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Kingfisher PLUS+

G30 Hardware Manual

G30 Hardware Manual 1.3 www.rtunet.com/support Page 2

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Document Control

Copyright Copyright CSE-Semaphore (Australia) Pty Ltd. ABN 35 006 805 910 [email protected], www.rtunet.com

Intellectual Property CSE-Semaphore asserts ownership of the intellectual property contained herein and claims copyright and authorship. CSE-Semaphore has and retains all rights of ownership and use of the material herein in its on-going business.

Licence

This document is provided to the intended recipient(s) under a non-exclusive licence. This licence permits Fair Use of the document for operational requirements, without payment of further royalty or licence fee. Fair Use includes making copies of the document for operational, backup and archive purposes. Fair Use includes distributing copies of the document to other entities for the purposes of their performing related works for the intended recipient(s). Fair Use does not include creating, selling or distributing copies of the document for other purposes. All copies must retain this statement of Intellectual Property and Copyright.

Revision History Rev. Date Summary 1.0 4/10/2007 First release. G30 (stand-alone) processor and supported hardware. Serial comms option card

will be supported in a future firmware release. Other comms option cards will soon be available. 1.1 20/3/2008 Updated G30 isolation specifications. G30 (firmware 1704+) now supports OPT-SER serial option

boards. Added more interface cables. 1.2 4/9/2008 Added Series 3 (G3, G30) to Series 2 (CP-xx, PC-1, LP-x) serial port conversion cable (allows

Series 2 standard cables to be directly connected). Added additional safety warnings. Updated Glossary. Updated GSM Modem cable. Added DIN rail mounting bracket. Updated RS422/RS485 wiring diagrams. Added wiring examples for PSO-ACR power supply card.

1.3 11/12/2008 Updated the digital input voltage range specification for the IOD-MXx modules. Added installation warning regarding Restricted Access Locations. Changed name of chapter “Mounting” to “Installation”

mailto:[email protected]

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SAFETY WARNINGS

Installation

CAUTION

This equipment shall be installed only in RESTRICTED ACCESS LOCATIONS by the appropriately trained service personnel. The unit should not be mains powered (AC or DC) unless it is installed correctly.

Fire Risk

CAUTION

A supply voltage above the specified limits may cause fire.

Class I Division 2 Classification

CAUTION

This equipment is suitable for use in Class I, Division 2, Groups A-D or non-hazardous locations only if used with a PSO-DCU power supply card If a PSO-ACR power supply card is used, this equipment is suitable for use in non-hazardous locations only. WARNING – EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2. AVERTISSEMENT: RISQUE D’EXPLOSION – LA SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATÉRIEL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2. WARNING – EXPLOSION HAZARD – DO NOT REPLACE UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS. AVERTISSEMENT – RISQUE D’EXPLOSION – COUPER LE COURANT OU S’ASSURER QUE L’EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX AVANT DE REPLACER LE. WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE COURANT OU S’ASSURER QUE L’EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX.


Contents

1. G30 Standalone RTU................................ ................................ ............ 5

G30 OLED Displays ....................................................................................................................................... 5 G30 Processor Specifications ........................................................................................................................ 6

2. Comms Cards................................ ................................ ....................... 8

Isolated Serial Card (OPT-SER) .................................................................................................................... 8

3. Power Supply Cards ................................ ................................ .......... 10

AC Input Card, Regulated (PSO-ACR) - Non Hazardous Locations Only ................................................... 10 DC Input Card, Unregulated (PSO-DCU)..................................................................................................... 13

4. IO Daughter Cards ................................ ................................ ............. 15

IO Daughter Card - MX2: 14DI, 8DO, 6AI (IOD-MX2) ................................................................................. 15 IO Daughter Card - MX3: 14DI, 8DO, 6AI, 2AO (IOD-MX3) ........................................................................ 15 IO Daughter Card - MX4: 16DI, 16DO (IOD-MX4)....................................................................................... 21

5. Interface Cables ................................ ................................ ................. 26

G30 Ethernet Connection Cable .................................................................................................................. 26 G30 Serial Port Converter ............................................................................................................................ 27 G30 to G30 Serial Crossover Cable............................................................................................................. 27 G30 to CP-xx Serial Crossover Cable.......................................................................................................... 27 PSTN Modems and GSMs ........................................................................................................................... 28 Trio M Series Radio...................................................................................................................................... 28 MaxStream External Spread Spectrum Radio ............................................................................................. 29

6. Installation................................ ................................ .......................... 30

Panel Installation .......................................................................................................................................... 30 DIN Rail Installation...................................................................................................................................... 30

7. Glossary................................ ................................ .............................. 31

8. Appendix: Assembly Instructions ................................ .................... 32


1. G30 Standalone RTU

FEATURES

C-tick and electrical safety compliant for Australia/NZ

Supports logic written in any of the international IEC61131-3 control languages

OLED Display and four status lights

Three button controls

Up to three communications ports

One power supply card

Optional IO card

Optional comms card The G30 is a standalone (self contained) RTU that allows a power supply card (required), an IO card (optional) and a comms card (optional) to be installed within its enclosure. This allows the G30 to be setup for a wide variety of applications that require a compact RTU.

