs to be configured to supply sufficient power for these devices. Refer to the modules specification for specific power requirements. It is recommended that systems with 5000 Series I/O modules be configured with a 5V Auxiliary Output.

26 26 SCADAPack ES Hardware Manual Internal Fuses Internal fuses are provided for last resort protection of the SCADAPack ES. It is highly recommended that external fuses and circuit breakers be used for protection and isolation of the unit and associated power supplies. External fuses to protect analog input circuits should be provided. The DC Supply I/P and Auxiliary DC O/P fuses require removal of the upper I/O board before replacement. The locations of FS1 through FS4 are shown in Figure RISK OF EXPLOSION WARNING Before replacing the fuse verify that the area is non-hazardous and disconnect power. Failure to follow these instructions can result in death, serious injury or equipment damage. Before replacing the fuse assess the impact that disconnecting power may have on other devices. UNEXPECTED EQUIPMENT OPERATION WARNING Evaluate the operational state of the equipment monitored and controlled by the SCADAPack E RTU. Failure to follow these instructions can result in death, serious injury or equipment damage. Replace a blown fuse with a fuse of the same rating. Under no circumstances should a fuse be bypassed or replaced with a fuse of a higher rating. UNEXPECTED EQUIPMENT OPERATION WARNING Replace the fuse with a fuse of the same rating. Failure to follow these instructions can result in death, serious injury or equipment damage. Table 6.2: Fuse Ratings Function Fuse Ref Fuse DC Supply (I/P on CPU board) FS1, FS2 3.15A max.

27 SCADAPack ES Hardware 27 5V Auxiliary DC Out (O/P on CPU board) 5V Auxiliary DC Out (O/P on CPU board) 10V or 24V Auxiliary DC Out (O/P on CPU board) FS3 FS4 FS3, FS4 Littelfuse CMI part number Lower value fuses can be used in 24V applications. 2A Littelfuse CMI part number Bypassed. 1A Littelfuse CMI part number Analog In (I/O board) FS mA fast acting Littelfuse R CMI part number

28 28 SCADAPack ES Hardware Manual 5.5 SCADAPack ES Inputs/Outputs (I/O) Inputs and outputs contained on the SCADAPack ES I/O boards are described in the sections that follow. See the section SCADAPack ES Model Numbers 10 for the I/O available for each model type. These Inputs and Outputs can be: monitored & controlled from a SCADA master station monitored & controlled from a remote outstation used to perform local control (using ISaGRAF user application code) transferred to an attached PLC for processing by that PLC time-stamped and stored locally for later retrieval manually or automatically any combination of the above. These facilities are provided by the SCADAPack ES Operating System firmware. For more information see the SCADAPack E Technical Overview.

29 SCADAPack ES Hardware Digital Inputs Digital Inputs are organized into groups of eight inputs each with a single (shared) common. The common for a group of inputs is isolated from the common for other input groups on the same SCADAPack ES I/O card. Optical isolation is provided on digital inputs. Wetting voltage for the volt-free contacts is usually provided by the SCADAPack ES DC power used with the SCADAPack ES. The example shown in Figure below has one switch contact monitored by Digital Input COM COM I/O Board COM COM + Power Supply Figure 6.4: Digital Input Connections The SCADAPack ES I/O board time-stamps digital input changes for Sequence Of Event (SOE) applications. The following table shows the SOE capabilities on the SCADAPack ES I/O board models. Table 6.3: Digital Input facilities I/O board Model SOE timestamping Max. DI de-bounce De-bounce resolution A 10 ms 2500 ms 10 ms E 10 ms 2500 ms 10 ms

30 30 SCADAPack ES Hardware Manual The SCADAPack ES I/O board also provides digital input state de-bouncing. The minimum resolution for de-bouncing and the maximum de-bounce period is shown in the table above. If the SCADAPack ES configuration enables de-bouncing on a digital input channel, then SOE timestamping on the digital point has the same resolution as the de-bounce resolution. Each digital input channel on the SCADAPack ES can also be used as a counter input. Specific digital input channels have hardware counter support providing high-speed counter facilities. The other digital input channels have support for configuration as software counters. For more information see Section Counter Inputs E Configuration Technical Reference manual. 31, and configuration information in the SCADAPack

31 SCADAPack ES Hardware Counter Inputs SCADAPack ES digital input channel can also be used as counter input channel. SCADAPack ES counter inputs are represented as 32-bit counters. As defined in the following table, some inputs can be used as software counters only, whilst others have high-speed hardware counter capability. Table 6.4: Counter Input facilities I/O board Model Counter Inputs (DI channels) Software-only Counter Inputs Maximum Software Count Rate Hardwarecapable Counter Inputs Maximum Hardware Count Rate A , Hz 13-16, khz E Hz khz When Software-Only Counter Input channels are used, the corresponding digital input de-bounce and invert settings are applied prior to counting transitions of the input. If set as non-inverting (default configuration), counter input points count OFF to ON transitions. If configured as an inverted digital input point, ON to OFF transitions are counted on the corresponding counter channel. De-bounce is applied to input state changes in both directions, regardless of the point s invert settings. A contact bounce of duration less than the de-bounce period will not increment the software counter. Hardware counting on hardware-capable counter channels does NOT include the capability for input debounce or input state inversion. The hardware counts ON to OFF transitions only. It is recommended that only clean-edge signals be counted using hardware counters. If a de-bounce period is set on a digital input point corresponding to a Hardware-capable Counter input, hardware counting is de-activated. The input will become a Software Counter with both de-bounce and invert capability. In this case the software counter specifications apply.

32 32 SCADAPack ES Hardware Manual Digital Outputs Each SCADAPack ES digital output is driven by a low-power relay. Electrical isolation is provided between the SCADAPack ES and the device being controlled. Relays comprise a DPDT relay. Each relay output connection comprising three terminals; COM, N.O. and N.C. contacts for one relay pole. A signal from the second pole on each relay is provided as feedback to software to verify correct relay activation on each operation. The relays have MOV protection provided across the outputs to provide basic surge protection and to protect against spikes that can occur if the relays are used to drive inductive loads. External lightning protection is required if the device being controlled is outside the area (building/cubicle) in which the SCADAPack ES is located. The example shown in Figure below has Load 3 controlled by the NO contact of DO 3 and Load 7 controlled by the NO contact of DO7. Load 3 is switched from the +ve side of the power supply. Load 7 is switched by the ve side of the power supply. NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C DO 9 DO 10 DO 11 DO 12 DO 13 DO 14 DO 15 DO 16 I/O Board DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO + Power Supply + Load 3 + Load 7 Figure 6.5: Digital Output Relay Connections

33 See the Specifications 97 section for contact ratings of these outputs. SCADAPack ES Hardware 33

34 34 SCADAPack ES Hardware Manual Analog Inputs SCADAPack ES Model A RTU has 12 analog inputs for external connection to analog field devices. Each analog input can be individually configured to accept one of the following input signals: Standard calibration is 4 20mA Optional calibration is 1 5V Custom calibrations possible. Contact the factory. The input signal for each input is selected through a combination of hardware jumpers and software calibration. Each analog input is optically isolated from both the SCADAPack ES logic electronics, and the other analog inputs. For each analog input channel there is one jumper. This jumper selects between current and voltage input modes. If a voltage exceeding 16VDC is connected to the Analog Input channel terminals, the AI channel protection fuses will blow. The analog inputs are polarity sensitive. The polarity is marked on the cover of the SCADAPack ES and in Figure The default analog input calibration is 4-20mA. Removal of the jumper associated with the analog input will result in an un-calibrated 1-5V analog input. Refer to Table for jumper settings for analog inputs. Table 6.5: Analog Input Jumpers Model A Analog Channel # Model E Analog Channel # Input type jumper (Voltage/Current) AI 1 AI 1 J2 AI 2 AI 2 J4 AI 3 AI 3 J6 AI 4 AI 4 J8 AI 5 AI 5 J10 AI 6 AI 6 J12 AI 7 AI 8 AI 9 AI 10 J14 J16 J18 J20

