CONTROL MICROSYSTEMS. TeleSAFE Micro16 Controller. Hardware Manual

Transcription

1 TeleSAFE Micro16 Controller Hardware Manual CONTROL MICROSYSTEMS SCADA products... for the distance 48 Steacie Drive Telephone: Kanata, Ontario Facsimile: K2K 2A9 Technical Support: Canada 888-2CONTROL

2 2007 Control Microsystems Inc. All rights reserved. Printed in Canada. Trademarks TeleSAFE, TelePACE, SmartWIRE, SCADAPack, TeleSAFE Micro16 and TeleBUS are registered trademarks of Control Microsystems Inc. All other product names are copyright and registered trademarks or trade names of their respective owners. Material used in the User and Reference manual section titled SCADAServer OLE Automation Reference is distributed under license from the OPC Foundation. 1

3 Table of Contents 1 OVERVIEW IMPORTANT SAFETY INFORMATION INSTALLATION Field Wiring Controller Board Field Wiring Connectors Power Supply System Grounding Adding Model 5103 Power Supplies Internal Analog Inputs Digital/Counter Inputs DIN/Counter Inputs Wiring Examples Interrupt Input INT/Cntr Input Wiring Example Status Output SERIAL COMMUNICATION RS-232 Serial Communication Ports COM1 RS-232 Serial Port COM2 RS-232 Serial Port DE-9P Connector for RS RS-232 Wiring Examples DTE to DTE without Handshaking DTE to DTE with Handshaking DTE to DCE with Handshaking RS-485 Serial Communication Port Four Wire Mode Two Wire Mode Termination Resistors RS-485 Wiring Examples Four wire mode RS-485 Two wire mode

4 5 OPERATION Operating Modes Run Mode Service Mode Cold Boot Mode Sleep Mode LED Indicators Led Power Control Jumpers J5 Power Supply Jumper RS-485 Termination Jumpers Status LED and Output I/O Module Error Indication Register Assignment Checksum Error Configuration Switches Digital Input Filters Hardware Reset Option Switches MAINTENANCE Fuse Lithium Battery Battery Replacement Procedure SPECIFICATIONS General Micro16 Controller Communication Visual Indicators Power Supply I/O Expansion Capacity Digital Inputs and Outputs Approvals and Certifications

5 Index of Figures Figure 1: 5203 Controller Board Layout... 8 Figure 2: 5204 Controller Board Layout... 8 Figure 3: Power Supply Wiring... 9 Figure 4: Digital/Counter Input Wiring...12 Figure 5: Interrupt Input Wiring...13 Figure 6: Status Output Wiring...14 Figure 7: RS-232 Port Connector...16 Figure 8: RS-232 DTE to RS-232 DTE without Handshaking...18 Figure 9: RS-232 DTE to RS-232 DTE with Handshaking...18 Figure 10: RS-232 DTE to RS-232 DCE...19 Figure 11: RS 485 Field Wiring Four Wire Mode...22 Figure 12: RS 485 Field Wiring Two Wire Mode

6 1 Overview The TeleSAFE Micro16 controller consists of a 5203 or 5204 controller board. Application programs for the controller can be written in either TelePACE Ladder Logic, or optionally IEC61131, and C language. The 5203 or 5204 Controller provides an integrated power supply, three digital/counter inputs, an interrupt input and a status output. The two serial communication ports enable connection to a large variety of communication networks. The 5203 Controller has two RS-232 serial communication ports and the 5204 Controller has one RS-232 and one RS-485 serial communication ports. The RS-232 serial communication ports on the controller board support half-duplex and full-duplex communication. They support RTS/CTS hardware handshaking for connection to modems and radio modems. The RS-232 and RS-485 ports operate at baud rates from 300 baud to baud. Using 5000 Series I/O modules can expand the I/O capacity of TeleSAFE Micro16 Controllers. A maximum of forty 5000 Series I/O modules may be connected for an expansion of up to 512 digital outputs, 512 digital inputs, 128 analog inputs, 32 counters and 32 analog outputs. TeleSAFE Micro16 memory is expandable to 2MBytes flash ROM, and 1MBytes RAM. The CMOS RAM is non-volatile (battery backed). An EEPROM (1kBytes) stores configuration parameters. A real time clock calendar provides for time of day operations and alarms. A hardware watchdog timer protects against application program failures. Low power applications can benefit from the TeleSAFE Micro16 sleep mode feature. During sleep mode only the counter inputs, interrupt input and real time clock alarms remain active. The 5000 Series I/O bus is shut down. Low power applications also benefit from the TeleSAFE Micro16 ability to enable and disable status LED s on all modules connected to the 5000 Series I/O bus including the controller board. 5

7 2 Important Safety Information Power, input and output (i/o) wiring must be in accordance with Class I, Division 2 wiring methods Article (b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in accordance with the authority having jurisdiction. WARNING! EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2. WARNING! EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES. WARNING! EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS. 6