G30 OLED Displays

GENERAL:

RTU address 1 System ID AE

Firmware 1595

YY/MM/DD HH:MM:SS

ETHERNET:

IP 192.168.0.1 Sub 255.255.255.0

Gwy 0.0.0.0

Interface UDP

Tx Pkts 12345 Rx Pkts 12345

STATISTICS:

RX Failures 5 RX Successes 100

TX Failures 8

TX Successes 118

HARDWARE:

PSO-xxx OK IOD-xxx OK

Ethernet OK

POWER SUPPLY:

Type PSO-xxx

V-out 13.8V

I-out mA 200mA I-bat mA 150mA

Temperature 21°C

DI1 OFF DI9 ON

DI2 OFF DI10 ON DI3 ON DI11 OFF

DI4 OFF DI12 OFF

DI5 ON DI13 OFF DI6 OFF DI14 ON

DI7 ON DI15 ON

DI8 ON DI16 OFF

DO1 ON DO9 ON

DO2 OFF DO10 ON DO3 ON DO11 OFF

DO4 OFF DO12 OFF

DO5 ON DO13 OFF DO6 OFF DO14 ON

DO7 ON DO15 ON

DO8 ON DO16 OFF


G30 Processor Specifications Processor Cirrus EP9301 (ARM9), 133 MHz maximum (internal) Word Size 32 bit data bus (internal) Flash Memory 16 MB. Permanent memory. Used to store the RTU configuration, logic,

retained variables and event logs. If power to the G30 processor is lost, non-retained variables and the current state of execution will be reset.

SDRAM 32 MB NV Static RAM 32 kB (128 kB optional). Permanent memory (NV = non volatile). Initial

storage location of event logs. Event logs are then transferred to Flash. Realtime Clock Yes. Accuracy + 1 minute/month (after calibration, at calibrating

temperature) Realtime Clock Backup Note: flash memory and NV static RAM does not require battery backup

Super-capacitor TBD/50 hours @ 25/70 C up to 1000 hours operation TBD/TBD hours @ 25/70 C after 5 years TBD/TBD hours @ 25/70 C after 10 years

Communications Ports Port 1: 10 or 100 Mbps Twisted Pair Ethernet. Has auto speed and link detect Port 2: USB 2.0 Host, Full Speed (12 Mbps max) Port 3: Option card

Ethernet Protocols Supported

TCP/IP, UDP, TCP, ARP and ICMP TCP/UDP Kingfisher protocol port number: 4058

OLED Display Color 96 x 64 pixel OLED (Organic Light Emitting Diode) Displays 8 lines of 19 characters

LEDs (left to right) LED1: Power ON = Power OK LED2: Currently unassigned LED3: Currently unassigned LED4: Currently unassigned

Push buttons Three - UP (left), DOWN (middle) and ENTER (right) Configuration Software Toolbox PLUS+ RTU Address Range 1-65535 Supported Protocols Kingfisher, Modbus, DNP3, SNMP and more. For a complete list, please

obtain Protocols.PDF from www.rtunet.com/support Logic Processing IEC 61131-3, Implemented using ISaGRAF Version 5.xx Input voltage range 9 to 30 VDC Power Consumption 2.5 W maximum

Operating Temperature -40 to 70 C Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

EMC & Safety Compliance C-Tick Port Isolation Ethernet port: Working voltage in respect to system earth/ground must not

exceed 150 VAC maximum. Isolation voltage (transient): 1 kV. USB Port: None Option Card Port: Depends on the Option Card installed.

Dimensions - G30 Stand Alone RTU

175 H x 70 W x 128 D mm (includes mounting brackets)

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Port 1 Ethernet Pinout

RJ45 Pin Ethernet Function

1 TX+ 2 TX- 3 RX+ 4 N/C 5 N/C 6 RX- 7 N/C 8 N/C

RJ45 Socket RJ45 Plug

87654321 12345678

(EIA-561 / RS232D International Standard) Note: the above pin numbering is opposite to CP-11/21/30, PC-1 and LP-1 ports.

Port 1 Ethernet LEDs

LED Description YELLOW ON when there is traffic GREEN ON when port is connected to an ethernet network

G30 Standalone RTU Part Numbers

G30-SW-OPT-PSO-IOD

Power Supply Option: ACR - AC Input regulated DCU - DC Input unregulated

IO Daughter Card Option: MX2 - 14DI, 8AI, 8DO MX3 - 14DI, 8AI, 8DO, 2AO MX4 - 16DI, 16DO

Comms Option: 000 - None SER - RS232/422/485 Serial

Slot Width: SA - Stand Alone

Eg. G30-SA-000-ACR-MX4 The above option cards are detailed in the following chapters.


