Hardware User Manual: For The

Hardware
User Manual
for the: SCD5200
Document ID: 2005662

Revision: 1.2
I/A Series Intelligent SCADA System Page 1 of 66
Hardware User Manual
for the SCD5200
2005662 - Rev. 1.2
Foxboro Australia Pty Ltd The Foxboro Company

10 Brandl Street 33 Commercial Street,
Eight Mile Plains QLD 4113 Foxboro Massachusetts 02035-2099
Australia United States of America
Telephone: +61 7 3340 2111 Telephone: +1-888-369-2676
Acknowledgements
Invensys, Foxboro, I/A Series and, Invensys logo are trademarks of Invensys plc, its subsidiaries,
and affiliates.
All other brand names may be trademarks of their respective owners.
Checked By & Date: Approved By & Date:

Hardware Representative SCADA Director of Development
D. Leske P. Holloway
COPYRIGHT RESERVED
The information and design as detailed in the document are the property of Foxboro Australia Pty Ltd and/or
its associates and must be returned on demand. It is issued on the strict condition that except with our written
permission, it must not be reproduced, copied or communicated to any third party, nor be used for any
purposes other than that stated in the particular inquiry, order or contract with which it is issued. The
reservation of copyright in this document extends from each date appearing thereon and in respect of the
subject matter as it appeared at that relevant date.
© Foxboro Australia Pty. Ltd. 2003–2010

ACN 000 522 261
All rights reserved

for the SCD5200
2005662 - Rev. 1.2
Document Revision History:
Rev. Date Comments Prepared By

1.1 27 Mar, 2003 Initial writing D. Krautz
L. Murray
1.2 12 Nov, 2003 Add the 8 x 10 Amp Digital (Relay) Output Module (8DO) D. Krautz
L. Murray

for the SCD5200
2005662- Rev. 1.2
Contents
1. Introduction............................................................................................................. 9
1.1 Scope ..............................................................................................................................9
1.2 Audience .........................................................................................................................9
1.3 Product Overview ...........................................................................................................9
1.4 Definitions and Abbreviations........................................................................................9
1.5 Referenced Documents ...................................................................................................9
2. File and Module Arrangement.............................................................................. 10
3. 100 Watt Power Supply Module ........................................................................... 12
4. CPU / OptoNet / Power Supply / Ethernet Module (COPE) ................................ 14
5. Communication Modules ..................................................................................... 21
5.1 Dual Communications Modules ...................................................................................21

5.1.1 V.28 Dual Communications Module ..................................................................22
5.1.4 Glass Optical Dual Communications Module ....................................................26
5.2 Eight Channel Serial Module .......................................................................................27

5.2.1 Eight Channel RS-485/RS-232 Communications Module .................................27
6. Input/Output Modules........................................................................................... 31
6.1 Identification of I/O Module front termination assembly features and parts ...............32
6.2 32 Digital Input / 4 Analog Input Module (32 DI / 4 AI) .............................................35
6.3 20 Channel Analog Input Module (20 AI) ...................................................................37
6.4 4 Channel Analog Output Module (4 AO) ...................................................................39
6.5 12 Digital (Relay) Output Modules (12 DO) ...............................................................40
6.6 8 x 10A Digital (Relay) Output Module (8 DO) ..........................................................42
6.7 Multi Input/Output Module (24DI/6AI/6DO, 24DI/6AI/8DO) ....................................43
7. Power Supply Connection and Disconnection ................................................... 47
8. Installation, Grounding, and Wiring Guidelines ................................................. 48

for the SCD5200
2005662 - Rev. 1.2
8.1 Installing the Ten I/O Slot File .....................................................................................48
8.2 Installing the Five I/O and One I/O Slot File ...............................................................49
8.3 Earthing of the File .......................................................................................................50
8.4 I/O Wiring Guidelines ..................................................................................................51
9. Preventative Maintenance and Inspection .......................................................... 52
10. File, Backplane Slot Identification, and SYSFAIL Alarm .................................... 53
11. Appendices ........................................................................................................... 55
Appendix A Definitions and Abbreviations ..............................................................55
Appendix B Referenced Documents .........................................................................56
Appendix C Summary of Part Numbers ....................................................................57
Appendix D Environmental Specification .................................................................58
Appendix E Calibration ............................................................................................59
Appendix F Electromagnetic Compatibility .............................................................63
Appendix G Safety Compliance ................................................................................64
Appendix H Non-compliance with the Australian Telecommunications Labelling

Notice 2001 [5] .....................................................................................65
Appendix I COPE Error Codes ................................................................................66

for the SCD5200
2005662 - Rev. 1.2

for the SCD5200
2005662 - Rev. 1.2
IMPORTANT: For the safety of the user and protection and

performance of the SCD5200
Symbols are used throughout this document to highlight areas of the SCD5200
which relate to user personal safety, and equipment protection and
performance, under electrical fault and EMC conditions.
CAUTION: Risk of electric shock. A hazardous voltage may be present.
CAUTION: Identifies an area of concern that the user should be aware of,
and which relates to safety, or protection and performance of the
SCD5200.
These symbols are also located in visible places on the SCD5200 modules,
warning the user to use caution. Whenever these symbols are encountered in
this document, the accompanying information should be read and understood,
or implemented as required.
Safety Compliance: refer to Appendix G.
Users of the V.23 Dual Communications Board in Australia: refer to Appendix H.