8 3 Installation The installation of TeleSAFE Micro16 controllers requires mounting the TeleSAFE Micro16 controller on the 7.5mm by 35mm DIN rail and connecting the TeleSAFE Micro16 controller to the system I/O Bus. Refer to the System Configuration Guide for complete information on system layout, I/O Bus cable routing and TeleSAFE Micro16 controller installation. 3.1 Field Wiring TeleSAFE Micro16 controllers use screw termination style connectors for termination of field wiring. These connectors accommodate solid or stranded wires from 12 to 22 AWG. The connectors fit over pins on the controller board and the 5601 I/O module. The connectors are removable allowing replacement of the TeleSAFE Micro16 Controller without disturbing the field wiring. Leave enough slack in the field wiring for the connector to be removed. CAUTION: Remove power before servicing unit. To remove the termination connector: Pull the connector upward from the board. Apply even pressure to both ends of the connector. To install the termination connector: Line up the pins on the module with the holes in the connector. Make sure all the pins line up properly. Push the connector onto the pins. Apply even pressure to both ends of the connector Controller Board Field Wiring Connectors The controller board has four connectors for field wiring. Refer to Figure 1: 5203 Controller Board Layout or the Figure 2: 5204 Controller Board Layout for connector locations. Primary power input connections; output power connection and ground connections are wired to a six-pole connector labeled P3. Refer to the Figure 1: 5203 Controller Board Layout and Figure 2: 5204 Controller Board Layout sections for more information. The three digital/counter inputs (DIN/Counters), interrupt input/counter (INT/Cntr) and status output (STATUS) are wired to an eight-pole connector labeled P6. Refer to the Digital/Counter Inputs, Interrupt Input and Status Output sections for more information. The 5203 version of the controller board has two RS-232 serial communication ports that are wired to DE-9P plug connectors. COM 1 connector is labeled P3 and COM 2 connector is labeled P4. See Figure 1: 5203 Controller Board Layout. Refer to the RS-232 Serial Communication Ports section for more information on the serial ports. The 5204 version of the controller board has one RS-232 serial communication port, COM 2, which is wired to a DE-9P plug connector and one RS-485 serial communication port, COM 1, which is wired to a six-pole connector. COM 1 connector is labeled P3 and COM 2 connector is labeled P4. See Figure 2: 5204 Controller Board Layout. Refer to RS-232 Serial Communication Ports and RS-485 Serial Communication Port sections for more information on the serial ports. 7

9 CPUStatus LEDS DIN Status LEDS com1 Status LEDS com2 Status LEDS J5 I/O Bus Connector Configuration Switches LED Power Switch I/O Bus Connector Fuse Power Connector (P5) Field Termination Connector (P6) com1 RS-232 DTE Connector com2 RS-232 DTE Connector AC/DC + PWR IN DC PWR + + INT STATUS COM DIN/COUNTER Figure 1: 5203 Controller Board Layout CPU Status LEDS DIN Status LEDS com1 Status LEDS com2 Status LEDS J5 I/O Bus Connector Configuration Switches LED Power Switch I/O Bus Connector Fuse Power Connector Field Termination Connector com1 RS-485 Connector com2 RS-232 DTE Connector AC/DC + PWR IN DC PWR + + INT STATUS COM DIN/COUNTER + Tx + Rx Figure 2: 5204 Controller Board Layout 3.2 Power Supply The TeleSAFE Micro16 controller has an integrated power supply. It is sufficient to power the controller and several 5000 Series I/O modules. Note: Voltage referred to as Vrms (or VAC on some products) indicates AC power. Voltage referred to as V indicates DC power. The power supply provides a 5V output to power 5000 Series I/O modules connected to both the right and left side 5000 Series bus connectors. This supply has a 1.0 ampere output capacity and is sufficient to power the controller with approximately 800mA remaining for I/O modules. For complete information on I/O module power requirements refer to the System Configuration Guide. The TeleSAFE Micro16 can enter an extremely low power mode called sleep mode by switching off the 5V supply to all I/O modules and most of the controller board circuits. Refer to the Sleep Mode section for more information. 8

10 The TeleSAFE Micro16 power supply accepts AC or DC input power. Connect a power source to the input power in one of the following ways: CAUTION: Power can be applied to either the AC/DC power input OR the DC power input. DO NOT apply power to both inputs. Damage to the power supply may result. A 16Vrms source connects to the AC/DC PWR IN terminals. Figure 3: Power Supply Wiring shows this AC power source coming from a transformer. A 13-24V source may be connected to the AC/DC PWR IN terminals instead of the 16Vrms source, although this is not common. The polarity of the source does not matter. An 11-24V source connects to the DC PWR terminals. Figure 3: Power Supply Wiring shows this DC power source coming from a battery. The AC/DC power input typically connects to a 16Vrms source or a 24V source. Under these conditions, 22V to 24V are available at the DC PWR terminals, suitable for powering 20mA loop transmitters. The DC PWR input typically connects to 12V batteries. There is no battery charger with the TeleSAFE Micro16 controller. Under these conditions, no connection should be made to the AC/DC power input. J5 P5 24 Volts AC/DC DC PWR PWR IN Volts Opens during Sleep Mode. Inter-module cable, right and left side circuits Class 2 Transformer To other modules requiring 24 Volts 120 VAC 16 VAC Note: If the AC/DC input power is provided from a source other than a class 2 transformer, then the input power must be suitably fused. Optional 12 Volt Gel Cell Battery connects to 5 and 6 when no power source is connected to 3 and 4. Figure 3: Power Supply Wiring System Grounding In most applications, it is desirable to connect the system power supply common to chassis, or panel ground. The (negative) side of the 24V supply on the TeleSAFE Micro16 controller can be connected to the enclosure by wiring pin 1 to pin 2 on P5. 9

