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Control Microsystems SCADAPack 32 Hardware Manual

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SCADAPack 32 Controller
Hardware Manual
CONTROL
MICROSYSTEMS
SCADA products... for the distance
48 Steacie Drive
Kanata, Ontario
K2K 2A9
Canada
Telephone:
613-591-1943
Facsimile:
613-591-1022
Technical Support:
888-2CONTROL
888-226-6876

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Summary of Contents for Control Microsystems SCADAPack 32

  • Page 1 SCADAPack 32 Controller Hardware Manual CONTROL MICROSYSTEMS SCADA products... for the distance 48 Steacie Drive Telephone: 613-591-1943 Kanata, Ontario Facsimile: 613-591-1022 K2K 2A9 Technical Support: 888-226-6876 Canada 888-2CONTROL...
  • Page 2 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.
  • Page 3 DIGITAL INPUTS..................20 Digital/Counter Inputs................... 20 7.1.1 Wiring Examples..................20 Interrupt Input....................21 7.2.1 Wiring Example..................21 DIGITAL OUTPUTS..................23 Wiring Example .................... 23 SERIAL COMMUNICATION................ 24 RS-232 Serial Communication Ports............24 SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 4 Led Power Control ..................41 11.4 Status LED and Output ................41 11.4.1 I/O Module Error Indication ..............42 11.4.2 Register Assignment Checksum Error............ 42 11.4.3 Too Many I/O Operations Requested Error ..........42 SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 5 APPROVALS AND CERTIFICATIONS ............54 Index of Figures Figure 1: 5232 Controller Board Layout................9 Figure 2: Recommended AC Power Supply Configuration ..........11 Figure 3: Recommended DC Power Supply Configuration..........11 SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 6 Figure 19: Description of SW1 DIP Switches..............43 Figure 20: Analog Input Offset DIP Switches..............44 Figure 21: Analog Output Offset DIP Switches..............45 Figure 22: Line Frequency DIP Switches................45 Figure 23: Low Pass Filter DIP Switches................46 SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 7 The SCADAPack 32 comprises of a 5232 controller board and an optional integrated I/O module. As the most powerful model in the series using 32 bit processing, the SCADAPack 32 offers high performance, built-in Ethernet and a wide range of analog and digital I/O options. The product offers Modbus RTU and Modbus ASCII as native protocols and is remotely programmable, as a master slave, through a choice of flexible programming languages.
  • Page 8 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. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 9 Integrated SCADAPack 32 An integrated SCADAPack 32 controller comprises of a 5232 controller and a lower integrated I/O module. Communication between the controller board and the I/O module occurs via an Inter Module Cable (IMC). The IMC cable also provides 5V from the controller board power supply to the integrated I/O module and expansion 5000 series modules.
  • Page 10 Int erupt and Count ers COM Port J9 J1 RS232 RS485 COM1 COM2 COM4 RS-232/ 485 RS-232 RS-232 AC/ DC – – – LED POWER DC PWR STATUS Figure 1: 5232 Controller Board Layout SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 11 Refer to the user manual of your respective I/O module for a sample power supply calculation. Power Supply Input Connections Input power is connected to the SCADAPack 32 controller board in one of the following ways: • A 16Vac source connects to the AC/DC PWR IN terminals on the Controller board and on the 5601 I/O Module.
  • Page 12 12 - 24Vdc Power Supply – 24V t o I/ O Module Refer t o sect ion of manual for wiring of corresponding I/ O module Figure 3: Recommended DC Power Supply Configuration SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 13 4.2.3 Recommended Battery Supply Configuration This configuration uses a high capacity source, such as a battery, to power the SCADAPack 32. The DC power supply input inrush current can be reduced if required. Battery operated systems have high current capabilities that may cause nuisance fuse blowing. It possible to reduce the DC power supply inrush current by cutting link J3.