2. Comms Cards

Isolated Serial Card (OPT-SER) FEATURES

2.5 kV Isolation

RS232 / RS422 / RS485 Interface

Port Pinout RJ45 Pin RS232 RS422 /

RS485* 1 DSR NC 2 DCD NC 3 DTR NC 4 GND GND 5 RXD RX- 6 TXD TX- 7 CTS RX+ 8 RTS TX+

RJ45 Socket RJ45 Plug

87654321 12345678 (EIA-561 / RS232D Standard)

Note: the above pin numbering is opposite to CP-11/21/30, PC-1 and LP-1

ports. * Connect TX- and RX- together to obtain LINE- (RS485) and connect TX+ and RX+ together to obtain LINE+ (RS485). The Isolated serial card supports full hardware flow control. Isolated Serial Card Specifications Baudrate 300 to 115200 bps Data Format 8 data bits, no parity, 1 stop (8, N, 1) Interface Types RS232 or RS422 or RS485 Power Consumption 0.5 W maximum

Operating Temperature -40 to 70 C Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

RS422 Line drive 10 Receivers RS485 Line drive 32 Receivers Isolation 2.5 kV


Wiring Diagram - RS422 4-Wire

The Master RTU can transmit to or receive from any one Remote RTU at any time or each Remote RTU can transmit to or receive from the master RTU, one at a time. Note: Remote RTUs cannot communicate with each other. Up to 10 RTUs (or other RS422 devices) can be connected to the RS422 bus. Maximum RS422 wire length:1200 m.

100 Ohm

100 Ohm

... TX+

RX+

T

X-

RX-

RTU SERIAL PORT

Master

Line termination required

EARTH

100 Ohm 1/2 W

GND w ire can be tied directly to EARTH if 100 ohm resistor not available GND *

* If GND w ire not available, each GND terminal can be tied to EARTH locally using a 100 ohm 1/2 W resistor or directly to EARTH (if resistors not available).

GN

D

TX+

RX+

T

X-

RX-

Remote

GN

D

TX+

RX+

T

X-

RX-

Remote

GN

D

RTU SERIAL PORT RTU SERIAL PORT

Wiring Diagram - RS485 2-Wire

Each RTU can transmit/receive to any RTU, one at a time. Up to 32 RTUs (or other RS485 devices) can be connected to the RS485 bus. Maximum RS485 Wire Length: 600 m.

120 Ohm

RTU SERIAL PORT

LIN

E+

LIN

E-

GN

D ...

120 Ohm

RS485 DEVICE

TX+

R

X+

TX-

R

X-

GN

D

LIN

E+

LIN

E-

TX+

R

X+

TX-

R

X-

GN

D

LIN

E+

LIN

E-

TX+

R

X+

TX-

R

X-

GN

D

LIN

E+

LIN

E-

EARTH

100 Ohm 1/2 W

GND w ire can be tied directly to EARTH if 100 ohm resistor not available

GND *

* If GND w ire not available, each GND terminal can be tied to EARTH locally using a 100 ohm 1/2 W resistor or directly to EARTH (if resistors not available).

RTU SERIAL PORT RTU SERIAL PORT


3. Power Supply Cards

AC Input Card, Regulated (PSO-ACR) - Non Hazardous Locations Only

FEATURES

AC or DC Input Supply

Auxiliary DC Output

Monitoring - supply voltage and current

Low Voltage Shutdown

Backup Battery Charging

This power supply card accepts AC / DC mains input (or DC battery input) and outputs DC voltages used to power the G30 and external equipment such as a radio. It also provides monitoring and protection of the power supply circuitry. WARNING: If a PSO-ACR power supply card is used, the G30 RTU is suitable for use in non-hazardous locations only.


PSO-ACR Specifications

Input Supply 90-260 VAC, 50-60 Hz 96-340 VDC Note: can also be powered using 11 to 14.5 VDC when powered from the backup battery terminals.

Input Protection Under Voltage (< 80 VAC) and Over Voltage (> 400VAC) on the mains input Reverse Voltage and Over Voltage (> 18 VDC) on the battery input

Output Power Regulated 35W Total

Nominal Voltage 13.8 VDC. Boost charges battery using up to 14.2 VDC @ 7 A max.

Battery Fuse 6A @ 20 C polyfuse (auto-resettable). Provides short circuit and overload protection.

Deep Discharge Protection Yes. RTU shuts down at < 10.5 V Restarts at > 11.5 V

Backup Battery

Intelligent Battery Charging Yes. Temperature compensated.

Auxiliary Output 12 VDC @ 2.5 A max. Protected against short circuit and overload Controllable using logic (can switch OFF and ON)

Isolation Maximum working voltage: 300 VRMS Dielectric Strength: 2600 VAC or 3000 VDC for 1 minute

Input Supply Fuse 1.6 A

Connectors IEC 60320-C14 Mains Power Inlet (standard IEC computer power socket) 6-way pluggable terminal block for Auxiliary output, external Temperature Sensor and Battery Operating Temperature -40 to 70 oC Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

Output Noise 500 mV peak-to-peak over 10 Hz to 10 MHz.