for the SCD5200
2005662 - Rev. 1.2
Blank Page

Hardware User Manual 1 Introduction
for the SCD5200
2005662 - Rev. 1.2
1. Introduction
1.1 Scope
This document describes the I/A SCADA remote device, the SCD5200. A
detailed technical description is given of the SCD5200 and its components.
1.2 Audience
Information provided herein is of a detailed technical nature suitable for use by
Installers and Maintenance Personnel. Non-authorised personnel should not
access the internals of the SCD5200. Operators have access to powering the
device, or resetting the device only. This document also identifies the visual
indications that may be helpful for non-authorised personnel.
1.3 Product Overview

The SCD5200, a station computing device (SCD), inherits the functionality of
the I/A SCADA remote device, the RTU50. The architecture allows the full
spectrum from small single device station configurations, through to redundant
(duplicated and path diverse) communications networks. A key development of
the SCD5200 is the integration of the CPU, OptoNet, Power Supply, and
Ethernet into the main processor board to provide a compact single module for
specialised communications, local networking, applications processing, and the
integration of station devices and meters.
The SCD5200 requires software part number 1101155 revision K or later. It is
configured using the System Configurator [1], and its diagnostic utility is the
Remote Terminal Viewer (RTV) [3].
1.4 Definitions and Abbreviations

Definitions and abbreviations found in this document are listed in Appendix A.
1.5 Referenced Documents

Documents referenced in this manual are listed in Appendix B.

Hardware User Manual 2 File and Module
for the SCD5200 Arrangement
2005662 - Rev. 1.2
2. File and Module Arrangement

The maximum size SCD5200 assembly consists of a 19” rack mounted file with
a CPU, OptoNet, Power Supply and Ethernet (COPE) module and up to ten I/O
or communication modules. This is shown in Figure 1.




















 











  
 

 


Figure 1. Ten I/O Slot File

The maximum number of communication modules and I/O modules that can be
installed together is ten (10). Refer to Section 10 for backplane slot
identification.
While the COPE module includes a power supply, the 100 watt power supply is
always required to correctly power the 19” ten I/O slot file.
Smaller file arrangements are in two standard arrangements: Five I/O slot and
One I/O slot as shown in Figure 2 and Figure 3 respectively. The power supply
incorporated into the COPE module is used to power these arrangements.

Hardware User Manual 2 File and Module
for the SCD5200 Arrangement
2005662 - Rev. 1.2
















 

 

 



 





Figure 2. Five I/O Slot File

As shown in Figure 2, for the five I/O Slot File, the maximum number of communication modules
and I/O modules together is five (5).







 




 











Figure 3. One I/O Slot File

As shown in Figure 3, for the one I/O Slot File, only one communication or I/O module can be
fitted.

Hardware User Manual 3 100 Watt Power Supply
for the SCD5200 Module
2005662 - Rev. 1.2
3. 100 Watt Power Supply Module

Figure 4 shows the 100 Watt Power Supply Module’s front panel, and each of
its components are described below. The numbered identifiers, n , in Figure 4
refer to the items discussed below.
1. Disconnect power before removal.

This power supply handles a wide range input by using voltage
boost. Avoid making contact with the primary circuits while
power is connected.
The power supply can have a high current output of over
12Amps at 5V. Breaking a high DC current can cause arcing.
Switch off and disconnect the power source before removing
the module.
2. ON/OFF Switch.
The switch does not disconnect power directly, rather it controls an
electronic switch. A delay of up to 2 seconds can occur on switch off.
3. Power In terminals.
Reversing polarity will blow the onboard fuse. If the source is current
limited and the fuse does not blow, eventually the reverse bypass diode
on the module may overheat. At first power up be prepared to disconnect
quickly to avoid damage. Better still, check the polarity first.
4. Loop power terminals route the input power back out on terminals 3 and
4. This may be useful to avoid multiple wires in one terminal.
5. System Fail alarm contacts.
In the power down condition, or when the SCD5200 is in a failed state,
the Common (C) to Normally Closed (NC) terminals will be shorted.
6. Controls Isolate Terminals.
It is normal to short these terminals to connect the relay control voltage
onto the backplane. Alternatively, a remote switch can be wired to these
terminals to control the isolation of relay power. Maximum load is 3A at
15V. Breaking this connection prevents Digital (Relay) Outputs from
operating.
7. IN OK Green ON The input voltage is high enough for
operation.
15V OK Green ON The +15V and –15V outputs are

above their under voltage limits.
8. Due to hazardous voltages, authorised personnel only should
access and maintain this module.
Figure 4 9. Part identification number. (0399131)

Hardware User Manual 3 100 Watt Power Supply
for the SCD5200 Module
2005662 - Rev. 1.2
The technical specifications of the 100 Watt Power Supply Module are
described below in Table 1.
Power Supply Voltage 18 to 164 Vdc A higher voltage will damage

components, a lower voltage and the
power supply will not start.
Efficiency > 75 % 130 Watts input for 100 Watts

output.
Output loading +5V @ 10A Maximum loading of 100 Watts

+15V @ 3A
–15V @ 0.45A
Input current 7.2A @ 18V At maximum loading of 100 Watts

0.75A @ 164V
Isolation 2000 Vac rms for 1 Primary to chassis, and primary to

minute secondary isolation.
Shorted input hold up 4 milliseconds at A shorted input event can occur

time 100W output when the power source feeds
multiple circuits, one of which is the
SCD5200. Each circuit is fused.
When a fault occurs on another
circuit, a hold up time for the
SCD5200 power supply is required
while the other circuit fuse or
breaker clears the fault.
Open input hold up 20 milliseconds Interruption in input supply.