35 SCADAPack ES Hardware 35 Model A Analog Channel # AI 11 AI 12 Model E Analog Channel # Input type jumper (Voltage/Current) J22 J24 Voltage input remove the two-pin jumper. Current input insert the two-pin jumper. If an Analog Input channel is changed from Current to Voltage mode or from Voltage to Current mode, the AI channel calibration should be checked. The example shown in Figure below has Transmitter 1 "grounded" and connected to AI1. Transmitter 6 is connected to the +ve supply and AI6. These two different connections are possible because the SCADAPack ES has isolated analog inputs. The SCADAPack ES has extensive spike and over-voltage protection on each analog channel, consisting of: gas arrestors, fuses, zener diodes and spike filters. If a transducer/transmitter connected to an analog channel is placed outside of the building or structure where the SCADAPack ES is installed, there is an increased possibility of extremely severe surges caused by lightning. In such cases additional surge protection needs to be supplied by the user. Presentation of analog channel quantities to the SCADAPack ES software is described in the SCADAPack E Configuration Technical Reference manual.

36 36 SCADAPack ES Hardware Manual AI 7 AI 8 AI 9 AI 10 AI 11 AI 12 Fuses FS7 to FS12 J14 J16 J18 J20 J22 J24 I/O Board J2 J4 J6 J8 J10 J12 Fuses FS1 to FS6 AI 1 AI 2 AI 3 AI 4 AI 5 AI Transmitter 1 + Power Supply + Transmitter 6 Figure 6.6: Analog Input Connections, Jumpers and Fuses

37 SCADAPack ES Hardware Analog Outputs The analog output (AO) channels need to be powered with an external 9 to 30VDC (nominally 12 or 24VDC) power supply. The SCADAPack ES analog output channels can be configured to be 4-20mA or 0-20mA. If a voltage output is required (say 1V-5V), run the 4-20mA signal to the device requiring the voltage input and place a 250 Ohm resistor across the device input terminals. The analog output is electrically isolated from the rest of the RTU, but not isolated from the power supply. There is a set of two jumpers controlling the operation of each analog output channel. These are 3 pin jumpers that have been permanently configured for external power required in the SCADAPack ES. The example wiring shown in Figure shows a load connected to AOUT2. 24V 0V + 24V 0V + AOUT 3 AOUT 4 I/O Board Jumpers J26 to J33 permanently configured for AOUT as externally powered. AOUT 1 + 0V 24V AOUT 2 + 0V 24V + Power Supply + L O A D Figure 6.7: Analog Output Connections, and Jumpers The AO circuitry is configured internally to accept power from an external power supply on pins 3 and 4 of the removable terminal block. Pin 1 (AO ) and pin 3 (power input ) are connected internally. Analog

38 38 SCADAPack ES Hardware Manual outputs are isolated from each other and the RTU logic. Figure below displays the allowable output resistance range for any given AO input supply voltage. The load resistance for any given power supply voltage is limited on the high resistance end by the requirement for proper operation of the analog output circuit and on the low resistance end to limited the power dissipation in the analog output. For instance, if the AO channel is powered using a 12VDC supply, the load resistance needs to be in the 0 to 250 ohm range. If the AO channel is powered using a 24VDC supply, the load resistance needs to be in the 0 to 850 ohm range. If the AO channel is powered using a 30VDC supply, the load resistance needs to be in the 150 to 1150 ohm range Load resistance (ohms) Resistance limits Power supply (V) Figure 6.8: Analog Output Load Resistance Range

39 SCADAPack ES Hardware Series I/O Expansion The SCADAPack ES I/O can be expanded using 5000 Series I/O expansion modules. The maximum number of modules that can be added is 16. The 5000 Series I/O modules mount on DIN rails. Modules addresses are configured using onboard DIP switches. Additional configuration is also possible on some modules using onboard DIP switches. For additional information on this feature, including supported I/O modules, refer to the SCADAPack E 5000 Series I/O Expansion Reference manual. Refer to the user manual for each expansion module for configuration information. The following 5000 series I/O modules are supported by SCADAPack ES controllers 5000 Series Module Type I/O 5304 Analog Out 4 Analog Outputs 5405 Digital In 32 Digital Inputs 5411 Digital Out 32 Digital Outputs 5414 Digital In 16 Digital Inputs 5415 Relay Output 12 Relay Outputs 5505 RTD 4 RTD (Temperature) Inputs 5506 Analog In 8 Analog Inputs 5606 Composite I/O 32DI, 16 Relay Out, 8AI, 2AO (optional with 5305) 5607 Composite I/O 16DI, 10 Relay Out, 8AI, 2AO (optional with 5305) 5608 Composite I/O 12DI, 6 Relay Out 5610 Composite I/O 16DI, 10 Relay Out Power & Software Requirements Inter Module Cables Installation Rules and Recommendations

40 40 SCADAPack ES Hardware Manual Power & Software Requirements Power Requirements 5000 Series Input/Output modules require 5V. The SCADAPack ES controller provides this 5V. SCADAPack ES models have a limited amount of current available at 5V. It is recommended that applications that use 5000 Series I/O expansion be configured with a 5V Auxiliary supply. Refer to the Power Supply 100 section for the power limitations of these 5V outputs. Some of the 5000 Series I/O modules require a nominal 24Vdc to power the field side circuitry. Refer to the individual module specifications for the voltage limits and the current requirements for these modules.

41 SCADAPack ES Hardware Inter Module Cables 5000 Series I/O modules are supplied with a short inter module cable suitable for connecting two adjacent modules. In larger systems it may become necessary to use longer inter module cables (IMC) to complete the system. These longer cables are available in a variety of different lengths ranging from 12 inches (0.3m) to 450 inches (1.14m) long. Table 6.6: Inter Module Cables Name Length PID IMC12 12 inches (0.30m) long IMC18 18 inches (0.45m) long IMC24 24 inches (0.61m) long IMC30 30 inches (0.76m) long IMC45 45 inches (1.14m) long The inter module cable connects to the connector in the lower right corner of the SCADAPack ES as shown in Figure Figure 6.9: 5000 Series I/O Expansion Connector

42 42 SCADAPack ES Hardware Manual Installation Rules and Recommendations Use the shortest length inter module cable possible. The maximum total length of inter module cables is 48 inches (1.22m). This length restriction does not include the short inter module cable supplied with the I/O module. The maximum number of modules is 16. Never run inter module cables near any electrical noise sources such inductive load switching or variable frequency drives. Do not install the inter module cable in the same cable tray or in parallel with field wiring. Inter module cables may cross field wiring at 90 if necessary. Connect the shielding wire on the inter module cable to a convenient chassis ground point. There is a self tapping screw supplied with each cable. There is a small hole in the I/O module for grounding the shielding wire. Confirm that the power supply is rated for the total number of modules in the system. Install additional power supplies if required. For additional details, refer to the SCADAPack E 5000 Series I/O Expansion Reference manual.