Item Accuracy Monitoring

Power Supply Voltage Power Supply Current Power Supply Temperature External Temperature (from ext. temp. sensor) Battery Current Battery present AC Present

+ 0.2 V + 100 mA + 3 °C + 3 °C + 100 mA

EMC & Safety Compliance

C-tick

Accessories (supplied with card)

2.5m right-angle IEC 60320-C13 mains power inlet lead (with no mains plug fitted) External Temperature Sensor 6-way Terminal Block plug

Power Consumption 1W maximum (consumed by power supply card)


PSO-ACR Wiring Diagram

OPTION

I/ OON

VA+

VA-

TS+

TS-

B+

B- USB

ETHERNET

1

AUX 12VOUTPUT

TEMPSENSOR

BATTERYIN/OUT

I O

OFF

POWER INPUT90-260 VAC

96-340 VDC~

Tape or cable tie the temperature sensor to the negative battery terminal to enable temperature compensated battery charging. Connect black striped wire of sensor to TS-.

+ -

TS+ TS- B+ B-

+ - VA+

VA-

OPTIONAL 12VDC EXTERNAL

DEVICE

A standard computer power cable can be used to power the card. However, the G30 door will not close.

Card is supplied with a right-angle IEC 60320-C13 mains power inlet plug and unterminated lead. Fit local mains plug where necessary.

E

N

A

OPTIONAL BACKUP BATTERY

+ -

B+

B -

+ - 11 to 14.5 VDC

POWER SUPPLY

Powering the PSO-ACR Using A Low Voltage DC Supply

A

N

+ - 96 to 340 VDC

POWER SUPPLY

Powering the PSO-ACR Using A High Voltage DC Supply

Instead of using AC mains power to power the PSO-ACR, the power supply card can be powered using a DC supply connected to the Battery terminals or to the AC input terminals as shown below.


DC Input Card, Unregulated (PSO-DCU) FEATURES

Monitoring - supply voltage and current

Power using an external DC supply

Auxiliary DC Output

This card is powered from a DC input supply. It provides over and reverse voltage protection but otherwise does not regulate the supply voltage. The card provides power for the G30, provides an auxiliary output for external equipment and monitors the input supply voltage and current. PSO-DCU Specifications

Input Supply 10-16 VDC, 2.5 A maximum

Input Protection Over voltage and reverse voltage

Outputs Auxiliary 2.0 A max @ Input Supply voltage. Auxiliary output has over current and short circuit protection and can be controlled (switched OFF and ON) using logic.

Input Supply - Low Voltage shutdown

<10 V

Isolation None

Supply Fuse Internal 6 A polyfuse (auto-resettable)

Connector 6-way pluggable terminal block for Auxiliary output, external Temperature Sensor and Input Supply Operating Temperature -40 to 70 oC Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

Item Accuracy Monitoring

Supply Voltage Supply Current Card Temperature External Temperature (from ext. temp. sensor)

+ 0. 2 V + 100 mA + 3 °C + 3 °C

EMC & Safety Compliance

C-tick

Accessories (supplied with card)

External Temperature Sensor 6-way Terminal Block plug

Power Consumption 1 W maximum (consumed by power supply card)


PSO-DCU Wiring Diagram

OPTION

I/ OON

VA+

VA-

TS+

TS-

+

- USB

ETHERNET

1

AUXOUTPUT

TEMPSENSOR

INPUT10~30VDC

I O

OFF

TS+ TS- + -

+ - VA+

VA-

OPTIONAL DC EXTERNAL

DEVICE

Ambient Temperature Sensor + - 10 to 16 VDC

POWER SUPPLY

INPUT 10~16VDC


4. IO Daughter Cards

IO Daughter Card - MX2: 14DI, 8DO, 6AI (IOD-MX2) IO Daughter Card - MX3: 14DI, 8DO, 6AI, 2AO (IOD-MX3)

FEATURES

6 Analog Inputs (software configurable as current or voltage inputs)

2 Analog Outputs (MX3 only)

16-Bit Analog Resolution

Isolated DC Output for Loop Power

8 Transistor Outputs

14 Digital Inputs

500V RMS Channel to Logic Isolation

The MX3 is identical to the MX2 except it has two additional Analog outputs. Digital Inputs: Can be powered from the card's own auxiliary output or an external supply can be used. Current through an input (in either direction) results in a logic 1 in the status register. Digital Outputs: Can be configured for high speed pulse outputs if desired. Analog Inputs: Can be configured as current or voltage inputs using software. Analog Outputs (IOD-MX-3 only): Provide current and voltage outputs. Outputs can be powered by the card itself or from an external supply.