time
On board Fuse 10A / 250V Type T

20 x 5mm
Replace with same Type T 20 x

5mm (Time lag antisurge
characteristic) with quick blow at
high overcurrent. Only replace while
power source is removed.
SysFail relay contact 200mA at 30Vdc, Contact to chassis isolation is 1000

rating 3VA maximum Vac rms.
Part Number 0399131 100 Watt power supply 35mm

module.
Table 1. 100 Watt Power Supply Module Specification

Hardware User Manual 4 CPU / OptoNet / Power
for the SCD5200 Supply / Ethernet Module
2005662 - Rev. 1.2 (COPE)
4. CPU / OptoNet / Power Supply /

Ethernet Module (COPE)
A singe module incorporates four major functions:
Part Number 0399129 CPU / OptoNet / Power Supply / Ethernet functions

includes in a 35mm module.
power supply
Figure 5 shows the Power Supply/CPU/OptoNet/Ethernet module, part number

0399129, front panel. Each of its components are described below.
1. Disconnect power before removal.
This power supply handles wide range input by using voltage

boost. Avoid making contact with the primary circuits while power
is connected.
2. ON/OFF Switch.
The switch does not disconnect power directly, rather it controls an

electronic switch. A delay of up to 2 seconds can occur on switch off.
3. Power In terminals.
Reverse polarity will blow the inboard fuse. If the source is current limited
and the fuse does not blow, eventually the reverse bypass diode on the
module may overheat. At first power up, be prepared to disconnect quickly
to avoid damage. Better still, check the polarity first via the Power In
terminals.
DO NOT power the 0399129 assembly if the 100W power

supply is being used. Also, remove link LK3 on 0399129
(COPE 1V reference to backplane) if the 100W power
supply (0399131) is being used. The 100W power supply
will source the 1V reference itself.
Figure 5

2005662 - Rev. 1.2 (COPE)
4.
The CPU has correctly started normal

RUN (Green) RUN ON operations when the Green RUN indication is
FAIL OFF ON.
 FAIL
CPU in the reset condition, at an incomplete

 RUN RUN OFF initialisation stage, or in Bootstrap mode,
FAIL ON when the Red FAIL indication is ON.
FAIL (Red)
The input voltage is high enough for power

IN OK ON supply operation when the Green indication is
ON.
The +15V and –15V outputs are above their

15V OK ON under voltage limits when the Green
indication is ON.
5. Sense/Reset momentary toggle switch.
A downward toggle will reset the SCD5200. An upward toggle is sensed by

the CPU and several operations can be performed by this action. One
operation is to put the SCD5200 into Bootstrap mode, a mode which does
not require a configuration, and allows files to be downloaded to install a
configuration.
This Bootstrap toggle operation should be performed immediately after the

reset toggle is performed.
Another operation is to enable or disable the flash memory file system.

Writing files or appending to open files in the flash memory should not be
terminated prematurely. The software must ensure that flash files are
correctly closed before, for example, a reset. The status of the flash file
system is shown by the 3rd most significant diagnostic LED on the front
panel. It is ON if the flash file system is disabled. It is desirable, and a
precaution, to close files properly, prior to resetting the RTU. Writing to
flash files mainly occurs during downloading of configuration or
calculation files.
Disabling the flash file system will not stop normal SCD5200 operation
once the firmware has been transferred from flash memory to main memory
to run. But leaving it disabled will prohibit a remote download, without
first a remote reset operation.

2005662 - Rev. 1.2 (COPE)
down Reset the SCD5200.
Reset the SCD5200 and hold the toggle in the

down
up position until the first beep, to put into
up
Bootstrap mode.
Enable or disable the flash memory file system.

up Status indicated by the 3rd most significant
diagnostic LED.
6. Diagnostic display.
The 8 status LEDs indicate the most significant (MS) to the least
significant (LS) bits of a diagnostic code. During start up this code will
change. If there is a problem, the code will remain displayed, indicating the
problem. Refer to Appendix I for a list of codes. If you submit an incident
report, always include the error code even if you are not sure if it is relevant
to the problem.
During normal operation the status LEDs indicate various activities or

conditions, as described in the table following.
Diagnostic Meaning Expected State

LED
8 (MS) 10ms timer Pulses on every 250 milliseconds.
interrupt
7 10s timer interrupt Pulses on every 10 seconds.
6 (3rd most Flash memory On for flash memory file system disabled.
significant) enabled/disabled Off when enabled, writing to the flash
memory may be in progress.
5 Flash memory On while erasing. Flashing slowly while

write in progress writing data to flash file.
4 Flash memory read On while reading flash memory.

in progress

2005662 - Rev. 1.2 (COPE)
7. Serial Communications Port 1 and Port 2.
COM1 and COM2 (use LK1 for COM2 only) in RS-232 Mode (Default
setting)
Pin Function Direction
1 Data Carrier Detect DCD Input
2 Receive Data RXD Input
3 Transmit Data TXD Output
 4 Data Terminal Ready DTR Output




5 Signal ground - -
6 Data Set Ready DSR Input
7 Request to Send RTS Output
8 Clear to Send CTS Input
9 Ring Indicate RI Input
Frame Connected to chassis of SCD5200 - -
Note: COM1 is always in the RS-232 mode.
COM2 RS-232 mode is set using LK1 in position 2.
COM2 RS-485 4 wire mode (use LK1 set to position 3)

This table only applies to COM2, since COM2 can be set to RS-485 mode.
1 Connected to an RS-232 input -
8 RS-485 VA receive signal Input
2 RS-485 VB receive signal Input