43 SCADAPack ES Hardware Serial Communication The SCADAPack ES support 5 asynchronous serial data communication ports. The data communication ports are labeled: PORT 0, PORT 1, PORT 2, PORT 3 and PORT 4. The serial communication ports support data rates from 300 to bps and RS232 interfaces are supported on each serial ports. Ports 0, 1, & 2 Ports 3 & See the RJ-12 Modular Connector 46 and the Serial Communication Cables 47 sections for connection details on serial ports. Table 6.8: Serial Port Communication Configurations PORT 0 PORT 1 PORT 2 PORT 3 PORT 4 RS-232 Fixed Fixed Configurable (default) Configurable (default) Fixed RS-422 N/A N/A Configurable Configurable N/A RS wire RS wire N/A N/A Configurable Configurable N/A N/A N/A Configurable Configurable N/A N/A indicates Not Available. RJ-12 Modular Connector 46 Serial Communication Cables 47

44 44 SCADAPack ES Hardware Manual Ports 0, 1 & 2 Port 0 PORT 0 is a general-purpose serial data communications port. This port is fixed as an RS-232C communication port. Port 0 uses an industry standard RJ-12 terminal socket conforming to RS-232 standards. The RJ-12 connection on the SCADAPack ES is a Data Terminal Equipment (DTE) connection. Default setting: RS232C, 9600 bps, 8 data bits, 1 start bit, 1 stop bit and no parity. Port 1 PORT 1 is a general-purpose serial data communications port. This port is fixed as an RS-232C communication port. Port 1 uses an industry standard RJ-12 terminal socket conforming to RS-232 standards. The RJ-12 connection on the SCADAPack ES is a Data Terminal Equipment (DTE) connection. Default setting: RS232C, 9600 bps, 8 data bits, 1 start bit, 1 stop bit and no parity. Port 2 PORT 2 is a general-purpose serial communication data port. This port is normally configured as an RS- 232C communication port. Optionally, it can be configured as an RS-422 port or RS-485 port by selecting RS-422 or RS-485 for PORT 2 using the SCADAPack E Configurator. PORT 2 uses an industry standard RJ-12 terminal socket conforming to RS-232C signaling standards when used as an RS-232C port. The RJ-12 terminal socket also allows for a RS-422 or RS-485 port connection. The RJ-12 connection on the SCADAPack ES is a Data Terminal Equipment (DTE) connection. This port could be used as the network connector to implement an RS-485 network on twisted pair. A maximum of 32 SCADAPack ES and other devices can be connected to any one RS-485 network. Default setting: RS232C, 9600 bps, 8 data bits, 1 start bit, 1 stop bit and no parity.

45 SCADAPack ES Hardware Ports 3 & 4 Port 3 PORT 3 is a general-purpose serial communication data port. This port is normally configured as an RS- 232C communication port. Optionally, it can be configured as an RS-422 port or RS-485 port by selecting RS-422 or RS-485 for PORT 2 using SCADAPack E Configurator. PORT 3 uses an industry standard RJ-12 terminal socket conforming to RS-232C signaling standards when used as an RS-232C port. The RJ-12 terminal socket also allows for a RS-422 or RS-485 port connection. The RJ-12 connection on the SCADAPack ES is a Data Terminal Equipment (DTE) connection. This port could be used as the network connector to implement an RS-485 network on twisted pair. A maximum of 32 SCADAPack ES and other devices can be connected to any one RS-485 network. Default setting: RS232C, 9600 bps, 8 data bits, 1 start bit, 1 stop bit and no parity. Port 4 Port 4 is generally used for diagnostic or programming purposes, but is functionally similar to Port 0 and can be used as a general-purpose communications port. Port 4 uses an industry standard RJ-12 terminal socket conforming to RS-232C signalling standards when used as an RS-232C port. The RJ-12 connection on the SCADAPack ES is a Data Terminal Equipment (DTE) connection. Default setting: RS232C, 9600 bps, 8 data bits, 1 start bit, 1 stop bit and no parity.

46 46 SCADAPack ES Hardware Manual RJ-12 Modular Connector The following table describes the pin assignments for the SCADAPack E RTU RJ-12 connectors. The same connector is used for the various serial interfaces. Pin numbering is shown for cables connecting to RTU s RJ-12 connectors: 1 6 RJ-12 PLUG PIN SIDE Figure 6.10: RJ-12 Pin Connector Table 6.9: RJ-12 Pin Connections Pin No. RS-232 pin function RS-422/485 pin function 1 RTS/DTR out TXD out 2 TXD out TXD+ out 3 GND GND (biasing) 4 GND 5 RXD in RXD out 6 CTS/DCD in RXD+ out Each SCADAPack ES serial port can be configured for a variety of communications protocols, functions, speeds and data formats. See the SCADAPack E Configurator User Manual for configuration details.

47 SCADAPack ES Hardware Serial Communication Cables TO RTU (DTE) TxD GND GND RxD TO RS232 DEVICE (DTE) RJ RJ-12 PLUG PIN SIDE 9 PIN D TYPE FEMALE Figure 6.11: SCADAPack ES RS-232 using 9-pin connector

48 48 SCADAPack ES Hardware Manual 1 TxD- 2 TxD+ GND 3 TO RTU ( DTE ) 4 5 RxD- TO RS485 4-wire device(s) 6 RxD+ RJ RJ-12 PLUG PIN SIDE Figure 6.12: SCADAPack ES RS-422 / 4-wire RS-485 cable 1 TxD- 2 TxD+ TO RS485 2-wire GND 3 TO RTU ( DTE ) 4 5 RxD- 6 RxD+ RJ RJ-12 PLUG PIN

49 SCADAPack ES Hardware 49 Figure 6.13: SCADAPack ES RS-422/2-wire RS-485 cable 1 DTR 2 TO RTU ( DTE ) TxD 1GND GND RxD DCD MODEM RS232 ( DCE ) RJ RJ-12 PLUG PIN 25 PIN D MALE Figure 6.14: SCADAPack ES - Modem cable Certain Hayes Registers may have to be set within the modem for correct operation. Refer to the SCADAPack E Communication Interface Reference manual.

50 50 SCADAPack ES Hardware Manual 5.7 Ethernet Communication The SCADAPack ES provides two physical Ethernet network interfaces. Two external connectors are provided permitting connection to the IEEE standard 10/100Base-T local area network (LAN) types. The UTP Ports use RJ-45 connectors. Both ports can run at 10Mbps or 100Mbps, at Half or Full duplex. The SCADAPack ES automatically detects an active Ethernet port and the supported speed of the connected device, giving preference to 100Mbps Full Duplex connection if possible. The upper GREEN LED situated adjacent to the UTP (RJ-45) Ethernet connector is lit when the UTP Ethernet interface is ACTIVE. The lower GREEN LED blinks with Ethernet RX and TX activity. The UTP ports are used for point-to-point Ethernet connections. They are usually connected to an Ethernet Hub or Switch, although it is possible to connect devices together directly using an RJ-45 reversal or crossed cable. The SCADAPack ES supports TCP/IP networking and communications integration. The SCADAPack ES conforms to the relevant IEEE and TCP/IP RFC standards, and may be used in a wide range of LAN and WAN topologies, including systems using Routers, Bridges, Terminal Servers, Hubs, Switches, etc. Each SCADAPack ES Ethernet port can be configured for a variety of communications protocols, functions, speeds and data formats. See the SCADAPack E TCP/IP Technical Reference manual and the SCADAPack E Configurator User Manual for configuration details. 10/100BASE-T Networks These networks are also known as UTP (unshielded twisted pair), copper wire, Category 3, 4 and 5 Ethernet wire, or twisted pair. The IEEE BASE-T specification requires that 10BASE-T and 100BASE-T devices support UTP Ohm unshielded twisted pair cables of not less than 100m in length. This requirement does not factor in losses due to connectors, patch panels, punch-down blocks, or other cable management hardware, which introduce additional loss. For each connector or other intrusive cable management device in the total link, subtract 12m from the total allowable link length. As long as specifications are met for the entire length of the cable, UTP cable segments can be run up to a maximum allowable length of 200m.