11 3.2.2 Adding Model 5103 Power Supplies When additional power is required by the system, 5000 Series 5103 power supplies can be used in combination with the TeleSAFE Micro16 Controllers. The 5103 power supplies can be connected anywhere downstream (to the right) of the controller. They will supply power to the modules downstream of them. Note: The Sleep Mode feature of the controller applies only to those modules powered by the controller. The 5103 power supply may also be connected upstream (to the left) of the TeleSAFE Micro16 controller, if the following conditions are observed. No power is applied to the power inputs of the TeleSAFE Micro16 controller. The external power supply jumper is installed at position J5 (refer to the J5 Power Supply Jumper section for more information). The sleep mode feature is not used. For more information on adding 5103 power supply modules refer to the System Configuration Guide. 3.3 Internal Analog Inputs The TeleSAFE Micro16 Controller has two internal analog inputs in addition to the analog inputs on the 5601 I/O Module. These internal analog inputs are accessed form the user application program. The ambient temperature input measures the temperature at the controller circuit board. It is useful for measuring the operating environment of the controller and returns an integer value in the range 40 to 75 deg C or 40 to 167 deg F. The temperature reading represents temperatures in the range - 40 C to 75 C or -40 F to 167 F. Temperatures outside this range cannot be measured. For TelePACE applications use the AIN Controller Temperature register assignment to read the ambient temperature in degrees C and degrees F. For ISaGRAF applications use the aintemp I/O connection to read the ambient temperature in degrees C and degrees F. The lithium battery input measures the voltage of the battery that maintains the non-volatile RAM in the controller. The reading returned from this input is in the range from representing the battery voltage in mv. It is useful in determining if the battery needs replacement. The 3.6V lithium battery will return a typical value of 3600 or A reading less than 3000 (3.0V) indicates that the lithium battery requires replacement. For TelePACE applications use the AIN Controller RAM Battery V register assignment to read the lithium battery voltage. For ISaGRAF applications use the ainbatt I/O connection to read the lithium battery voltage. 3.4 Digital/Counter Inputs The controller board has three Digital / Counter inputs. These inputs are labeled DIN/Counter 0, 1 and 2 on the P4 terminal connector. The DIN/Counter inputs have one standard voltage range, 24V AC or DC, and operate as digital inputs and as counter inputs. For DC inputs the maximum input voltage is 30V and the minimum voltage to turn the input ON is 10V. 10

12 For AC inputs the maximum input voltage is 24Vrms and the minimum voltage to turn the input ON is 10Vrms. For counter inputs the maximum frequency is 5KHz with the filters off. The DIN/Counter inputs can be used as both digital inputs and counter inputs in an application program. For TelePACE applications use the CNTR Controller Counter Inputs register assignment to read the DIN/Counter inputs as counters and the DIN Controller Digital Inputs register assignment to read the DIN/Counter inputs as digital inputs For ISaGRAF applications use the cntrctrl I/O connection to read the DIN/Counter inputs as counters and the dinctrl I/O connection to read the DIN/Counter inputs as digital inputs. Each of the three DIN/Counter inputs on the controller has a switch selectable filter, which limits the maximum input frequency. Filtering limits the maximum digital input or counter frequency to approximately 30Hz. SW1 is used to enable or disable filtering. Refer to the Digital Input Filters section for filter selection information using SW3. Use a filter for 50 or 60Hz digital inputs and for low speed counting applications that experience problems due to contact bounce. Do not use filtering for high speed counting applications DIN/Counter Inputs Wiring Examples An example of wiring each type of input is shown in the diagram below. 11

13 SW3 FILTER 0 FILTER 1 FILTER 2 Example: Filter 0 is CLOSED to debounce contacts. Filter 1 is CLOSED to filter AC. Filter 2 is OPEN for high speed counting. P6 Digital/Counter Inputs COM Volts 16 VAC + Pulse Output Figure 4: Digital/Counter Input Wiring 3.5 Interrupt Input The TeleSAFE Micro16 has one Interrupt digital input. This input is labeled INT/Cntr on the P6 terminal connector. This input operates as a DC digital input and as a counter input. The INT/Cntr input is also used to wake the controller from sleep mode. See the Sleep Mode section for more information on this feature. For DC input the maximum input voltage is 28V and the minimum voltage required to turn the input ON is 2.5V. For counter input the maximum frequency is 500Hz. The INT/Cntr input can be used as both a digital input and a counter input in an application program. For TelePACE applications use the CNTR Controller Interrupt Input register assignment to read the INT/Cntr input as a counter and the DIN Controller Interrupt Input register assignment to read the INT/Cntr input as a digital input. For ISaGRAF applications use the cntrint I/O connection to read the INT/Cntr input as a counter input and the dinint I/O connection to read the INT/Cntr input as a digital input. 12

14 3.5.1 INT/Cntr Input Wiring Example The diagram below shows how to wire this input. P6 Interrupt Input V Figure 5: Interrupt Input Wiring 3.6 Status Output The status output indicates an alarm condition to an external device. The output is ON (capable of conducting current) during normal operation. The output is OFF (high impedance) during the following conditions: power failure controller RESET application program defined conditions The status output is an optically isolated transistor. The polarity of the output must be observed. The output current must be limited to 60mA during the ON condition. The output voltage must be limited to 30 Volts during the OFF condition. A typical application of this output is shown in Figure 6: Status Output Wiring. The output energizes a relay. The normally closed contacts of this relay are used to activate an alarm. The relay in this application has a 24V coil with greater than 400-ohm resistance. 13

15 P6 + STAT Volts Relay Coil Specifications: 24 Volt > 400 ohms < 60mA NO COM NC NC ALARM CONTACTS: closed during power failures and fault conditions. Figure 6: Status Output Wiring 14