 4 Connected to an RS-232 output -



5 Signal ground -
3 RS-485 VA transmit signal Output
7 RS-485 VB transmit signal Output
Frame Connected to chassis of SCD5200 -

2005662 - Rev. 1.2 (COPE)
COM2 RS-485 2 wire mode (LK1 not fitted)

This table only applies to COM2, since COM2 can be set to RS-485 mode.
3 RS-485 VA transmit/receive signal Input / Output
7 RS-485 VB transmit/receive signal Input / Output




 




4 Connected to an RS-232 output -
5 Signal ground -
2 Connected to a disabled input -
Note: For RS-485 data signals a space (0) condition is VA > VB.
The shaded signals in the above tables are configured by LK1 to
be RS-485 signals on COM2. The remaining non-shaded signals
are RS-232 handshake and modem control signals, and do not
require connection, except for signal ground.
8. Ethernet 10 Base-FL Port 1 and Port 2.
10 Base-FL is the 10MHz fibre link IEEE 802.3 Ethernet standard.
Port 1
LNK1 Port 1 fibre link is established
MT-RJ
ACT1 Port 1 link is receiving
Port 2
LNK2 Port 2 fibre link is established
MT-RJ
ACT2 Port 2 link is receiving
The MT-RJ fibre optic transceivers use the 840nm wavelength. Either
50/125 m or 62.5/125 m multimode cable, up to 2000m in length, can be
used.
There are 2 fibres in each MT-RJ transceiver. When inserted into the
Ethernet port, the top fibre is transmit, and the bottom fibre is receive. This
is also indicated by the arrows on the port. The outward arrow (that is, the

2005662 - Rev. 1.2 (COPE)
arrow pointing towards the board’s front panel) indicates transmit, and the
inward arrow indicates receive.
9. OptoNet Port 1 and Port 2.
OptoNet Port 1 and Port 2 make up one node. The node uses two transmit
and receive ports to transmit and receive in two directions simultaneously,
as shown in Figure 6. Where a single failure in the network occurs, the
logical ring topology is maintained. In a situation where two network
failures occur, two island networks are established. The two networks
reconfigure themselves and continue to operate in isolation from each
other. This situation does not affect the operation of the individual nodes.
Should one (or both) of the failed network elements re-establish itself, the
network self-heals and resumes normal operation.
Figure 6. A 3 Node (SCD5200) OptoNet

There may be 500m distance between nodes, with a maximum number of
63 nodes. The total network length may be 6,200m less 40m per node.
OptoNet ports use industry standard ST fibre connectors. The fibre optic
transmitters and receivers use the 820nm wavelength. Either 50/125 m or
62.5/125 m multimode cable, up to 500m in length, can be used.
Interpreting OptoNet behaviour using the indicators:
The transmit and receive LEDs will fast flash (may appear on) during
normal operation. A slow flashing transmit LED means that the only
source of transmissions is the local SCD5200, i.e. no incoming messages
from another node are being re-transmitted.
TX LED RX LED Behaviour indicated by a permanent

LED state
Off On Receive connection broken
Off Off Transmit connection broken

2005662 - Rev. 1.2 (COPE)
10. Due to hazardous voltages in the power supply area, authorised

personnel only should access and maintain this module.
11. Part identification number. (0399129)
Part number 0399129 includes the power supply with the characteristics
described in Table 2.
Power Supply Voltage 18 to 164 Vdc A higher voltage will damage components, a lower
voltage and the power supply will not start.
Efficiency > 65% 60 Watts input for 40 Watts output.
Output loading +5V @ 4.5A Maximum loading of 40 Watts output.

+15V @ 1A
–15V @ 0.15A
Input Current 3.3A @ 18V At maximum loading of 40 Watts output.

0.34A @ 164V
Isolation 2000 Vac rms Primary to chassis and Primary to Secondary

for 1 minute isolation.
Shorted input hold up 4 milliseconds at 40W A shorted input event can occur when the power
time output source feeds multiple circuits external to the
SCD5200, one of which is the SCD5200. Each
external circuit is fused. When a fault occurs on
another circuit, a hold up time for the SCD5200
power supply is required while the other circuit fuse
or breaker clears the fault.
Open input hold up 10 milliseconds Input supply interruption.

time
On board fuse 6.3A / 250V Type T
Replace with same Type T, Foxboro part number.

1009140. Only replace while unpowered.
On board memory and 6 months in storage. Replace with

clock backup battery 7 years in use.
(20mm Li/MnO2 cell) Renata CR2032
Duracell DL2032
Varta CR2032.
Foxboro part no. 1024026.

A software low battery alarm is provided.
Table 2. Power Supply/CPU/OptoNet/Ethernet Module Specification

Hardware User Manual 5 Communication Modules
for the SCD5200
2005662 - Rev. 1.2
5. Communication Modules
The communications module is identified by the type of interface used, and for
Dual Communications Modules, the firmware protocol installed on the module.
The communications modules are listed in Table 3.
The shaded communications modules are currently supported by the System
Configurator, and can therefore be configured for the SCD5200.
Module Interface Type Protocol

0399111 2 x V.23 Conitel/Baker/C300
0399112 2 x V.28 Conitel/Baker/C300
0399119 2 x V.23 DNP3
0399120 2 x V.28 DNP3
0399121 2 x V.11 DNP3
0399122 2 x Optical DNP3
0399126 2 x V.28 IEC 60870-5-101
0399127 2 x Optical IEC 60870-5-103
0399132 8 x RS 485 / RS 232 DNP3, Modbus, User defined protocols
Table 3. Communication Modules