51 SCADAPack ES Hardware Hex Switches and Special Function Modes The SCADAPack ES has two Rotary Hex Switches. They are used for selecting the operating mode of the RTU. The dual rotary hex switches provide a unique hexadecimal number from 00h to FFh. Settings F0h to FFh are used for special modes such as firmware loading, calibration, etc. see the SCADAPack E Operational Reference for more information. SCADAPack ES calibration is described in Section Calibration 73. The Hex Switches may be altered with power applied to the unit and that this may (in most cases will) initiate an automatic SCADAPack ES operating system restart. Single SCADAPack ES Where the SCADAPack ES is utilized as a single RTU, it is recommended that the HEX Switches be set to 00. In this mode, the SCADAPack ES is a Main RTU with all facilities enabled. SCADAPack ES Remote I/O Where multiple SCADAPack ES RTUs are used in Remote I/O architectures, the HEX Switches identify Main and Remote I/O units. For more information see the SCADAPack E Remote I/O Technical Reference manual. See Startup Modes 54.

52 52 SCADAPack ES Hardware Manual 5.9 Battery Replacement A flat-package Lithium battery located on the bottom processor card of the SCADAPack ES provides backup power to the RTU's real time clock and RAM memory. This battery is a user replaceable component. It may be desirable to replace the battery on-line if it is still capable of sustaining the SCADAPack ES memory. This should be the case if the battery is replaced soon after the RTU has reported an internal BATTERY LOW condition. Take care not to confuse this with an external power supply low condition. The following procedure requires the SCADAPack ES to be powered off briefly, but maintains the SCADAPack ES configurations if there is some capacity remaining in the on-board battery. To replace the battery, follow the steps given below: 1. Power-off the RTU 2. Remove the RTU cover 3. Unfasten the holding screws between I/O board and processor board 4. Carefully unplug the I/O board from the processor board 5. Observe static handling procedures when handling the I/O board 6. Power-on the RTU 7. Carefully remove the flat lithium battery from its socket 8. Replace battery with any industry standard 3V lithium cell type CR2450. "+" side of the battery is facing up. 9. Power-off the RTU 10. Carefully plug the I/O board back into the processor board lining up all pin connectors between the two boards 11. Fasten the holding screws between the I/O board and processor board 12. Replace the RTU cover 13. Power-on the RTU CAUTION SCADAPack ES memory contents will be lost if the on-board battery goes flat or is replaced with the power disconnected. If this occurs, user configurations will need to be re-loaded for correct RTU operation.

53 SCADAPack ES Hardware SCADAPack E Configurator The SCADAPack ES system is maintained and diagnosed using the SCADAPack E Configurator software package. SCADAPack E Configurator is included on the Installation CD that is included with all Schneider Electric shipments. Contact Schneider Electric if you do not have a copy of SCADAPack E Configurator. This package is used to build and load RTU configurations. SCADAPack E Configurator executes on PC desktop or server hardware using Windows 2000 / XP Professional / 2003 / VISTA Business, Ultimate, Enterprise and provides graphical user interfaces for configuring and diagnosing SCADAPack E operations. It also integrates with the ISaGRAF Workbench for building and diagnosing IEC sequences. Figure 6.16: SCADAPack E Configurator For more information refer to the SCADAPack E Configurator User Manual.

54 54 SCADAPack ES Hardware Manual 6 Startup Modes The user can change the startup mode of SCADAPack E RTUs for maintenance purposes. SCADAPack ES Startup Modes SCADAPack ES RTUs use HEX Switches 51 for setting the startup mode. 00 on the HEX Switches is the normal RTU startup mode. See Run Mode 55. F0 on the HEX Switches is Service mode. See Service Mode 56. FC on the HEX Switches is Cold Boot mode. See Cold Boot Mode EF settings are used for SCADAPack ES Remote I/O addresses. See SCADAPack ES Remote I/O Switch Settings 60 Other HEX Switch settings are used for selecting special startup modes. See Other Startup Modes. 58

55 SCADAPack ES Hardware Run Mode The RUN mode is the normal operating mode of the SCADAPack ES controller. The controller starts in RUN mode when the HEX Switches are set to 00. When the controller starts: The RTU loads the defined serial and Ethernet communication parameters, for COM ports RTU database configuration and point attributes are loaded ISaGRAF application programs are loaded and executed If there is no ISaGRAF application program in RAM and there is an application program in flash ROM then the flash ROM program will be loaded in RAM and executed.

56 56 SCADAPack ES Hardware Manual 6.2 Service Mode SERVICE mode is used for configuration, programming and maintenance work, usually when the communication settings are unknown. When the HEX Switches are set to F0, the SCADAPack ES controller restarts in SERVICE mode. When the controller starts up: Temporarily sets the DNP3 node address to zero (0), enabling communication via SCADAPack E Configurator at a known DNP address. Connect SCADAPack E Configurator to PORT 0, PORT 1 or PORT 2. The ISaGRAF user applications are stopped. Programs and configurations are retained in non-volatile memory. PORT 4 is set as Cmd Line mode at 9600 bps (No Parity, 8-bits, 1 stop-bit). Normal RTU functions are operational, other than port communication settings. Serial port configurations are restored to default (see tables below) SCADAPack ES Default Port Settings PORT 0 PORT 1 PORT 2 PORT 3 PORT 4 Serial interface type RS232 RS232 RS232 RS232 RS232 Port speed 9600 bps 9600 bps 9600 bps 9600 bps 9600 bps Duplex Full Full Full Full Full Parity None None None None None Data bits 8-bits 8-bits 8-bits 8-bits 8-bits Stop bits 1-bit 1-bit 1-bit 1-bit 1-bit Protocol ISaGRAF DNP3 DNP3 DNP3 Cmd Line

57 SCADAPack ES Hardware Cold Boot Mode The FC startup mode HEX Switch setting is used for COLD BOOT Mode for SCADAPack ES and SCADAPack ER RTUs only. To Cold Boot a SCADAPack ES controller: Set the HEX Switches to FC mode Power the controller OFF and then ON When a SCADAPack ES controller starts in COLD BOOT mode: The ISaGRAF user applications are erased. The RTU point database is cleared RTU configurations are returned to default DNP3 Device Address is set to 0 Ethernet configurations are restored to default (Ethernet communications disabled) Serial port configurations are restored to default (see tables 57 below) Cold Boot mode does not format the Flash file system. See Format Boot in Other Startup Modes 58. SCADAPack ES Default Port Settings PORT 0 PORT 1 PORT 2 PORT 3 PORT 4 Serial interface type RS232 RS232 RS232 RS232 RS232 Port speed 9600 bps 9600 bps 9600bps 9600bps 9600bps Duplex Full Full Full Full Full Parity None None None None None Data bits 8-bits 8-bits 8-bits 8-bits 8-bits Stop bits 1-bit 1-bit 1-bit 1-bit 1-bit Protocol ISaGRAF DNP3 DNP3 DNP3 Cmd Line