16 4 Serial Communication The TeleSAFE Micro controller board has two RS-232 serial ports, identified as COM1 and COM2. The TeleSAFE Micro controller board has one RS-232 serial port identified as COM2 and one RS-485 serial port identified as COM1. COM1 COM2 TeleSAFE Micro controller board RS DE-9P connector designated P3 on the Controller. RS DE-9P connector designated P4 on the Controller. TeleSAFE Micro controller board RS-485 Terminal Connector P3 on the Controller. RS DE-9P connector designated P4 on the Controller. 4.1 RS-232 Serial Communication Ports All RS-232 wiring must use shielded cable. The shield should be connected to chassis ground at one point. Failure to properly shield the cable may result in the installation not complying with FCC or DOC radio interference regulations COM1 RS-232 Serial Port For 5203 controller boards COM1 is an RS-232 serial port. Connections are made through a DE-9P connector. The wiring and pin connections for this connector are described in the DE-9P Connector for RS-232 section. The following table shows the serial and protocol communication parameters supported by COM1. These parameters are set from TelePACE, ISaGRAF Workbench or from an application program running in the controller. Default values are set when a Cold Boot or Service Boot is performed on the controller. Parameter Supported Values Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, Default: 9600 Duplex Full or Half Default: Full Parity Odd, None or Even Default: None Data Bits 7 or 8 Bits Default: 8 Bits Stop Bits 1 or 2 Bits Default: 1 Bit Receive Flow Control ModbusRTU or None Default: ModbusRTU Transmit Flow Control Ignore CTS or None Default: None Station 1 to Default: 1 Protocol None, Modbus RTU, Modbus ASCII and optionally DF1 Or DNP. Default: Modbus RTU 15

17 Parameter Addressing Mode Supported Values Standard or Extended Default: Standard COM2 RS-232 Serial Port Connections to COM 2 are made through a DE-9P connector. The wiring and pin connections for this connector are described in the DE-9P Connector for RS-232 section. The following table shows the serial and protocol communication parameters supported by COM1. These parameters are set from TelePACE, ISaGRAF Workbench or from an application program running in the controller. Default values are set when a Cold Boot or Service Boot is performed on the controller. Parameter Supported Values Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, Default: 9600 Duplex Full or Half Default: Full Parity Odd, None or Even Default: None Data Bits 7 or 8 Bits Default: 8 Bits Stop Bits 1 or 2 Bits Default: 1 Bit Receive Flow Control ModbusRTU or None Default: ModbusRTU Transmit Flow Control Ignore CTS or None Default: None Station 1 to Default: 1 Protocol None, Modbus RTU, Modbus ASCII and optionally DF1 Or DNP. Default: Modbus RTU Addressing Mode Standard or Extended Default: Standard DE-9P Connector for RS-232 RS-232 ports are 9-pin male D-sub-miniature (DE-9P) connectors configured as Data Terminal Equipment (DTE). A maximum cable length of 50ft (15.2m) is allowed. Figure 7: RS-232 Port Connector shows the pin connections on the RS-232 connectors. 1 DCD 2 RxD 3 TxD 4 DTR 5 Gnd 6 7 RTS 8 CTS 9 +5V Figure 7: RS-232 Port Connector 16

18 In the following table a MARK is a voltage of +3V or greater; a SPACE is a voltage of 3V or less. Pin Type Description. Pin 1 DCD Pin 2 RxD Pin 3 TxD Pin 4 DTR Pin 5 Ground Pin 6 Pin 7 RTS Pin 8 CTS input input output output output input The DCD led is on for a MARK level. The level is SPACE on standby and MARK for received data. The RxD LED is lit for a MARK level. The level is SPACE on standby and MARK for transmitted data. The LED is lit for a MARK level. This pin is normally at a MARK level. This pin is at a SPACE level when DTR is de-asserted. This pin is connected to the system ground. This pin is not connected. This pin is a MARK if full-duplex operation is selected for the port. This pin is set to a MARK just before and during transmission of data if half-duplex operation is selected. This pin is set to a SPACE when no data is being transmitted. The LED is ON for a MARK level. This level must be a MARK for the communication port to transmit data. When the attached device does not provide this signal, the controller keeps the line at a MARK. When the attached device does provide this signal, it must set CTS to MARK to allow the controller to transmit data. The LED is on for a MARK level. Pin 9 output This pin is connected to the 5V power supply. Exercise caution when using it. This pin must NOT be connected if it is not used. 4.2 RS-232 Wiring Examples DTE to DTE without Handshaking There are several methods for wiring the RS-232 COM port to DTE and DCE (Data Communications Equipment) devices. The simplest connection requires only 3 wires: RxD, TxD and signal ground. Figure 8: RS-232 DTE to RS-232 DTE without Handshaking shows a common RS-232 COM port to DTE device. 17

19 RS-232 COM port (DTE) DTE DCD RxD TxD DTR GND DCD RxD TxD DTR GND 6 RTS CTS 7 8 RTS CTS +5V 9 See device specifications for pin numbers Figure 8: RS-232 DTE to RS-232 DTE without Handshaking DTE to DTE with Handshaking Some DTE devices may require hardware handshaking lines. The most common are the CTS and RTS lines. Less common are the DTR and DCD lines. The controller does not require these lines. Refer to the specifications of the external device for exact requirements. Figure 9: RS-232 DTE to RS-232 DTE with Handshaking shows a common connection of an RS-232 COM port with a DTE device requiring handshaking lines. RS-232 COM port (DTE) DTE DCD RxD TxD DTR GND DCD RxD TxD DTR GND 6 RTS CTS 7 8 RTS CTS +5V 9 See device specifications for pin numbers Figure 9: RS-232 DTE to RS-232 DTE with Handshaking DTE to DCE with Handshaking DCE devices require different wiring. The handshaking lines must be connected in most cases. Note that many DCE devices are half duplex. Select half-duplex operation with these devices. Figure 10: RS-232 DTE to RS-232 DCE shows common connection of a TeleSAFE Micro16 with a DCE device requiring handshaking lines. 18