There are two categories of communications modules: Dual Communications
Modules and the Eight Channel Serial Module. Both types are described below.
5.1 Dual Communications Modules

These modules may also be referred to as DCBs (Dual Communication
Boards). Four types of interfaces are provided:
V.28
V.23
V.11
Glass Optical
Each interface is described below.
This section should be read in conjunction with specific protocol user manual
and software release notes. Where specific link settings are required for a
specific DCB and protocol, reference should be made to the module assembly
drawings (for example, 0399121-AS) to determine those link settings.

for the SCD5200
2005662 - Rev. 1.2
5.1.1 V.28 Dual Communications Module

V.28 uses RS-232 voltage level signals. The maximum baud rate depends on
the communications protocol in use. Refer to the relevant protocol user manual
for details. Figure 7 shows the V.28 DCB’s front panel. Each of its components
is described below.
1. Module identification number.
Determined by the protocol firmware installed (refer to Table 3).

2. Run (Green) or Fail (Red) indication.
For the normal running condition the indicator will be green. At reset of the
SCD5200 the indicator will be red until the module has correctly
initialised.
3. Communication Port 1 and Port 2.

1 Connected to frame -




 

 
 4 Request to Send RTS Output
6 reserved (do not connect) -
7 Signal ground -
9 +12V (50mA maximum fused) Output
10 -12V (50mA maximum fused) Output
11 reserved (do not connect) -
12 Data Terminal Ready DTR Output
13 Receive Clock RXCLK Input
14 Transmit Clock Out TXCLK OUT Output
15 Transmit Clock In TXCLK IN Input
4. Due to hazardous voltages on adjacent modules, and the

Figure 7 possibility of physical contact, authorised personnel only should
access and maintain the module in situ.

for the SCD5200
2005662 - Rev. 1.2

V.23 is a voice frequency standard which uses a 1300Hz tone to indicate a
Mark, and a 2100Hz tone to indicate a Space.
The V.23 DCB can also generate Bell-202 tones. Refer to the System
Configurator user manual [1] for settings and parameters. Baud rates up to 1200
bits/second are configurable.
Figure 8 shows the V.23 DCB’s front panel, and its components are described
below.

2. Run (Green) or Fail (Red) indicator.
For the normal running condition the indicator will be green. At reset of the
initialised.
3. Channel activity indicators.
RTS Request To Send means the carrier has been turned on.
TXD Transmit Data means that a Space is being transmitted.
DCD Data Carrier Detect means that the carrier is being received.
RXD Receive Data means that a Space is being received.
4. Radio key relay output.
A single normally open contact per channel is provided to key a radio prior
to carrier turn on.
1 Amp at 30 Vdc maximum

Contact rating
10 A at 10mV minimum
Radio key use, and turn on parameters, are set using the System
Configurator [1].
Figure 8

for the SCD5200
2005662 - Rev. 1.2
5. Communication line terminals.



TX/RX terminal pair is used to
transmit in 2 wire or 4 wire

 
mode, and to receive in 2 wire
 

mode.


 
 
4W RX terminal pair is used to

 


 receive in 4 wire mode.



2 wire or 4 wire connection is determined by a link setting for each

channel.
Channel 1 LK6 Configuration

Channel 2 LK5
4 wire mode (default setting)
1 2 3
2 wire mode
1 2 3
An additional link setting for each channel can change the input
impedance of the received circuit from 600 to high impedance. High
impedance may be used in party line arrangements.
Channel 1 LK4 Configuration

Channel 2 LK5
Install for 600 receive (default)
Remove for high impedance

receive
6.
Due to hazardous voltages on adjacent modules, and the possibility
of physical contact, authorised personnel only should access and
maintain the module in situ. Communication lines may be at a
hazardous voltage under fault conditions.
Refer to Appendix E for adjusting communications levels on this module.

for the SCD5200
2005662 - Rev. 1.2

V.11 uses RS-485 voltage level signals. The maximum baud rate depends on
the communications protocol in use. Refer to the relevant protocol user manual
for details.
Figure 9 shows the V.11 DCB’s front panel, and its components are described
below.
For normal running conditions the indicator will be green. At reset of the
initialised.
3. Communication Port 1 and Port 2.
Pin Function (per ISO 4903) Direction

1 Connected to Frame -
2 Transmit data VA Output
9 Transmit data VB Output








 

3 Request to send VA Output
10 Request to send VB Output
7 Transmit clock VA Output
14 Transmit clock VB Output
8 Signal ground -
6 Receive clock VA Input
13 Receive clock VB Input
4 Receive data VA Input
11 Receive data VB Input
5 Data carrier detect VA Input
12 Data carrier detect VB Input
15 reserved -
Figure 9 Frame connected to chassis -
For V.11 data signals a space (0) condition is VA > VB

For V.11 control or timing signals an ON condition is VA > VB
Shading identifies the signal pairs.
4. Due to hazardous voltages on adjacent modules, and the possibility
maintain the module in situ.

for the SCD5200
2005662 - Rev. 1.2
5.1.4 Glass Optical Dual Communications Module

Use the Optical DCB for isolated serial links up to 2000 metres. The maximum
baud rate depends on the communications protocol in use. Refer to the relevant
protocol user manual for details.
Figure 10 shows the Optical DCB’s front panel, and its components are
described below.

RTU the indicator will be red until the module has correctly initialised.
TXD Data being transmitted

RXD Data being received
4. Optical Port 1 and Port 2.
The optical ports use industry standard ST fibre connectors. The fibre optic
transmitters and receivers use the 820nm wavelength. Either 50/125 m or
62.5/125 m multimode cable, up to 2000m in length, can be used.