58 58 SCADAPack ES Hardware Manual 6.4 Other Startup Modes The complete list of HEX Switch settings applicable to SCADAPack ES RTUs is shown below. Switch settings F0-FF are used for RTU startup modes on SCADAPack ES RTUs. (The SCADAPack E device address for the various RTU protocols is set by software configuration and is not by the switch settings). As there are startup modes that force the SCADAPack E DNP3 device address to 0, it is recommended that DNP3 device Address 0 not be configured for use in SCADAPack E RTU DNP3 systems. For more information see the SCADAPack E DNP3 Technical Reference manual. Changing the HEX switch settings to a value in the range 00-F0 will cause an RTU system restart with entry into the appropriate start mode. Switching the RTU to addresses F1 - FF will require the RTU to be separately reset (e.g. powered off & on) in order for the special operation to take affect. Table 5.1: SCADAPack ES Startup Mode HEX Switch Settings RTU Switch Setting (Hex) Description Notes 00 RUN Mode Normal RTU startup mode. See Run Mode EF Remote I/O addresses See SCADAPack ES Remote I/O Switch Settings 60. RTU functions vary by Remote I/O settings. F0 F1 F8 F9 Service Mode Clear ISaGRAF applications System memory test Boot Monitor Re-programming mode Overrides DNP3 device address and serial port settings so device can be accessed with known configurations. See Service Mode 56. Normal RTU functions are operational, other than port communication settings. Clears ISaGRAF applications from RAM and FLASH memory. Command line interface is available on PORT 4. Connect a serial terminal program to PORT 4 at 9600 bps. Normal RTU functions are NOT operational. Runs a test on the RAM of the SCADAPack E RTU. Normal RTU functions are NOT operational. Connect a serial terminal program to PORT 4 at 9600 bps. Allows Boot Monitor Flash to be reprogrammed. Connect SCADAPack E Configurator to PORT 4 on SCADAPack E.

59 SCADAPack ES Hardware 59 RTU Switch Setting (Hex) FB FC FE FF Description Format Boot Mode Cold Boot Mode Calibrate Hardware Flash Firmware transfer Notes Normal RTU functions are NOT operational. This mode forces the Command line interface on PORT 4 so that file system format commands can be entered. Connect a serial terminal program to PORT4 at 9600 bps. Normal RTU functions are NOT operational. For more information see SCADAPack E Operational Reference manual. See Cold Boot Mode 57. Normal RTU functions are NOT operational. Calibration interface is provided on PORT 4. Connect an ANSI (VT) terminal program to PORT 4 at 9600 bps. Normal RTU functions are NOT operational. Allows RTU Operating System Firmware in Flash memory to be re-programmed. Connect SCADAPack E Configurator to PORT 4 on SCADAPack E. Normal RTU functions are NOT operational.

60 60 SCADAPack ES Hardware Manual 6.5 SCADAPack ES Remote I/O Switch Settings The SCADAPack ES and SCADAPack ER RTUs use hardware HEX switches to set MAIN and Remote I/O Group and Unit addresses for SCADAPack ES Remote I/O. Both SCADAPack ES and SCADAPack ER RTU supports operation as a MAIN RTU for communication with SCADAPack ES Remote I/O units via serial and Ethernet links. Remote I/O operation uses HEX switch settings in the range 00- EF. The first switch setting (first hex digit) indicates the Remote I/O Group number. Up to 15 different Remote I/O groups are supported on the same physical link(s), being selected by switch settings 0 9, A E. Each Remote I/O Group needs to have 1 Main unit and may have multiple Remote I/O units. In many systems there is only one remote I/O group. Typically the group number is set to 0. The second switch setting (second hex digit) indicates the Remote I/O Unit number. One MAIN unit is permitted per Remote I/O group (unit address 0), and up to 15 Remote I/O units may be connected to the same Main unit, being selected by switch settings 1 9, A F. Each Main and Remote I/O unit on the same physical network needs to have a unique HEX address switch setting. For normal RTU operation as a Single RTU, it is recommended that the SCADAPack ES or SCADAPack ER RTU HEX Switches be set to 00. For more information see the SCADAPack E Remote I/O Technical Reference manual. 7 SCADAPack ES Diagnostics A range of diagnostic information is provided by the SCADAPack ES RTUs in order to facilitate troubleshooting and understanding of RTU operation. Start-Up and Diagnostic Display Session 66 Command Line Diagnostics Error Codes 68 Internal Analog Points Internal Binary Points Communication Statistics 72 67

61 SCADAPack ES Hardware On Board Indication LEDs The SCADAPack ES has several Light Emitting Diodes (LEDs), which provide status information such as: Each digital input and output has an individual LED, which illuminates when the input/output is active (on) Tx and Rx LEDs which illuminate data is transmitted or received Several LEDs are provided by the processor board and displayed through the enclosure of SCADAPack ES. These can be used for diagnostic and operational indication. Table shows the LED name, color and description. LED Name Color Description Table 6.-10: Indication LEDs RUN Red Blinks when the SCADAPack ES is running TX Yellow Transmitting data on a Network communication port RX Red Receiving data on a Network communication port LED1 / LANIP Green Blinks with Ethernet or TCP/IP activity LED2 / COMM Green Blinks with peripheral communication activity UTIL Red Blinks upon completion of a specific operations on the Compact FLASH Utility port Ethernet 1 Green (Upper) UTP Ethernet 1 Link Up Ethernet 1 Green (Lower) UTP Ethernet 1 RX/TX Ethernet 1 Green (Internal) UTP Ethernet 1 Full Duplex Ethernet 2 Green (Upper) UTP Ethernet 2 Link Up Ethernet 2 Green (Lower) UTP Ethernet 2 RX/TX Ethernet 2 Green (Internal) UTP Ethernet 2 Full Duplex RUN indicates the operational status of the SCADAPack ES micro-controller and software operation. When the SCADAPack ES Boot Monitor is starting up, this LED will blink at approximately a 0.5- second rate. Following Boot Monitor startup, it will blink rapidly in succession to indicate initialization of the SCADAPack ES operating system firmware. After initialization is complete it blinks at approximately a 1.5-second rate. If it ceases to blink (i.e. remains continuously on or off) for more than approx. five seconds, the SCADAPack ES is not functioning correctly. RX indicates receipt of date by the SCADAPack ES from a telemetry interface port (may be serial and/ or Ethernet depending upon the SCADAPack ES configuration). RUN / RX LEDs may flash alternately when the SCADAPack ES is in Boot Monitor programming mode. For more information see the SCADAPack E Operational Reference manual and the SCADAPack E Firmware Update User Manual. TX is turned on while the SCADAPack ES is transmitting data to a telemetry interface port (may be serial and/or Ethernet depending upon the SCADAPack ES configuration). LED1 or LANIP usually indicates TCP/IP communication activity on either of the SCADAPack ES Ethernet Ports or via a serial port configured with a valid PPP configuration.