20 RS-232 COM port (DTE) DCE DCD 1 RxD 2 TxD 3 DTR 4 GND 5 DCD RxD TxD DTR GND 6 RTS 7 CTS 8 RTS CTS +5V 9 See device specifications for pin numbers Figure 10: RS-232 DTE to RS-232 DCE 4.3 RS-485 Serial Communication Port For 5204 controller boards COM1 is an RS-485 serial port. Connections are made through a 6 pin terminal connector. The wiring and pin connections for this connector are described in the Four Wire Mode and the Two Wire Mode sections. The following table shows the serial and protocol communication parameters supported by COM1. These parameters are set from the ISaGRAF Workbench or from an application program running in the controller. Default values are set when a Cold Boot or Service Boot is performed on the controller. Parameter Supported Values Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, Default: 9600 Duplex Full or Half Default: Full Parity Odd, None or Even Default: None Data Bits 7 or 8 Bits Default: 8 Bits Stop Bits 1 or 2 Bits Default: 1 Bit Receive Flow Control None or XON/XOFF Default: ModbusRTU Transmit Flow Control None or XON/XOFF Default: None Station 1 to Default: 1 Protocol None, Modbus RTU, Modbus ASCII and optionally DF1 Or DNP. Default: Modbus RTU Addressing Mode Standard or Extended Default: Standard 19

21 The RS-485 port transmits and receives differential voltages to other RS-485 devices. The RS-485 specification allows a maximum of 32 devices. It is recommended that the cable length should not exceed a maximum of 4000 feet (1200 m), and be terminated at each end. The signal grounds of the RS-485 devices are not connected together but instead are referenced to their respective incoming electrical grounds. The grounds of the RS-485 devices must be within several volts of each other. The RS-485 port operates in two or four wire mode Four Wire Mode Four-wire operation uses one pair of wires for transmitting data and a second pair for receiving data. The transmitting pair is connected to the terminals marked +TX and TX on the termination block. The receiving pair is connected to the terminals marked +RX and RX P3 + Tx + Rx Terminate the shield on one end of the cable only Two Wire Mode Two-wire operation uses one pair of wires for transmitting and receiving data. The +TX terminal must be connected to the +RX terminal. The TX terminal must be connected to the RX terminal. This pair of wires becomes the transmitting and receiving pair P3 + Tx + Rx Termination Resistors Termination resistors are required on the first and last station on the RS-485 wire pair. All other stations should not have termination resistors. Resistors for receiver and transmitter termination are pre-installed on the 5204 controller board. To connect the termination resistors: 20

22 Install a jumper across the top two pins on J7 to terminate the RX pair. Install a jumper across the bottom two pins on J7 to terminate the TX pair. To disconnect the termination resistors: Remove the jumper from across the top two pins on J7 to disconnect termination of the RX pair. Remove the jumper from across the bottom two pins on J7 to disconnect termination of the TX pair. The 5204 controller board uses a traditional termination scheme with one 120 resistor across the line. Special fail-safe receivers have been used that guarantee that the received data will be in an idle state for the following conditions on the RX pair: Open inputs. Terminated inputs. Shorted inputs. This termination scheme may not be compatible with other RS-485 devices. RS-485 receivers that cannot tolerate a differential input voltage of 0V (line terminated but not driven) should be terminated with resistors that bias the line to known state during these conditions. 4.4 RS-485 Wiring Examples Four wire mode Four-wire operation uses one pair of wires for transmitting data and a second pair for receiving data. The transmitting pair is connected to the terminals marked +TX and TX on the termination block. The receiving pair is connected to the terminals marked +RX and RX. See Figure 11: RS 485 Field Wiring Four Wire Mode for wiring details. 21

23 MASTER RX +RX TX +TX First station in network requires terminations. SLAVE RX +RX TX +TX SLAVE RX +RX TX +TX RS-485 network 4000 feet (1200 m) maximum length SLAVE RX +RX TX +TX Last station in network requires terminations. Figure 11: RS 485 Field Wiring Four Wire Mode RS-485 Two wire mode Two-wire operation uses one pair of wires for transmitting and receiving data. The +TX terminal must be connected to the +RX terminal. The TX terminal must be connected to the RX terminal. This pair of wires becomes the transmitting and receiving pair. See Figure 12: RS 485 Field Wiring Two Wire Mode for wiring details. 22

24 5204 RX +RX TX +TX First station in network requires terminations RX +RX TX +TX Other RS- 485 Device RS-485 network 4000 feet (1200 m) maximum length TX/RX +TX/RX 5204 RX +RX TX +TX Last station in network requires terminations. Figure 12: RS 485 Field Wiring Two Wire Mode 23

25 5 Operation 5.1 Operating Modes The TeleSAFE Micro16 controller may start up in RUN mode, SERVICE mode, or COLD BOOT mode. RUN mode automatically executes Ladder Logic and C programs in the controller memory. SERVICE mode stops the programs to allow reprogramming and controller initialization. COLD BOOT mode erases Ladder Logic and C programs in the controller memory and initializes the controller Run Mode RUN mode is the normal operating mode of the TeleSAFE Micro16 controller. No action is required to select RUN mode. When power is applied to the controller: The user defined serial communication parameters, for all COM ports are used. If a TelePACE Ladder Logic, or ISaGRAF application program is loaded in RAM, it is executed. If a TelePACE C, or ISaGRAF C, application program is loaded in RAM and the program checksum is correct, it is executed. If there is no application program in RAM and there is an application program in flash ROM then the flash ROM program will be executed. The controller lock settings and password are used Service Mode SERVICE mode is used during application programming and maintenance work. When the TeleSAFE Micro16 controller starts in SERVICE mode: The default serial communication parameters are used (see the Specifications section for the default parameters). The Ladder Logic or ISaGRAF program is stopped. The C program is stopped. All programs are retained in non-volatile memory. The controller lock settings and password are used. SERVICE mode is selected by performing a SERVICE BOOT using the following procedure: 1. Remove power from the TeleSAFE Micro16 controller. 2. Hold down the LED POWER button. 3. Apply power to the controller. 4. Continue holding the LED POWER button until the STAT LED turns on. 5. Release the LED POWER button. Note: If the LED POWER button is released before the STAT LED turns on, the TeleSAFE Micro16 controller will start in RUN mode. 24