Specifications

MX2 / MX3 General Processor Atmel ARM7 Real Time Operating System

ThreadX

Auxiliary Output 24 VDC @ 250 mA (6 W) Isolated (for powering IO) Protected against continuous short circuit Isolated to 1500 V (for up to 60 seconds) Maximum capacitive load 100 µF

IO Connector (on card) 40 pin IDC Male Operating Temperature -40 to 70 oC Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

Accessories Supplied with a 1, 2 or 5 metre interface cable, 40 pin IDC female to female Supplied with a terminal interface block that is DIN rail mountable (as shown)

Power Consumption MX2: 3 W / 9 W maximum with Auxiliary output OFF / ON

MX3: 4 W / 10 W maximum with Auxiliary output OFF / ON


MX2 / MX3 Digital Inputs Inputs per card 14 Rated Input Voltage 24 VDC (supports reverse polarity) Input Type Current Sinking Input Grouping 2 groups: inputs 1 to 6 and inputs 7 to 14. Each group has a separate common

Impedance 4.7 k On-state Voltage + 19.2 to 28.8 VDC Off-state Voltage + 0 to 5.0 VDC On-state Current 1.4 mA minimum. Current=(Vin-1.2) / 5.7 mA

Input Characteristics

Off-state Current 0.5 mA maximum Isolation 500 V RMS channel to logic

100 V RMS channel to channel between input groups 250 V RMS channel to field power 250 V RMS channel to other types of IO channels (DO, AI and AO) No isolation between channels in the same group

Input Scan Time 1 ms (for all channels) Debounce 0 (default) to 16000 ms configurable on any channel(s). Channel Inversion Yes. Selectable on any channel(s). Sequence Of Events Yes. Selectable on any channel(s). Triggered on change of state.

Can capture up to 1000 events per second Accurate to 1 ms.

Edge Counting Yes. Selectable on any channel(s). Can count rising or falling edges. Frequency Counting 10 kHz maximum on channels 1 and 2

500 Hz maximum on all other channels Quadrature Counting Selectable on input channels: 1&2, 3&4, 5&6, 7&8, 9&10, 11&12, 13&14


MX2 / MX3 Digital Outputs Outputs per card 8 Rated Switched Voltage 12 to 24 VDC Output Type Transistor, Open Collector, Current Sinking Output Grouping 2 groups: outputs 1 to 4 and outputs 5 to 8

Each group has a separate common Maximum Switched Voltage 60 VDC

Maximum Switched Current 100 mA per channel, self limited

Isolation 500 V RMS channel to logic 100 V RMS channel to channel between input groups 250 V RMS channel to field power 250 V RMS channel to other types of IO channels (DI, AI and AO) No isolation between channels in the same group

Output Protection Yes. Protected against reverse polarity and transient over voltage and current Output Update Time 1 ms (for all channels) Failsafe Yes. Software configurable on any channel(s). If failsafe is disabled, output

holds last state. Failsafe is triggered after 10 seconds of no communications to the G30.

Pulse / Frequency Generation

High Speed: 10 kHz maximum, 1 Hz minimum @ 50% nominal duty cycle Configurable on channels 1 to 4 Accurate to 0.01% Low Speed: 500 Hz maximum @ 50% nominal duty cycle Configurable on channels 5 to 8 Accurate to 2% @ 500 Hz, 0.5% @ 100Hz, 0.1% @ 1 Hz Configurable Pulse ON or OFF time: 1 to 16,000 ms Note: Low Speed pulse frequencies are determined by the time it takes to generate one pulse ie. Pulse Period = Pulse ON + Pulse OFF times. Pulse frequency (Hz) = 1000 / Pulse Period (ms).


MX2 / MX3 Analog Inputs Inputs per card 6

Input Ranges 4-20 mA, 0-20 mA, 1-5 V, 0-5 V (software selectable for each individual channel)

Isolation 500 V RMS channel to logic 250 V RMS channel to field power 250 V RMS channel to other types of IO channels (DI, DO and AO) No isolation between Analog input channels

Input Scan Time 1 ms (for all channels) Input impedance 250 for current input

1 M for voltage input Accuracy +0.05% @ 20 °C

+ 0.15% @ -40 to 70 °C Resolution 16 bit

MX3 Analog Outputs (not applicable to MX2) Outputs per card 2

Output Ranges 4-20 mA, 0-20 mA, 1-5 V, 0-5 V (software selectable for each channel)

Isolation 500 V RMS channel to logic 250 V RMS channel to field power 250 V RMS channel to other types of IO channels (DI, DO and AO) No isolation between Analog output channels

Resolution 16 bit

Accuracy + 0.1% @ 20 °C + 0.2% @ -40 to 70 °C

Output Update Time 1 ms (for both channels) Settling Time 20 ms max. per channel

User Load 850 maximum for current output 1 k minimum for voltage output

Output Protection Protected against continuous short circuit. Failsafe Yes. Software configurable on any channel(s). Can specify 0-100% failsafe

value. If failsafe is disabled, output holds last value. Failsafe is triggered after 10 seconds of no communications to the G30.