62 62 SCADAPack ES Hardware Manual LED2 or COMM usually indicates communication activity with peripheral devices, such as PLC s, external to the SCADAPack ES. UTIL may flash to indicate completion of an operation on the Compact FLASH Utility port (e.g. Security key configuration successfully loaded from Compact FLASH card - for more information see SCADAPack E Security Technical Reference Manual). Ethernet LEDs adjacent to each Ethernet ports on the SCADAPack ES processor board indicates an active UTP Ethernet connection and RX/TX data activity.

63 SCADAPack ES Hardware I/O board LED Enable Jumper By default, the indication LEDs on the SCADAPack ES I/O boards are enabled. The default configuration for the LED Enable Jumper on the I/O Board appears below (jumper across pins 2 &3, located on the top I/O board). To disable indication LEDs on the I/O board, move the J1 jumper from the lower pins (2&3) to the upper pins (1&2). J1 Figure 6.15: Standard Setting for I/O Board LED Enable Jumper

64 64 SCADAPack ES Hardware Manual 7.2 Internal Analog Points Internal analog points measure RTU input Supply voltage and the controller's ambient temperature. These can be accessed from a user application program or via remote RTU communications. Internal temperature Internal Temperature o C System Analog Point This analog system point measures the ambient temperature at the controller circuit board in degrees Celsius. It is useful for measuring the operating environment of the controller and returns an integer value in the range 40 to 75. The temperature reading represents temperatures in the range 40 C to 75 C. Temperatures outside this range cannot be measured. Use the system point directly by assigning an analog point of this point number (50062) in the RTU database Read the system point into a user ISaGRAF application as an Integer or Real variable from an Input Board connection Internal Temperature o F System Analog Point This analog system point measures the ambient temperature at the controller circuit board in degrees Fahrenheit. It is useful for measuring the operating environment of the controller and returns an integer value in the range 40 to 167. The temperature reading represents temperatures in the range 40 C to 167 F. Temperatures outside this range cannot be measured. Use the system point directly by assigning an analog point at this point number (50063) in the RTU database Read the system point into a user ISaGRAF application as an Integer or Real variable from an input board

65 SCADAPack ES Hardware Internal Binary Points Internal system binary points are provided which indicate the status such as the RTU input Supply voltage and the controller's on-board lithium battery. These can be accessed from a user application program or via remote RTU communications. Local Input Power Supply Low Binary System Point An internal binary point indicates the condition of the input power supply. It compares the Supply Voltage System Analog Point with the Low Voltage Alarm Level set in SCADAPack E Configurator General / Control Modes page. If the input power supply is lower than the Low Voltage Alarm Level then this Binary System Point is activated. Use the system point directly by assigning a binary point to this point number (50206) in the RTU database For ISaGRAF applications, read the status point through an Input Board connection. Local On Board Battery Low Binary System Point An internal binary point indicates the condition of a monitor on the lithium battery that maintains the nonvolatile RAM in the controller. If active, the point indicates that the on-board controller battery needs replacement. Use the system point directly by assigning a binary point to this point number (50207) in the RTU database For ISaGRAF applications, read the status point through an Input Board connection.

66 66 SCADAPack ES Hardware Manual 7.4 Start-Up & Diagnostic Display Session Start-Up Diagnostics At start-up, the SCADAPack ES can display information about its start-up sequence and configuration. If a CmdLine command line port is configured on the RTU, ASCII text is displayed through this port as the RTU starts up. After completion of the RTU start-up, the SCADAPack ES usually terminates the diagnostic session and enters command mode. The entry to command mode after start-up can be optionally disabled, leaving the RTU in the diagnostic display session. This is achieved using the SYSDIAG OVERRIDE command described in SCADAPack E Operational Reference manual. Diagnostic Display Session The SCADAPack ES, through the Diagnostic Display session, may indicate exceptional RTU operating conditions. This is available from a CmdLine command line port on the RTU using the DIAG command. Alternatively, a Command Line shell through an RTU ISaGRAF port (when IEC Target 3 is enabled only), or via Telnet provides access to the diagnostic display session. Where a direct serial connection or Telnet is not available, diagnostics can be remotely acquired by directing the diagnostics to an RTU file. This is achieved using the FILEDIAG command described in SCADAPack E Operational Reference manual. This diagnostics log file can then be retrieved using DNP3 file transfer for analysis. SCADAPack ES diagnostics are provided for every aspect of RTU communications and exceptional RTU operating conditions. The following operational diagnostics are specifically supported: DNP3 diagnostics at each protocol layer, including network routing. TCP/IP diagnostics including DNP3 over IP, IP servers, TCP service ports, etc. PLC communication diagnostics including protocol packet displays, communication status and device status for serial and network PLC services. RTU system diagnostics. SCADAPack ES diagnostics may indicate SCADAPack ES operational information that assists in trouble shooting. To sort these diagnostics from normal operational messages, it may be advantageous to disable DNP, TCP/IP, PLC and SYSTEM diagnostics using DNPDIAG, TCPDIAG, PLCDIAG and SYSDIAG commands from the command-line. Other RTU diagnostics use the following format to assist in identifying messages from various SCADAPack ES tasks: Task-name>>diagnostic text

67 SCADAPack ES Hardware Command Line Diagnostics The SCADAPack ES command line operations & diagnostic display can be accessed using an ASCII terminal via a SCADAPack ES port configured as Cmd Line, or its ISaGRAF port. Telnet can also be used via TCP/IP links. The RTU also supports a Remote Command Line whereby the command line interface can be accessed for remote SCADAPack ES units over DNP3 links. This uses DNP3 standard Virtual Terminal capability. A Remote Command Line (Virtual Terminal) window is provided in SCADAPack E Configurator to access this functionality in the RTU. At RTU start-up, configuration information and diagnostics are displayed on an ASCII terminal on the RTU s Cmd Line port. The RTU then defaults to command line mode. The Diagnostic Display mode can be connected by entering the DIAG command. To enter Command mode from Diagnostic Display press <Escape>. When in SYSDIAG OVERRIDE mode, the RTU remains in Diagnostic Display mode after start-up rather than entering Command mode. To enter Command mode press <Escape>. Command mode provides a wide range of commands for interrogating the operational status of a SCADAPack ES RTU. These are detailed in the SCADAPack E Operational Reference manual. Command line operations and diagnostic display are also supported on the ISaGRAF workbench port. The RTU need not be configured with a Cmd Line port in this case. An ASCII terminal can be connected to the ISaGRAF workbench port, and after inputting <Enter><Enter><Enter>, the port enters Command mode. To return to ISaGRAF Workbench debugging mode, enter the command BYE. CAUTION The "BYE" command should be issued prior to disconnecting the ASCII terminal for correct ISaGRAF operation. The Command line operations and diagnostic display are also supported via TCP/IP interfaces using Telnet. In addition, command line operations are also supported via DNP3 Virtual Terminal. The RTU need not be configured with a Cmd Line or ISaGRAF port in these cases. Multiple Telnet sessions may be established with the RTU on the same TCP/IP interface, or multiple sessions may be established on multiple TCP/IP interfaces, simultaneously.

68 68 SCADAPack ES Hardware Manual 7.6 Error Codes Error codes are reported by the SCADAPack ES from various RTU facilities. RTU error codes fall into the following major categories: DNP3 and PLC Device Communication Errors & TCP/TIP Errors SCADAPack ES System Error Points & ISaGRAF User Application Errors Refer to the SCADAPack E Operational Reference manual for details of these system error codes.