Figure 10

for the SCD5200
2005662 - Rev. 1.2
5.2 Eight Channel Serial Module

This module (also known as an Eight Channel Serial Board) provides an
RS-485 / RS-232 electrical interface. This interface is described below.
5.2.1 Eight Channel RS-485/RS-232

Communications Module
The eight RS-485/RS-232 channels can be used for local communications with
Intelligent Electronic Devices (IEDs), such as protection relays or flow meters.
The protocols used on each channel may be independently configured.
Protocols may be implemented by the user with High Level Serial Interface
(HLSI) functions. Refer to the “SALL High Level Serial Interface User
Manual” [2]. Configurable baud rates up to 38,400 bits/second are permitted
depending on main CPU loading and the selected communications protocol.
The communications module contains four isolated RS-485 channels 1 to 4, and
four non-isolated channels 5 to 8. Channels 5 to 8 can also be configured to
operate at RS-232 signal levels.
Channels Isolation Baud rate RS-485 RS-232

Configurations Configurable
1 to 4 1500 Vrms <= 38,400 2 wire no
5 to 8 nil <= 38,400 2 or 4 wire yes
Figure 11 shows the Eight Channel Communications Module’s (part number

0399132) front panel, and its components are described below.
TX Data being transmitted

RX Data being received
Figure 11

for the SCD5200
2005662 - Rev. 1.2
2. Isolated RS-485 Channels 1 to 4.

8 Terminal Connector (Removable)
Terminal Function Direction
1 Transmit/Receive data on VB In/Out
2 Transmit/Receive data on VA In/Out
3 Signal Ground -
4 Chassis – connected to SCD5200 Frame -
5 Chassis – connected to SCD5200 Frame -
6 Signal Ground -
7 Transmit/Receive data on VA In/Out
8 Transmit/Receive data on VB In/Out
Terminal 1 to 4 functions are directly connected to terminal 8 to 5
functions, to allow daisy chaining. For RS-485 data signals a space (0)
condition is VA > VB.
An optional 120 termination resistor may be linked across the

Transmit/Receive pair for each channel. (Default is not fitted). It is normal
practice to terminate an RS-485 line at each end only.
Link 120 Resistor

LK1 Channel 1
LK2 Channel 2
LK3 Channel 3
LK4 Channel 4
Typical terminations to the RS-485 connector.



 



 

 
 



 


 





 



 



 

 
 



  





 



 

for the SCD5200
2005662 - Rev. 1.2

SCD5200 the indicator will be red until the module has been correctly
initialised.
4. Non-isolated RS-485/RS-232 Channels 5 to 8.
Channel Mode Control Links.
Link Mode Control
LK5 Channel 5
LK6 Channel 6
LK7 Channel 7


LK8 Channel 8 

Channel in RS-232 mode (Default setting)

4 Data Terminal Ready DTR Output
5 Signal Ground -
6 Data Set Ready DSR Input
7 Request to Send RTS Output
9 Ring Indicate RI Input
Frame Connected to Chassis of SCD5200 -

for the SCD5200
2005662 - Rev. 1.2
Channel in RS-485 4 wire mode.

8 RS-485 VA Receive signal Input
2 RS-485 VB Receive signal Input
5 Signal ground -
3 RS-485 VA transmit signal Output
7 RS-485 VB transmit signal Output
Channel in RS-485 2 wire mode.

3 RS-485 VA Transmit/Receive signal Input/Output
7 RS-485 VB Transmit/Receive signal Input/Output
5 Signal ground -
Note: For RS-485 data signals a space (0) condition is VA > VB.
The shaded signals in the above tables are RS-485 signals. The
remaining non-shaded signals are RS-232 handshake and modem
control signals, and do not require connection.

6. Part identification number (0399132).

Hardware User Manual 6 Input/Output Modules
for the SCD5200
2005662 - Rev. 1.2
6. Input/Output Modules
An Input/Output module is identified by I/O function and capacity, operating voltage, and isolation
voltage; as shown in Table 4 below.
Module Function, Capacity, and Operating Voltage Isolation Voltage (rms)
Analog and Digital Input Modules (32DI / 4AI)
0399090 32 Digital Input (24V) / 4 Analog Input 2 kV digital / nil analog
0399081 32 Digital Input (24V) / 4 Analog (1 kV) Input 2 kV digital / 1 kV analog

Analog Input Modules (20 AI)

0399093 20 Analog Input nil analog
0399085 20 Analog Input (1 kV isolation) 1 kV analog
Analog Output Module (4 AO)

0399084 4 Analog Output 50 Vdc analog
Digital (Relay) Output Modules (12 DO, 8DO)

0399086 12 Pilot Relay Output 2 kV output
0399087 12 Magnetically Latched Relay Output 2 kV output
0399136 8 x 10 Amp Relay Output 2 kV output
Multi Input/Output Modules

(24DI / 6AI / 6DO, 24DI / 6AI / 8 DO)
24 Digital Input (24V) / 6 Analog Input / 2 kV digital / nil analog /
0399089
6 Pilot Relay Output 2 kV output
0399096
0399097
0399088
8 Mini-Pilot Relay Output 2 kV output
0399094
0399095
Table 4. Input/Output Modules

for the SCD5200
2005662 - Rev. 1.2
6.1 Identification of I/O Module front

termination assembly features and parts
The parts identified in the figure above are described below.