MX2 / MX3 Wiring Diagram

IO POWERED BY CARD IO POWERED EXTERNALLY ANALOG INPUTS ANALOG INPUTS

AI x 24V

AI 1-6 COM

Analog 2-Wire Transmitter

+ -

+ -


PWR

+ - Analog 4-Wire

Transmitter

AI x

24V

24V

AI 1-6 COM AI x

AI 1-6 COM 0V

PWR 0V

0V

+ -

AI x Analog 4-Wire Transmitter

PWR POWER SUPPLY

+ -

+ -

AI x

AI 1-6 COM


PWR POWER SUPPLY

+ -

AI 1-6 COM

+ - AI x

AI 1-6 COM


POWER SUPPLY

+

-

ANALOG OUTPUTS (IOD-MX3 only) * ANALOG OUTPUTS (IOD-MX3 only) *

24V AOxC

+ - Analog

Current Load AO 1-2 COM

0V

AOxV + - Analog

Voltage Load AO 1-2 COM

AOxC -

AO 1-2 COM POWER SUPPLY -

+ Analog Current Load

+

DIGITAL INPUTS DIGITAL INPUTS FIELD CONTACT

DI x 24V

DI y-z COM 0V

DI x

DI y-z COM

+ FIELD CONTACT

POWER SUPPLY

DIGITAL OUTPUTS DIGITAL OUTPUTS

DI14 DI13 40

DI12 DI11 38

DI10 DI9 36

33 DI8 DI7 34

DI 7-14 COM

DI 1-6 COM

32

DI6 DI5 30

DI4 DI3 28

DI2 DI1 26

DO8 DO7 24

DO6 DO5 22

DO 5-8 COM

DO 1-4 COM

20

DO4 DO3 18

DO2 DO1 16

AI6 AI5 14

AI4 AI3 12

AI2 AI1 10

AI 1- 6 COM

AO 1-2 COM*

8

AO2C* AO1C* 6

AO2V* AO1V* 4

24V 0V 2

39

37

35

31

29

27

25

23

21

19

17

15

13

11

9

7

5

3

1

Viewing Front Of Card TOP

NO

TCH

* IOD-MX3 Only

24V LOAD DO x

- +

DO y-z COM 0V

When output is energised, output channel is shorted to the DO COM terminal.

DO x

DO y-z COM

+ POWER SUPPLY

-

+ - LOAD


* Note: When using a mix of current and voltage Analog outputs, the accuracy of the voltage output will only be preserved if the voltage output has its own common wire (ie. not shared with the current output[s]).


IO Daughter Card - MX4: 16DI, 16DO (IOD-MX4)

FEATURES

16 Digital Inputs

16 Transistor Outputs

Isolated DC Output for Loop Power

500 V RMS Channel to Logic Isolation

Digital Inputs: Can be powered using the card's own auxiliary output or an external supply can be used. Current through an input (in either direction) results in a logic 1 in the status register. Digital Outputs: Can be configured for high speed pulse outputs if desired.


Specifications

MX4 General Processor Atmel ARM7 Real Time Operating System

ThreadX

Auxiliary Output 24 VDC @ 250 mA (6 W) Isolated (for powering IO) Protected against continuous short circuit Isolated to 1500 V (for up to 60 seconds) Maximum capacitive load 100 µF

IO Connector (on card) 40 pin IDC Male Operating Temperature -40 to 70 oC Environment Operating Humidity 5-95% RH @ 0 to 40 C non-condensing

Accessories Supplied with a 1, 2 or 5 metre interface cable, 40 pin IDC female to female Supplied with a terminal interface block that is DIN rail mountable (as shown)

Power Consumption 2 W / 8 W maximum with Auxiliary output OFF / ON


MX4 Digital Inputs Inputs per card 16 Rated Input Voltage 24 VDC (supports reverse polarity) Input Type Current Sinking Input Grouping 2 groups: inputs 1 to 8 and inputs 9 to 16. Each group has a separate common

Impedance 4.7 k On-state Voltage + 19.2 to 28.8 VDC Off-state Voltage + 0 to 5.0 VDC On-state Current 1.4 mA minimum. Current=(Vin-1.2) / 5.7 mA

Input Characteristics

Off-state Current 0.5 mA maximum Isolation 500 V RMS channel to logic

100 V RMS channel to channel between input groups 250 V RMS channel to field power 250 V RMS channel to Earth 250 V RMS channel to other types of IO channels (DO, AI and AO) No isolation between channels in the same group

Input Scan Time 1 ms (for all channels) Debounce 0 (default) to 16000 ms configurable on any channel(s). Channel Inversion Yes. Selectable on any channel(s). Sequence Of Events Yes. Selectable on any channel(s). Triggered on change of state.

Can capture up to 1000 events per second Accurate to 1 ms.

Edge Counting Yes. Selectable on any channel(s). Can count rising or falling edges. Frequency Counting 10 kHz maximum on channels 1 and 2

500 Hz maximum on all other channels Quadrature Counting Selectable on input channels: 1&2, 3&4, 5&6, 7&8, 9&10, 11&12, 13&14,

15&16


MX4 Digital Outputs Outputs per card 16 Rated Switched Voltage 12 to 24 VDC Output Type Transistor, Open Collector, Current Sinking Output Grouping 2 groups: outputs 1 to 4 and outputs 5 to 8

Each group has a separate common Maximum Switched Voltage 60 VDC

Maximum Switched Current 100 mA per channel, self limited

Isolation 500 V RMS channel to logic 100 V RMS channel to channel between input groups 250 V RMS channel to field power 250 V RMS channel to Earth 250 V RMS channel to other types of IO channels (DI, AI and AO) No isolation between channels in the same group

Output Protection Yes. Protected against reverse polarity and transient over voltage and current Output Update Time 1 ms (for all channels) Failsafe Yes. Software configurable on any channel(s). If failsafe is disabled, output

holds last state. Failsafe is triggered after 10 seconds of no communications to the G30.