69 SCADAPack ES Hardware System Status Codes SCADAPack E RTU provides a system status code through an RTU Analog System Point The most recent status is retained as the value of the system status. DNP3 event reporting may be configured for the system status point to provide a time-stamped history of status codes. System status is reported through the RTU System Error Point. User defined status codes may be generated via ISaGRAF using RTUPARAM function block with the SYS_ERR_CODE parameter. ISaGRAF user application statuses are reported using the following RTU facilities: To the ISaGRAF Workbench Debugger if connected (locally or remotely) Through the SCADAPack E System Error Point Via the SCADAPack E Diagnostic Display session. Table 7.1: SCADAPack E System Status Codes Status Code Name Description 0 Normal Normal status on SCADAPack ES RTU ISaGRAF Target Status See SCADAPack E ISaGRAF Technical Reference manual. For Target 5, see SCADAPack E Target 5 Technical Reference manual User defined Status See SCADAPack E ISaGRAF Function Blocks Reference manual -RTU_PARAM function block. For Target 5, see SCADAPack E Target 5 Function Block Reference manual ISaGRAF Application Load Status Did not load ISaGRAF application files or memory application for ISaGRAF targets Configuration Status Configuration File status Profile Status Profile configuration status Event & Trend Status Event storage threshold status Data Processing Status Run time data processing status codes Remote I/O Status Firmware mismatch status codes Magna I/O Status (SCADAPack ER only) Magna I/O Status (SCADAPack ER only) I/O status reported by main OS firmware I/O status reported by 386 IO Interface firmware TCP/IP Status TCP/IP configuration & run-time status

70 70 SCADAPack ES Hardware Manual Status Code Name Description See SCADAPack E TCP/IP Technical Reference manual For SCADAPack E System Error Point details see the SCADAPack E Operational Reference manual.

71 SCADAPack ES Hardware DNP3 and PLC Device Communication Errors & TCP/IP Errors DNP3 Communication Errors DNP3 communication errors are reported by the RTU through the Diagnostic Display session as DNP3 driver diagnostic information. These error codes are also reported through the ISaGRAF Peer Communication function blocks in the output STATUS variable. The DNP3 communication errors are NOT reported via the RTU System Error Point. See the SCADAPack E DNP3 Technical Reference manual for a complete list of DNP3 Communication Error Codes. PLC Device Communication Errors Error codes reported from PLC Device drivers on the RTU are through Analog System Points that represent an error code resulting from communication between an ISaGRAF PLC Device I/O Board and a PLC Device. The PLC Device communication errors are NOT reported via the SCADAPack E System Error Point. These error codes are detailed in the following manuals: SCADAPack E ISaGRAF Technical Reference manual SCADAPack E Target 5 Technical Reference manual SCADAPack E Modbus Communication Interfaces manual TCP/IP Errors TCP/IP communication and configuration errors are reported by the RTU through the Diagnostic Display session as TCP/IP diagnostic information. These error codes are also reported through the ISaGRAF TCP/IP function blocks in the output STATUS variable. The TCP/IP errors are reported via the RTU System Error Point for TCP/IP configuration problems. See the SCADAPack E TCP/IP Technical Reference manual for a complete list of TCP/IP Communication Error Codes.

72 72 SCADAPack ES Hardware Manual 7.7 Communication Statistics A variety of communication statistics are provided by the RTU via System Analog points. These analog points may be read from the RTU using specific DNP3 point range read requests. Alternatively they may be read into an ISaGRAF user application via Input Boards, or Function Blocks. Communication Statistic point values may be reset at any time by controlling the relevant System Point value and setting it to 0. This may be done by an ISaGRAF user application or via DNP3 point controls. The Communication Statistics System Analog points cannot be directly added to the RTU point database and returned in DNP3 Class data polls. To map Communication Statistic points to a SCADA Master, the values may be imported in to an ISaGRAF user application, manipulated if required, then exported to a derived point, which can be configured for access by a SCADA Master. There are three types of communication statistic points provided by the RTU: SCADAPack E (global) communication statistics. Port communication statistics. TCP/IP communication statistics. Communication Statistics System Analog points may be accessed as 16-bit or 32-bit Analog Input points. For Communication Statistics details see the SCADAPack E Operational Reference manual.

73 SCADAPack ES Hardware 73 8 Calibration This section describes how to calibrate the I/O interfaces provided on the SCADAPack ES. CAUTION The SCADAPack ES has been factory calibrated using high precision equipment. Re-calibration of I/O should only be attempted by skilled personnel using high quality, high precision equipment. To check whether the calibration of the SCADAPack ES I/O meets the requirements of an attached device, check the hardware jumper settings on the I/O board, and use SCADAPack E Configurator software application to read from and control the RTU points associated with the device. For more information refer to the SCADAPack E Technical Reference Manuals. 1: The analog inputs provided on the RTU have an accuracy of 0.1% over the operating temperature range. Therefore when calibrating these a source with an accuracy of 0.05% or better should be used. Similarly the analog outputs provided on the RTU have an accuracy of 0.1% over the operating temperature range. Therefore when calibrating these, a meter with better than 0.05% accuracy should be used. 2: To confirm that maximum accuracy is obtained when calibrating the analog output channels two requirements need to be met. Firstly the RTU should be powered with each analog output driving maximum current into a load resistance of 270 to 560 for a duration of 30 minutes prior to calibration. This confirms that components have achieved operational temperature. In addition to this the calibration instrument used should have an accuracy of 0.05% or better, displaying the measurement to 3 decimal places or better. 3: Before calibrating the RTU, the RTU clock should be set with the correct date and time. See the SCADAPack E Configurator Users Manual (Transfer Menu) for instructions on setting the RTU time.

74 74 SCADAPack ES Hardware Manual 8.1 Overview The calibration interface is implemented as a simple menu system. To access the calibration menu, connect a null modem serial cable to Port 4 of the SCADAPack ES RTU, set the configuration Hex switches to FE, and cycle power to the controller. The calibration menu enables calibration of the physical I/O as well as the voltage monitor. Additional information can also be entered via the calibration interface that enables the generation of a Test and Calibration certificate. If any attempts are made to calibrate physical I/O, the user will be prompted to enter the following information: operator name calibration equipment (source and measurement). The following items are consistent throughout the calibration screens: The menu title is shown at the top, in the middle of the screen. The menu options are drawn in the centre of the screen. The currently selected menu item is shown in reverse video. To activate the currently selected menu item press the enter key. To change the currently selected menu item, use the arrow keys. Alternatively the short-cut k ey, shown to the left of the menu item, may be used to immediately activate any menu item. The screen may be refreshed at any time by pressing the space bar. The R short-cut key can be used from any menu to return to the previous menu (explanation of this menu option is omitted from the remainder of this section). At the bottom of the screen is the feedback area. This area displays the state of various calibration settings and physical I/O. The information displayed in this area changes depending on the menu being displayed. For each of the following sections where selection of a menu item leads to a further menu, detailed description of this item will be omitted from the section describing the higher-level menu, to avoid duplication. Calibration screen examples are given for a SCADAPack ES A model RTU with the 32/16/12/4 I/O board. Calibration screen contents may vary for different I/O board models.