1. Detailed identification label.
This label identifies the I/O module. The 0399 series number on the label is
the number which should be quoted to replace the complete module. The
complete module includes the front termination assembly together with the
rear microprocessor assembly. Separate sub-assemblies are identified by
their own 0303 series number and revision level.
2. Termination description label.
This label is located on the inside of the termination cover door. The
individual circuits which describe the termination circuit function are
illustrated.
3. Front identification label.
This label is located on the outside of the termination cover door, and
allows an identification of basic module function without needing to open
the door.
4. Run/Fail indication.
While the I/O module is initialising or after a reset, the indication will be
red (Fail). During normal operation the indication will be green (Run).
5. Removable termination cover door.
The door must be opened and removed before screwing terminals, or
removing the terminal blocks.

for the SCD5200
2005662 - Rev. 1.2
F
C

C
F
To open door: apply force (at F), outwards at To remove door: open the door to 90o and pull
top and bottom as required, and unlatch door outwards. The three retaining hinges will unclip.
clips (indicated by C), one at a time, by
applying a sideways force on each clip using a
screwdriver.
6. Removable screw termination blocks.

Insert in the window
A removable screw termination block is shown in Figure 12. Once the door
above the clamp.
is removed the screw termination blocks can also be removed. This will
allow easier wiring termination. The screw terminals will accommodate up
to 1.5mm2 wire size. It is important when inserting a wire, that the terminal
window is fully open in the correct way, by first screwing the terminal
screw anti-clockwise if necessary.
Use the correct screw blade size, 0.4 mm x 2.5 mm; for example, Phoenix
Do not insert in the
SZS 0.4 x 2.5. Do not use an oversized screwdriver as damage may result.
window below the clamp.
7. Cable tie facility (2).

Figure 12 Access holes located in the side of the assembly permit insertion and
anchoring of two cable ties (up to 3.5mm wide).
8. Wiring loom retainers (3).
The wiring loom retainers can be inserted down the inside of the base of the
assembly, to clamp down onto loose wires.
9. Securing screws (4).
The four securing screws attach the termination assembly to the front of the
SCD5200 file.

for the SCD5200
2005662 - Rev. 1.2
10. Warning mark (located on the inside door label).

Hazardous voltages may exist on the terminals, on the rear of the
termination assembly, and on the I/O microprocessor assembly
around the power supply area. Do not grasp the rear of the
termination assembly. Adjacent I/O modules may also have
hazardous live voltages present. Avoid contact with adjacent
modules while working.
CAUTION: Hazardous CAUTION: Avoid

live voltages may be contact with the rear of
present on the terminations, adjacent modules.
such that the rear of the
termination assembly is
energised.

for the SCD5200
2005662 - Rev. 1.2
6.2 32 Digital Input / 4 Analog Input Module

(32 DI / 4 AI)
The Analog Digital (ADI) modules provides 32 bi-directional DC inputs, in 4
groups of 8, each group sharing a common. Input voltages are 24V, 48V, or
129V. Each module also provides 4 analog inputs, either non-isolated, or
individually isolated to 1kVrms. A current to voltage resistor for each channel
is mounted in locations R1 to R4 on the rear of the termination assembly.
Figure 13 shows the front panel of a 32 Digital Input/4 Analog Input Module.
The Digital Input parameters and their permissible values are shown in the
table below.
Digital Input Parameters Value
Input voltage range 18 to 32V, nominal 24V
38 to 64V, nominal 48V
Input current 5 mA at 24V
5 mA at 48V
4 mA at 129V
ON/OFF time 2 milliseconds debounce
Common mode withstand 2kVrms / 1 minute
The Analog Input parameters and their permissible values are shown in the
table below.
Analog Input Parameters Value
Input range + 2V (+ 2.048V overrange)
0 – 20 mA using a 100 resistor
+ 10 mA using a 200 resistor
Conversion range + 4000 counts (+ 4095 overrange)
Overall accuracy + 0.25 % (over temp and maxV common mode)
+ 0.1 % (25oC and 0V common mode)
Common mode rejection 80 dB to 6V peak (non-isolated inputs)
120 dB to 1 kVrms (isolated inputs)
Differential mode rejection 60 dB at 60 Hz
Common mode withstand 50V peak (non-isolated inputs)
(channel to chassis and 1 kVrms (isolated inputs)
channel to channel)
Input update time 400 milliseconds (non-isolated inputs)
(maximum data age) 600 milliseconds (isolated inputs)
Figure 13

for the SCD5200
2005662 - Rev. 1.2
















Digital Input



 
 


 


 



 













Non-isolated Analog Input



 
 





















1kV isolated Analog Input

(single isolated channel shown)
Refer to Appendix E for scaling and calibration of Analog Input assemblies.

for the SCD5200
2005662 - Rev. 1.2
6.3 20 Channel Analog Input Module (20 AI)

This module provides 20 analog inputs, either non-isolated or individually
isolated to 1kVrms. A current to voltage resistor for each channel is mounted in
locations R1 to R20 on the rear of the termination assembly. Figure 14 shows
the front panel of the 20 Channel Analog Input Module.
The Analog Input parameters and their permissible values are described in the
table below.