  • Page 14 In this example, both analog outputs and only 4 of the 8 analog inputs are being used. Further assume all 12 digital output relays will be on with LEDs enabled. The minimum current requirement for each module on the SCADAPack P4 is given in the table below. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 15 P3 to power the integrated I/O board. This 24V power must be available for both analog outputs and all analog inputs that require power. In this example, both analog outputs SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 16 The 5604 DC Input supply current is calculated as follows: 5604 DC Input Current = (24 x Total Current @ 24V) / (12 x 0.88) = (24 x .20) / (12 x 0.88)) = 455mA SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 17 4 of the 8 analog inputs. Assume all 12 digital output relays will be on with the LEDs enabled. The minimum current requirement for each module on the SCADAPack P4 is given in the table below. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 18 On the 5232 controller board, the logic ground (pin 2) and the negative terminal of the DC PWR or the 24V power source (pin 6) on connector P3 are all referenced to the earth ground (pin 1). Controller Board AC/ DC DC PWR PWR IN – Figure 6: Grounding Configuration SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 19 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. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 20 The analog outputs produce 0-20mA of current but can easily be wired to provide an output voltage by connecting a load resistor across the output channel. Refer to the hardware manual of your respective I/O module for details. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 21 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. 7.1.1 Wiring Examples The figure below illustrates a wiring example where all DIN/COUNTERS channels are being used. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 22 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. 7.2.1 Wiring Example The diagram below shows how to wire this input. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 23 — 2.5-28V – Figure 8: Interrupt Input (INT) Wiring SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 24 The relay in this application has a 24V coil with greater than 400Ω resistance. – STAT Relay Coil Specificat ions: 24 V • – • >400 ohms NO COM NC ALARM CONTACTS: closed during power failures and fault condit ions Figure 9: STATUS Output Wiring SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 25 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 SCADAPack 32 controller. Default values are set when a Cold Boot or Service Boot is performed on the SCADAPack 32 controller.
  • Page 26 Connections to COM2 are made through a RJ-45 modular connector. The wiring and pin connections for this connector are described in the RJ-45 Modular Connector for RS-232 subsection. Refer to Figure 1: 5232 Controller Board Layout for the location of COM2 on the SCADAPack 32 controller board.
  • Page 27 15.2 meters. Shielded cable must be used and the shield should be connected to chassis ground at one end. The following diagram shows the pin connections for the RS-232 (RJ-45) port connector for COM1, COM2 and COM4. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 28 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. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 29 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. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 30 RJ-45 to DE-9S DTE This cable is used to connect from an RJ-45 based RS-232 port on the SCADAPack 32 controller to DE-9P connector on a DTE such as a PC. A 10 ft. long cable is available from Control Microsystems as part number 297217.
  • Page 31 DCE devices are half duplex. Select half-duplex operation with these devices. Figure 14: RS-232 DTE to RS-232 DCE shows common connection of a SCADAPack with a DCE device requiring handshaking lines. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 32 Figure 14: RS-232 DTE to RS-232 DCE RS-485 Serial Communication Port Serial port COM1 on the SCADAPack 32 controller may be configured as an RS-485 serial communication port. A jumper must be installed on J9 to operate COM1 in RS-485 mode. Refer to Figure 1: 5232 Controller Board Layout for the location of J9.
  • Page 33 9.6.2 RS-485 Bias Resistors The RS-485 receiver inputs on the SCADAPack 32 controller are biased to ensure that that received data is driven to a valid state (space) when there are no active drivers on the network. The value of these bias resistors is 4700 ohms from Ground to the –Rx input and 4700 ohms from +5V to the +Rx...
  • Page 34 –TX SLAVE –RX –TX RS-485 net work 4000 feet (1200 m) max imum lengt h SLAVE –RX –TX SLAVE –RX Last st at ion in net work –TX requires t erminat ions. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 35 Other RS- 485 Device –TX/RX + TX/RX 5232 –RX + RX Last station in network –TX may require terminations. + TX Figure 17: RS 485 Field Wiring – Two Wire Mode SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 36 RS-485 Cable This cable is used to connect from an RJ-45 based RS-485 port on the SCADAPack 32 controller to other RS-485 devices. The cable has a RJ-45 connector on one end and stripped wires at the other end. A 10-foot long cable is available from Control Microsystems as part number 297234.
  • Page 37 The following table shows the Modbus/TCP parameters supported by the LAN port. These parameters are set from the ISaGRAF Workbench or from an application program running in the SCADAPack 32 controller. Default values are set when a Cold Boot or Service Boot is performed on the SCADAPack 32 controller.