75 SCADAPack ES Hardware Main Menu After the RTU starts up in calibration mode, the Main Menu is displayed. The Main Menu, as shown in Figure , provides the highest-level overview of the operations that can be performed through the calibration interface. These operations include: Calibration of analog inputs Calibration of analog outputs Calibration of the voltage monitor Actuation of the output relays (toggles state) Viewing and Editing the Calibration Certificate Figure shows the feedback area associated with the Main Menu. It gives an overview of the state of various calibration settings and physical I/O including: On-board battery status The state of the digital inputs The raw value of the analog inputs Menu Items 1 is used to access the menus that permit the calibration of analog inputs 1 to 6. 2 is used to access the menus that permit the calibration of analog inputs 7 to is used to access the menus that permit the calibration of analog outputs 1 to 4. 4 is used to actuate the output relays for visual inspection and testing. s c x is used to access the menus that permit the calibration of the power supply. is used to access the menus that view and edit the calibration certificate. is used to restart the RTU. Figure 8.1: Calibration Main Menu Screen

76 76 SCADAPack ES Hardware Manual AI Menus Selection of menu items 1 or 2 from the Main Menu will display an AI Menu as shown in Figure This menu consists of a selection items for each analog input in the selected group. This menu is basically a springboard to the individual channel calibration screens. The feedback area on this screen is changed to show the state of calibration settings and current values for the selected analog input group. AI Menu S/N I/O Calibrate AI 01 CPU Calibrate AI 02 B/M Calibrate AI Calibrate AI Calibrate AI Calibrate AI 06 r. Return to previous menu Analog Input : Cal Minimum : Cal Maximum : Current Value : A/D Reference = (raw count) Figure 8.2: AI Menu

77 SCADAPack ES Hardware Calibrate AI Menu The Calibrate AI Menu is used to change the calibration settings for the analog inputs on a per channel basis and is shown in Figure The menu contains items for changing the following calibration settings and information for the selected AI channel: Minimum input (current/voltage) Maximum input (current/voltage) Calibration Range (for calibration certificate) Menu Options 1 will set the input minimum for the selected channel. This means that the input current/voltage applied to the terminals of the selected analog input, at the time of selecting this option, will be represented in the RTU by the value set as the user minimum (set by option 3). 2 will set the input maximum for the selected channel. This means that the input current/voltage applied to the terminals of the selected analog input, at the time of selecting this option, will be represented in the RTU by the value set as the user maximum (set by option 4). c will record the calibration range for the selected channel (e.g. 1 5V). This entry has no effect on the calibrations themselves and is provided for information purposes only. There is also an entry in the Calibration Certificate menu that will set the calibration range for analog inputs (see section Analog Input Calibration Range 91 ) Calibration Procedure Plug current/voltage source into selected channel. Apply desired minimum current to input and select menu option 1. Apply desired maximum current to input and select menu option 2. Select Calibration Range for this channel (if required). The range can be selected for ALL analog inputs from Calibration Certificate menu entry (see section Analog Input Calibration Range 91 ).

78 78 SCADAPack ES Hardware Manual Figure 8.3: Calibrate AI

79 SCADAPack ES Hardware AO Menus Selection of menu option 3 from the Main Menu will display an AO Menu as shown in Figure This menu consists of a menu item for each analog output. This menu is basically a springboard to the individual channel calibration screens. The feedback area on this screen is changed to show the state of calibration settings and current values for the analog output channels. Figure 8.4: AO Menu

80 80 SCADAPack ES Hardware Manual Calibrate AO Menu The Calibrate AO Menu is used to change the calibration settings for the analog outputs on a per channel basis and is shown in Figure The menu contains options for changing the following calibration settings and information for the selected AO channel: minimum and maximum current output 25%, 50% and 75% current output calibration range for this channel (for calibration certificate) Menu Options 1 used to access menu for calibration of the minimum current output 2 used to access menu for calibration of the 25% current output 3 used to access menu for calibration of the 50% current output 4 used to access menu for calibration of the 75% current output 5 used to access menu for calibration of the maximum current output c will record the calibration range for the selected channel (e.g. 4 20mA). This entry has no effect on the calibrations themselves and is provided for information purposes only. There is also an entry in the Calibration Certificate menu that will set the calibration range for analog outputs (see section Analog Output Calibration Range 92 ). Figure 8.5: Calibrate AO Menu Each of the menu entries shown in Figure allow calibration of the selected analog output channel at the minimum, 25%, 50%, 75%, and maximum levels. The minimum calibration menu is shown in

81 SCADAPack ES Hardware 81 Figure Figure 8.6: Calibrate Minimum Menu These lower level AO menus contains options for changing the calibration settings of the selected level (min, 25%, 50%, 75%, or max) as well as recording the measured value at that level (min, 50%, and max levels only). Menu Options 1 will set the channel s output current to the selected level (min, 25%, 50%, 75%, or max). will increase the output current associated with the selected level in large steps. / will increase the output current associated with the selected level in small steps. ; will decrease the output current associated with the selected level in large steps.. will decrease the output current associated with the selected level in small steps. 2 will prompt the user to enter the channel s measured output current for the selected level (valid for minimum, 50% and maximum levels only). Calibration Procedure Attach a current meter to the selected channel. Select the menu entries corresponding to the selected channel as shown in Figure Select the desired level for calibration (menu shown in Figure ). Select menu option 1 to set the output current to the nominal output. Use menu options, /, ; and. to set the output current to the desired value.

82 82 SCADAPack ES Hardware Manual Use menu option 2 to enter the measured output current for this calibration point (valid only for minimum, 50% and maximum levels).

83 SCADAPack ES Hardware Calibrate Voltage Monitor This menu is used to change the calibration settings for the supply voltage monitoring circuit. There is also a low supply voltage alarm. The low voltage alarm level is not set in the calibration screens as it is configurable at runtime and can be included in RTU configuration files (see the or the SCADAPack E Configuration Technical Reference Manual for low volts alarm point number and type). The menu, shown in Figure , contains items for performing the following operations: Setting minimum voltage point. Setting maximum voltage point. Menu Items 1 will set the minimum voltage. This means that the voltage applied to the supply terminals at the time of selecting this option will be represented in the RTU by the value set as the user minimum. 2 will set the maximum voltage. This means that the voltage applied to the supply terminals at the time of selecting this option will be represented in the RTU by the value set as the user maximum. Calibration Procedure Set the RTU power supply voltage to the recommended minimum value (displayed in menu entry) and select menu option 1. Set the RTU power supply voltage to recommended maximum value (displayed in menu entry) select menu option 2. (The unit should now indicate that it is calibrated, as can be seen in Figure ) Figure 8.7: Voltage Monitor Menu

84 84 SCADAPack ES Hardware Manual Calibration Certificate Menu This menu is used to view and edit the calibration certificate and is shown in Figure The calibration certificate displays I/O board calibrations along with other calibrations information entered by the user to provide a single page certificate suitable for archiving. The menu contains options for the following: displaying the calibration certificate entry of operator name and equipment used. entry of PCB serial numbers. entry of supplementary test data (e.g. dates of particular tests) entry of a single calibration range for analog inputs / outputs. Menu Options 1 will display the calibration certificate with the current calibration information 2 will prompt the user to enter their name 3 4 will prompt the user to enter the calibration equipment. (Two successive dialog boxes will prompt the user to enter both the generating and measuring equipment) will prompt the user to enter PCB serial number. (Two successive dialog boxes will prompt the user to enter both the I/O board and CPU board serial numbers) 5 will prompt the user to enter Processor Board PCB serial number. 6 will prompt the user to enter I/O Board PCB serial number. t i o is used to access the menus to enter the supplementary test dates menu will prompt the user to enter a single calibration range for analog inputs will prompt the user to enter a single calibration range for analog outputs