Pulse / Frequency Generation

High Speed: 10 kHz maximum, 1 Hz minimum @ 50% nominal duty cycle Configurable on channels 1 to 4 Accurate to 0.01% Low Speed: 500 Hz maximum @ 50% nominal duty cycle Configurable on channels 5 to 16 Accurate to 2% @ 500 Hz, 0.5% @ 100 Hz, 0.1% @ 1 Hz Configurable Pulse ON or OFF time: 1 to 16,000 ms Note: Low Speed pulse frequencies are determined by the time it takes to generate one pulse ie. Pulse Period = Pulse ON + Pulse OFF times. Pulse frequency (Hz) = 1000 / Pulse Period (ms).


MX4 Wiring Diagram

IO POWERED BY CARD IO POWERED EXTERNALLY DIGITAL INPUTS DIGITAL INPUTS

FIELD CONTACT DI x 24V

DI y-z COM 0V

DI x

DI y-z COM

+ FIELD CONTACT

POWER SUPPLY

Note: polarity can be reversed

DIGITAL OUTPUTS DIGITAL OUTPUTS

EARTH EARTH 40

DI16 DI15 38

DI14 DI13 36

DI12 DI11 34

DI10 DI9 32

DI9-16 COM

DI1-8 COM

30

DI8 DI7 28

DI6 DI5 26

DI4 DI3 24

DI2 DI1 22

DO16 DO15 20

DO14 DO13 18

DO12 DO11 16

DO10 DO9 14

DO9-16 COM

DO1-8 COM

12

DO8 DO7 10

DO6 DO5 8

DO4 DO3 6

DO2 DO1 4

24V 0V 2

39

37

35

33

31

29

27

25

23

21

19

17

15

13

11

9

7

5

3

1

NO

TCH

Viewing Front Of Card TOP

24V LOAD DO x

- +

DO y-z COM 0V


DO x

DO y-z COM

+ POWER SUPPLY

-

+ - LOAD



5. Interface Cables

G30 Ethernet Connection Cable To connect directly to a G30 with a PC, an Ethernet crossover cable (as supplied with Toolbox PLUS+) is required as illustrated below. If connecting to an Ethernet hub, a straight through cable or a crossover cable can be used.

G30

G30

Ethernet Crossover Cable

Ethernet Switch

Ethernet Switch

Ethernet Network

Ethernet Straight Through Patch Cables

The above cables are industry standard and are readily available.


G30 Serial Port Converter Converts a G30 serial port into a CP-xx serial port. Series 2 (CP-xx, PC-1, LP-1) serial port cables can then be used with the converted G30 serial port.

RJ45 Socket - Surface Mount Box (with screw terminals)

RJ45

5 DCD

8 DTR

2 RXD 4 GND

DSR 1 DCD 2 DTR 3

RXD 5 TXD 6

GND 4

G30 Serial Card

3 CTS 1 TXD

RJ45 Socket

87654321

G30

CP-xx Serial Port

6 RTS CTS 7 RTS 8

7 4.3 VDC n/c Patch lead wire

RJ45 Socket

12345678

n/c Box Wire

G30 to G30 Serial Crossover Cable

RJ45

RXD 5 TXD 6

GND 4

6 TXD 5 RXD 4 GND 7 CTS 8 RTS

Heatshrink (Wires joined inside as shown below) RJ45

RTS 8 CTS 7

Serial Crossover Cable

G30 Serial Card

RJ45 Socket

87654321

G30 Serial Card

RJ45 Socket

87654321

G30

G30

G30 to CP-xx Serial Crossover Cable

TXD 6 RXD 5 GND 4 CTS 7 RTS 8

Heatshrink (Wires joined inside as shown below) RJ45 RJ45

Serial Crossover Cable

G30 Serial Card

RJ45 Socket

87654321

2 RXD 1 TXD

4 GND

6 RTS 3 CTS

CP-xx (also PC-1, LP-1) RTU Serial Port

RJ45 Socket

12345678

G30


PSTN Modems and GSMs DB25 Male Banksia PSTN Modem

RJ45

3 RXD 2 TXD

7 GND

20 DTR 8 DCD

TXD 6 RXD 5 GND 4

CTS 7 RTS 8

DCD 2

G30 Serial Card

4 RTS 5 CTS

RJ45 Socket

87654321

G30

DB15 Male High Density Wavecom GSM

RJ45

6 RXD 2 TXD

9 GND 1 DCD

TXD 6 RXD 5 GND 4 DCD 2

G30 Serial Card

RJ45 Socket

87654321

G30

12 RTS CTS 7

RTS 8 8 DTR

(WM02-G900, Fastrack or Fastrack Supreme)