  • Page 38 10.1.3 RJ-45 Modular Connector for Ethernet The SCADAPack 32 can be connected directly to a wall jack or hub using standard RJ-45 Category 5 patch cables. The following diagram shows the pin connections for the RJ-45 modular connector. SCADAPack 32 Controller Hardware Manual...
  • Page 39 This may limit the practical distance to less than 100m or 350 feet. The Ethernet cables should not be run in parallel with power or any cables that generate noise. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 40 11.1 Operating Modes SCADAPack 32 Controllers may start up in RUN, SERVICE or COLD BOOT mode. Start up in the RUN mode automatically executes the application programs in the controller memory. Start up in the SERVICE mode stops the programs to allow reprogramming and controller initialization. Start up in the COLD BOOT mode initializes the controller and erases all programs.
  • Page 41 11.2 LED Indicators There are 23 LEDs on the SCADAPack 32 controller board. These LEDs are used to indicate the operational status of the controller. All LEDs except the 5V LED can be disabled to conserve power. Refer to section 11.3-Led Power Control subsection below for details.
  • Page 42 11.3 Led Power Control Power to the LEDs on the SCADAPack 32 controller board, integrated or external I/O modules connected to the controller can be disabled to conserve power. This feature is particularly useful when the SCADAPack 32 is used in solar powered or unattended installations.
  • Page 43 It indicates the custom application is requesting I/O operations faster than the system can process them and that the queue of pending operations is full. The custom application should reduce the rate at which it makes requests. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 44 Slide the switch actuator to the right side of the switch to enable the switch function. Slide the switch actuator to the left side of the switch to disable the switch function. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 45 11.5.1 Analog Input Range Selection The analog input channels on the integrated I/O modules on some versions of the SCADAPack 32 controller can be configured for a 0% or 20% offset using switch ‘Options 1’ on SW1. With the 0% offset, the input signal measurement range is 0-20mA in current mode or 0-5V in voltage mode.
  • Page 46 The 60Hz line frequency is enabled by default. 11.6.1 Digital Input Filters Each of the three digital / counter (DIN/Counters) inputs on the SCADAPack 32 controller board can be filtered. Filtering limits the maximum digital input or counter frequency to approximately 30Hz. •...
  • Page 47 5501 firmware 160246 Must be suffix D or later 160303 Must be suffix A or later 5521 firmware 160246 Must be suffix D or later 160303 Must be suffix A or later SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 48 The analog input and output circuitry is calibrated at the factory and does not require periodic calibration. Calibration may be necessary if the module has been repaired as a result of damage. If the SCADAPack32 controller is not functioning correctly, contact Control Microsystems Technical Support for information on returning the SCADAPack for repair.
  • Page 49 Cold boot the controller. (Refer to section 11.1.3-Cold Boot 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. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 50 Check that the digital inputs are not forced on. applied. The LED is off. Input is off when a signal is Check that the digital inputs are not forced off. applied. The LED is on. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 51 Check that the output is not forced on. on when they should be off. Output LED and relay are Check that the output is not forced off. off when they should be on. SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 52 Specifications Disclaimer: Control Microsystems reserves the right to change product specifications without notice. For more information visit www.controlmicrosystems.com 14.1 General I/O Terminations 6,8,9 and 10 pole, removable terminal blocks. 12 to 22 AWG 15A contacts Dimensions 8.40 inch (213mm) wide 6.13 inch (155mm) high...
  • Page 53 DC power Input 30V maximum 10.7V typical turn on DC PWR 9V typical turn off 5 Volt Power 5V at 1.3A capacity 5V at 500 mA required by SCADAPack 32 controller Output SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 54 30Hz maximum with filter ON (Counter 0, 1, 2) 500Hz maximum Counter Input Frequency (Counter 3) 14.7 Digital Outputs Status Output Opto coupler open collector transistor (STATUS) 30V, 60mA opens on fault SCADAPack 32 Controller Hardware Manual May 24, 2006...
  • Page 55 The Low Voltage Directive is not applicable to these products in applications below 30Vdc/60Vac. The Low Voltage Directive is not applicable to the P4A (5604) Model and is eligible to bear the CE mark. SCADAPack 32 Controller Hardware Manual May 24, 2006...