26 5.1.3 Cold Boot Mode COLD BOOT mode is used after installing new controller firmware. When the TeleSAFE Micro16 controller starts in COLD BOOT mode: The default serial communication parameters are used (see the Specifications for a description of the default parameters). The Ladder Logic or ISaGRAF program is erased. The C program is erased. The registers in the I/O database are initialized to their default values. The Register Assignment or I/O Configuration is erased. The controller is unlocked. COLD BOOT mode is selected by performing a COLD BOOT using the following procedure: 1. Remove power from the TeleSAFE Micro16 controller. 2. Hold down the LED POWER button. 3. Apply power to the TeleSAFE Micro16 controller. 4. Continue holding the LED POWER button for 25 seconds until the STAT LED begins to flash on and off continuously. 5. Release the LED POWER button. Note: If the LED POWER button is released before the STAT LED begins to flash, the TeleSAFE Micro16 controller will start in SERVICE mode Sleep Mode The TeleSAFE Micro16 controller is capable of extremely low power operation when in sleep mode. Sleep mode is enabled or disabled using the SLP function in TelePACE or the SLEEP function in ISaGRAF. During sleep mode the following happen. All programs stop executing. When J5 is not installed, the 5V power to most of the circuit is switched off. When J5 is not installed, the 5V power to the I/O bus is switched off. The three counters on the controller continue to function. The real-time clock and alarm continue to function. The interrupt input continues to function. 24V DC power is not affected. The TeleSAFE Micro16 controller enters the sleep modes under control of the application program. The TeleSAFE Micro16 controller wakes up from sleep mode under the following conditions: Hardware RESET caused by power removed and applied to the controller. The LED POWER push-button is pressed. A real time clock alarm, defined by application program, occurs. A signal is applied to the interrupt (INT) input. 25

27 Any of the counters rolls over. This will occur every pulses on each input. 5.2 LED Indicators There are 18 LEDs on the TeleSAFE Micro16 controller. The communication controller CPU powers the LEDs. All LEDs (except the 5V LED) can be disabled to conserve power. Refer to the Led Power Control section for details. The table below describes the LEDs. LED 5V RUN LEDS STAT FORCE DINS RX TX CTS RTS DCD Function On when 5V power is present. Off when the 5V power is absent or the controller is in sleep mode. On when the ladder logic program is executing. On when LED power is enabled. On or blinking when an error exists. On when I/O points are forced. On when a signal is applied to the corresponding digital input. On when receiving data on the corresponding serial port. On when transmitting data on the corresponding serial port. ON when the CTS input is asserted on the corresponding serial port. ON when the RTS output is asserted on the corresponding serial port. ON when the DCD input is asserted on the corresponding serial port. 5.3 Led Power Control LEDs on the TeleSAFE Micro16 controller and 5000 Series modules consume power when they are on. The controller module can disable the LEDs to conserve power. This is particularly useful in solar powered or unattended installations. The LEDS LED on the TeleSAFE Micro16 controller indicates the LED power state. It is on when the controller enables LED power. The LED POWER push-button toggles the LED power signal. Press the LED POWER push-button to toggle LED power from off to on, or from on to off. The default state of the power is set by the application program. The LED power returns to the default state 60 minutes after the LED POWER push-button is pressed last. The application program may change the default time and state. LEDs are enabled when a controller asserts the LED power signal. Power to the LEDs is provided by the /LEDON signal on the I/O bus. Asserting this signal will enable the LEDs. Releasing this signal disables the LEDs. In multiple controller systems, any controller can assert the /LEDON signal to enable the LEDs but all controllers must release it to disable the LEDs. Some LEDs are unaffected by the /LEDON signal. Refer to individual I/O module manuals for details. 26

28 5.4 Jumpers Most headers and jumpers on the controller board are reserved for manufacturing and test functions. The power supply jumper and the RAM Configuration jumpers may require user adjustment J5 Power Supply Jumper The J5 jumper is removed when sleep mode is used. In all other cases the J5 jumper is installed. The J5 jumper is installed when the TeleSAFE Micro16 controller internal power supply is used. Power is applied to one of the power inputs on the input power connector. This is the normal operating mode. The J5 jumper is installed when the controller is powered by an external power supply. No power may be applied to the input power connector. See the Adding Model 5103 Power Supplies section for wiring information RS-485 Termination Jumpers A jumper is installed on the top two positions of J7 when the RS-485 Rx line requires a termination. A jumper is installed on the bottom two positions of J7 when the RS-485 Tx line requires a termination. See the RS-485 Serial Port section for additional information. 5.5 Status LED and Output The status LED and output indicate alarm conditions. The STAT LED blinks and the STATUS output opens when an alarm occurs. The STAT LED turns off and the STATUS output closes when all alarms clear. Note: The STATUS output remains open continuously when an alarm condition is present. The STAT LED is on continuously during reset. The STAT LED blinks a binary sequence indicating alarm codes. The sequences consist of long and short flashes, followed by an off delay of 1 second. The sequence then repeats. The sequence may be read as the Controller Status Code. A short flash indicates a binary zero. A long flash indicates a binary one. The least significant bit is output first. As few bits as possible are displayed, all leading zeros are ignored. The application program defines the values of the alarm codes. The table below shows the meaning of the sequences. Sequence Off CONTROLLER STATUS CODE 0 = Normal 1 Long I/O Module Error Indication 1 Short, 1 Long Register Assignment Checksum Error I/O Module Error Indication When the Status LED flashes the controller status code 1 (i.e. a long flash, once every second), there is a communication failure with one or more I/O module. To correct the problem, do one of the following: 27