DB15 Male High Density

3G Data Modem Maxon MM-6280IND

RJ45

2 RXD 3 TXD

14 GND 1 DCD


G30 Serial Card

RJ45 Socket

87654321

G30

7 RTS CTS 7 RTS 8 13 DTR

Trio M Series Radio DB9 Male

RJ45

2 RXD 3 TXD

5 GND 1 DCD


TRIO M Series Radio With Modem Fitted (Eg. MR450)

G30 Serial Card

RJ45 Socket

87654321

G30

CTS 7 RTS 8


MaxStream External Spread Spectrum Radio The following Maxstream external spread spectrum RF modems are recommended: XTH9-PKI-R-128 Xtend 900MHz Spread Spectrum Modem RS232/485/422 for Australia

XT09-PKI-R Xtend 900MHz Spread Spectrum Modem RS232/485/422 for the USA

X24-019PKI-R Xstream 2.4GHz Spread Spectrum Modem RS232/485/422, 19200 bps throughput, International

DB9 Male

RJ45

2 RXD 3 TXD

5 GND 1 DCD

TXD 6 RXD 5 GND 4

CTS 7 RTS 8

DCD 2

MaxStream Spread Spectrum modem

8 CTS 7 RTS

DTR 3 4 DTR

G30 Serial Card

RJ45 Socket

87654321

G30

Please ensure that the MaxStream radio switches are set as follows:

1 2 3 4 5 6 O N

1 2 3 4 5 6 O N

Set for: RS232, RS485 termination=None and TX/RX mode=User Defined (Switch 1, 5 and 6 set ON)

Set for: RS232, RS485 termination=None and Parity=None (Switch 1 ON)

XTend XStream


6. Installation

Panel Installation

Use 4 screws to attach the G30 to a suitable flat surface. Ensure there is adequate ventilation below and above the unit and that any objects do not obstruct the ventilation holes.

CAUTION: This equipment shall be installed only in RESTRICTED ACCESS LOCATIONS by the appropriately trained service personnel.

CAUTION: The unit should not be mains powered (AC or DC)

unless it is installed correctly.

DIN Rail Installation

DIN rail bracket

G30 installed on DIN rail bracket


7. Glossary

AI, AO, DI, DO Analog Input, Analog Output, Digital Input and Digital Output respectively. Byte A group of 8 bits. Each bit can be a 0 (off) or a 1 (on) allowing up to 256 combinations. Card A PCB (printed circuit board) and its connectors. A card is housed within a module. Comms Communications Current Sinking Current is supplied into the RTU’s IO terminal. G30 A double width module that includes a Power Supply Card, a Processor Card and may

include an IO card and a comms option card. Runs the Linux operating system and supports ISAGRAF.

IO Input, Output IP Internet Protocol. Used for ethernet communications. Port A physical connection or socket on an RTU used for communications Processor Module Processor module containing a CPU (central processing unit) Protocol Refers to the format of messages that may be passed to, from and through an RTU in

communication with local and remote devices. Communications may use one or more RTU ports. Examples of protocols used within telemetry include Kingfisher, Modbus and DNP3.

RTU Acronym for Remote Terminal Unit. Describes a group of processor, communication and IO modules that comprise a device for monitoring and control of hardware and devices in remote locations.

TCP/IP Transfer Control Protocol / Internet Protocol. Commonly used for Ethernet communications.

UDP Universal Datagram Protocol.


8. Appendix: Assembly Instructions

This appendix describes how to assemble all the possible components in a G3-SA-xxx-xxx-xxx Stand Alone RTU.

WARNING: FOLLOW ANTI-STATIC PROCEDURES Electronic components can be damaged by even small amounts of static discharge. It is highly recommend that antistatic procedures be used. Avoid touching any components and metal parts. Do not store cards near strong electrostatic, electromagnetic, or radioactive fields. 1. Fit the OLED to the G30 processor card.

If OLED connector and PCB connector are different brands, the keyway on the PCB connector will need to be removed.

2. Connect the short cable to the G30 processor card. Bend cable as shown.

3. Connect the long cable to the G30 processor card.

4. Install the comms option card and fasten with screws


5. Connect short cable to MX card. Lay long cable underneath MX card and install MX card to centre of case.

6. Install the G30 processor card. Ensure OLED slides into top front of case.

7. Install right hand side of case

8. Install long cable to power supply card as shown.


9. Install power supply into left hand side of case. Ensure power supply card locates onto case support dowels.

10. Install left hand side case cover

11. Install the rubber buttons to the OLED display. Ensure rubber button dimples locate into the OLED circuit board holes.

Remove OLED screen protector

12. Install light tube into front case.

13. Superglue button surround onto front case

14. Affix bubble sticker onto top of front case


15. Install front case, taking care to locate the rubber buttons.

16. Install front door. Note: install bottom hinge first, then slide top hinge into position.

17. Install front panel.

18. Plug in green power supply connector.

19. Install mounting feet.


20. Affix side case label, inner door labels and bubble sticker.

21. Place serial number for G30 unit, and any options such as MX or PSO cards (if fitted) onto the main label.

22. The G30 is now completely assembled!

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