29 Ensure that every module contained in the Register Assignment Table is connected to the controller. Check that the module address selected for each module agrees with the selection made in the Register Assignment Table. If a module is still suspect of having failed, confirm the failure by removing the module from the Register Assignment Table. Download the changes to the controller. The Status LED should stop flashing. If a module is currently not connected to the controller, delete it from the Register Assignment Table. Download the changes to the controller. The Status LED should stop flashing. If unused modules must be intentionally left in the Register Assignment Table, the I/O error indication may be disabled from a selection box on the Register Assignment dialog Register Assignment Checksum Error When the status LED flashes the controller status code 2 (i.e. a short flash then a long flash followed by a 1 second of delay), this indicates the register assignment is not valid. To correct this, initialize the register assignment from the TelePACE software, or alternatively, perform a COLD BOOT as described in the Cold Boot Mode section of this manual. The status LED should stop flashing. 5.6 Configuration Switches The TeleSAFE Micro16 controller has 7 configuration switches. They specify digital input filters, reset action and application program options. The switches can be changed with the power applied. Digital filter and reset action changes take effect immediately. Application program option selections take effect as defined by the program. To select configuration switch functions: Remove the module cover and locate the configuration switches. See Figure 1: 5203 Controller Board Layout or Figure 2: 5204 Controller Board Layout for switch locations. Press the right hand side of the switch down to enable the switch function. Press the left hand side of the switch down to disable the switch function. The switch settings are described below Digital Input Filters Each of the three digital inputs can be filtered. Filtering limits the maximum digital input or counter frequency to approximately 30 Hz. Use a filter for 50 or 60 Hz digital inputs and for low speed counting applications that experience problems due to contact bounce. The FILTER 0, FILTER 1 and FILTER 2 switches control the input filter functions: To disable a filter, press the left side of the switch down (open). To enable a filter, press the right side of the switch down (closed) Hardware Reset The controller resets I/O modules when the controller starts. The reset signal clears all outputs to their power off state. 28

30 The I/O modules may be reset when the controller module fails. If hardware reset is enabled, the outputs are reset when the controller reset occurs. This happens due to low voltage or power failure. If hardware reset is disabled, the outputs remain in their last known state until the controller restarts. The HW RESET switch controls the hardware reset function: To disable hardware reset, press down the left side of the switch (open). To enable hardware reset, press down the right side of the switch (closed) Option Switches The OPTION 1, OPTION 2 and OPTION 3 switches control the application specific functions. Application programs can read the switches. Consult the programming manuals for information on reading the switches. To disable an option, press down the left side of the switch (open). To enable an option, press down the right side of the switch (closed). Analog Input Module Compatibility 5000 Series analog input modules 5501 and 5521 require firmware release D or newer if they are used with a Micro16 controller with a firmware release 1.19 or newer. Older 5501 or 5521 Series I/O module firmware must be upgraded. Using older 5501 or 5521 firmware with release 1.19 or newer of the TeleSAFE Micro16 firmware may result in bad data returned from the module. Check the version of the firmware in your 5501 or 5521 analog input module against the table below. Check Parts These Part Number Chip Location Revision Required 5501 firmware or 5521 firmware or U12 U12 U12 U12 suffix D or later suffix A or later suffix D or later suffix A or later 29

31 6 Maintenance The TeleSAFE Micro16 controller requires little maintenance. The 5V power LED indicates the status of the 5V supply. If the LED is off, and the TeleSAFE Micro16 controller is powered using the integrated power supply, on board fuse F1 may require replacing. If the LED is off, and the TeleSAFE Micro16 controller is powered using a 5103 power supply fuse F1 (5V) or F2 (24V) on the 5103 may require replacing. If the program is lost during power outages, the lithium battery may require replacement. If the TeleSAFE Micro16 controller is not functioning correctly, contact Control Microsystems Technical Support for more information and instructions for returning the module for repair. WARNING: Do not connect or disconnect any field wiring, including the wiring to the RS-232 ports P3 and P4, unless the power is off or the area is know to be non hazardous. 6.1 Fuse A 0.5 Amp, 5mm, slow-blow fuse (F1) protects the power supply. The fuse is mounted under the cover. Refer to Controller Board Field Wiring Connectors for F1 location. CAUTION: Remove power before servicing unit. Always replace a defective 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. In all cases investigate and correct the cause of the fuse failure before replacement. Common causes of fuse failure are short circuits and excessive input voltages. 6.2 Lithium Battery A small lithium battery powers the CMOS memory and real-time clock when input power is removed. The voltage of a functioning battery should be greater than 3.0 volts. An application program can monitor this voltage. Refer to the programming manual for details. The battery should not require replacement under normal conditions. The shelf life of the battery is 10 years. The battery is rated to maintain the real-time clock and RAM data for two years with the power off. Accidental shorting or extreme temperatures may damage the battery Battery Replacement Procedure The battery is plugged into the circuit board and secured with a tie-wrap. If necessary it can be replaced with an identical battery available from Control Microsystems. Save the existing program running in the SCADAPack, if applicable. Remove power from the SCADAPack. Remove the SCADAPack top cover and locate the battery. It is found at the far right side of the circuit board. The battery tie wrapped in place at the factory. This is to ensure the battery does not become disconnected during shipment. Cut the tie wrap using wire cutters. Remove the battery by gently lifting it straight up from the circuit board. The battery has two pins that mate with two sockets on the circuit board. Replace the battery. A replacement tie wrap is not necessary. 30

32 Cold boot the controller. (Refer to the Cold Boot Mode section in of this manual for the Cold Boot procedure.) Warning: If a cold boot is not done the behavior of the controller is unpredictable. The controller may now be programmed. 31

33 7 Specifications Disclaimer: Control Microsystems reserves the right to change product specifications without notice. For more information visit General I/O Terminations Dimensions Mounting Packaging Environment 6 and 8 pole, removable terminal blocks 12 to 22 AWG 15 amp contacts 8.50 inch (216 mm) wide inch (118 mm) high 1.75 inch (44 mm) deep 7.5 x 35 DIN rail corrosion resistant zinc plated steel with black enamel paint 5% RH to 95% RH, non-condensing 40 o C to 70 o C 40 o F to 158 o F 7.2 Micro16 Controller Processor Memory Non-volatile RAM Clock calendar Internal temperature Lithium battery monitor M bit CMOS microcontroller MHz clock integrated watchdog timer 1024KBytes CMOS RAM 512kBytes flash ROM 1kBytes EEPROM CMOS RAM with lithium battery retains contents for 2 years with no power 1 minute/month Measurement range -40 C to 75 C. Accuracy 5 C. Measurement range -40 F to 167 F. Accuracy 9 F. Accuracy 0.2V. 32

34 7.3 Communication 5203 Controller Two RS-232 serial ports Data Terminal Equipment (DTE) DE-9P male connector 5204 Controller One RS-232 serial port Data Terminal Equipment (DTE) DE-9P male connector One RS-485 serial port 2 wire half duplex 4 wire full or half duplex optional termination resistors Baud Rates 300, 600, 1200, 2400, 4800, 9600, 19200, Parity Word Length Stop Bits Duplex None, even, or odd 7 or 8 bits 1 or 2 bits Full or half with RTS/CTS control Cable Length RS-232 -maximum 50 ft (15.2 m) RS-485 -maximum 4000 ft (1200 m) Protocol TeleBUS (compatible with Modbus RTU and Modbus ASCII) Allen-Bradley Protocols optional Protocol Modes Slave, master, master/slave, store and forward 7.4 Visual Indicators Micro16 Controller 5203 Controller COM Controller COM Controller COM1 I/O module LED power status LED Status LED (shows functional status) 5V power LED Run LED Forced I/O LED Digital Inputs 0, 1 and 2 LEDs Received data (RxD) LED transmitted data (TxD) LED clear to send (CTS) LED request to send (RTS) LED data carrier detect (DCD) LED Received data (RxD) LED transmitted data (TxD) LED clear to send (CTS) LED request to send (RTS) LED data carrier detect (DCD) LED Received data (RxD) LED transmitted data (TxD) LED 33

35 5204 Controller COM2 Push-button 7.5 Power Supply Power Input AC/DC PWR IN DC power Input DC PWR 5 Volt Power Output (5203) 5 Volt Power Output (5204) DC power Output (16VAC applied) Efficiency Received data (RxD) LED transmitted data (TxD) LED clear to send (CTS) LED request to send (RTS) LED data carrier detect (DCD) LED I/O module LED power toggle 16VAC 20% 14 to 28VDC 28VDC maximum 10.0 to 11.5VDC turn on 9VDC typical turn off 12VDC at 10mA during Sleep Mode 5V at 1.0A capacity 5V at 175mA required by controller 5V at 825mA available for 5000 Series I/O 5V at 1.0A capacity 5V at 250mA required by controller 5V at 750mA available for 5000 Series I/O 20-24VDC with 1.0Vp-p maximum ripple. 360mA available at 5V/0.2A, derate linearly to 80mA at 5V/1.0A 70%, 12VDC on DC PWR input 7.6 I/O Expansion Capacity 5000 Series I/O Expansion Capacity Maximum 20 I/O modules. 7.7 Digital Inputs and Outputs On-board I/O Capacity Digital Inputs Counter Input Frequency 3 digital/counter inputs, opto coupler isolated interrupt input, opto coupler isolated status output 24VAC/30VDC maximum input 10VAC/VDC minimum ON input 2VDC maximum OFF input Typical threshold voltage is 4 to 6 V Typical input hysterisis 0.3 V Typical input current 5mA at 10 V 12mA at 24 V 5 khz maximum with filter OFF 30 Hz maximum with filter ON 34

36 Interrupt Input Interupt Input Frequency Status Output 30V maximum input 4V minimum ON input 2V maximum OFF input Input current 1mA at 5V 3mA at 12V 7mA at 24V 200Hz maximum Opto coupler open collector transistor 30 VDC, 60mA opens on fault 7.8 Approvals and Certifications Safety Non-Incendive Electrical Equipment for Use in Class I, Division 2 Groups A, B, C and D Hazardous Locations. Digital Emissions Immunity Declaration FCC Part 15, Subpart B, Class A Verification EN : 2001 Electromagnetic Compatibility Generic Emission Standard Part2: Industrial Environment EN : 2001 Electromagnetic Compatibility Generic Standards Immunity for Industrial Environments This product conforms to the above Emissions and Immunity Standards and therefore conforms with the requirements of Council Directive 89/336/EEC (as amended) relating to electromagnetic compatibility and is eligible to bear the CE mark. The Low Voltage Directive is not applicable to this product. 35