Input range + 2V (+ 2.048V overrange)
0-20mA using a 100 resistor
+ 10mA using a 200 resistor
Conversion range + 4000 counts (+ 4095 overrange)
Overall accuracy + 0.25 % (over temp and maxV common mode)
+ 0.1 % (25oC and 0V common mode)
Common mode rejection 80 dB at 6V peak (non-isolated input)
120 dB at 1kVrms (isolated input)
Differential mode rejection 60 dB at 60 Hz
Common mode withstand 50V peak (non-isolated input)
(channel to chassis and
channel to channel) 1kVrms (isolated input)
Input update time 65 milliseconds (non-isolated input)

(maximum data age)
600 milliseconds (isolated input)
Figure 14

for the SCD5200
2005662 - Rev. 1.2



 
 


 


 
















 



















Isolated Analog Input
Refer to Appendix E for scaling and calibration of analog input assemblies.

for the SCD5200
2005662 - Rev. 1.2
6.4 4 Channel Analog Output Module (4 AO)

This module provides 4 individually isolated 4-20mA current loop outputs.
Each current loop is powered by an externally connected 24V supply. Link
selection is able to remove the 4mA offset to permit 0-10mA or 0-16mA output.
Figure 15 shows the front panel of the 4 Channel Analog Output Module.
The Analog Output parameters and their permissible values are described in the
table below.
Analog Output Parameters Value
Output range (link selectable) 4-20mA
0-16mA
0-10mA
Loop resistance 0-600 ohms
External loop power 19-36V (nominal 24V)
40mA maximum/channel
Accuracy 4-20mA +0.1% at 25oC
+0.25% over temp
Accuracy 0-10, 16mA +0.5% over temp
Output update rate < 100 milliseconds / channel
External power fail detection Yes per channel
Loop open detection Yes per channel
Common mode withstand (channel to 50V dc or peak ac.
channel and channel to chassis)





  

 
 










 











Figure 15
Refer to Appendix E for scaling and calibration of analog output assemblies.

for the SCD5200
2005662 - Rev. 1.2
6.5 12 Digital (Relay) Output Modules (12 DO)

On 12 DO modules, twelve relays are mounted on the rear of the termination
board, providing an individually isolated Form A dry contact for each output.
Either a normal relay or a magnetic latching relay module is used. The
magnetic latching relay module saves power, as well as remembering the relay
state on power down. This option can be used for a “SETPOINT” output of up
to 12 bits in length. Figure 16 shows the front panel of the 12 Relay Output
Module.
The Relay Output (Digital Output) parameters and their permissible values are
described in the table below.
Relay Output Parameters Value
A.C. contact rating 1, 2 5A 250Vac cos = 0.4 (30,000
operations)
D.C contact rating 1, 2 5A 30 Vdc, 1A 50Vdc L/R 40ms
(30,000 operations)
200mA 129Vdc L/R 40ms (30,000
operations)
Minimum switching load 10mA@10V (not previously having
switched heavy loads)
Relay on delay approx. 5 milliseconds
Relay off delay approx. 3 milliseconds
Common mode withstand (contact 2kVac rms / 1 minute
to contact and contact to chassis)
Relay coil current 3 27mA nominal
1. The trackwork and relay contacts require external fuse protection

so that the printed circuit tracks do not burn out, or contact damage
occur, on extended overload conditions above 5A.
2. When inductive loads of any amount are switched (particularly
when the relay contact breaks the current) sparking across the
contact will cause EMC problems and contact degradation unless
the energy is suppressed. Ensure that a snubbing diode is fitted
across the inductive load. For A.C. inductive loads use a varistor.
Relay contact to Inductive load

be protected on (interposing relay
Output module or contactors in
the field)
Diode reverse breakdown voltage 3 x V, for example 1N5404

Figure 16 Varistor working voltage rating 1.2 x maximum Vac rms

for the SCD5200
2005662 - Rev. 1.2
3. Where many relays are to be simultaneously operated, consider the

power supply +15V capacity. The COPE module power supply
+15V rating is 1A. Therefore in applications which use the COPE
module, up to 35 (27mA) relays can be energised simultaneously.
If many relays are required to be held simultaneously, consider
using the magnetic latching relay module.
Using the 100W power supply module, the +15V rating is 3A.
Therefore up to 100 relays can be energised simultaneously.
4. The controls isolate feature of the 100W power supply permits
disconnection of the relay coil supply.
For the 12 Pilot Relay Output module (0399086) this ensures that no
relay contact can be closed.
For the 12 Magnetically Latched Relay Output module (0399087) this
ensures that no relay contact can change state.
5. Do not disconnect terminal blocks while load current is

passing through any relay contact. This will cause connector
arcing while the load current is broken. Note that for
Magnetically Latched Output modules, contacts may be
closed and load current flowing, even when the SCD is
unpowered. Terminating to the Magnetic Latched Relay
terminal board may immediately energise external circuits, if
the relay is in the latched closed state.

for the SCD5200
2005662 - Rev. 1.2
6.6 8 x 10A Digital (Relay) Output Module (8 DO)

The 8 x 10 Amp module uses high switching capacity relays to break heavy DC
inductive loads at high DC voltage of nominally 129V DC, or heavy current
110 Vac loads. Figure 17 shows the front panel of the 8 x 10 Amp Relay
Output Module.
The 8 relay output circuits are mounted on the main control board, providing
individually isolated Form A dry contacts. Each output contact circuit is
bridged by a protective varistor, rated at a nominal 150V DC operating voltage.
This varistor is used for inductive load arc suppression on contact opening.
The 8 x 10 Amp relay output parameters and their permissible values are
Relay Output Parameters Value

1
A.C. contact rating 10A 130 Vac cos = 0.4 (30,000
operations)
D.C. contact rating 1,2 10A 150 Vdc resistive (30,000
operations)
5A 150 Vdc L/R 40ms (30,000
operations)
Relay on delay approx. 14 milliseconds
Relay off delay approx. 5 milliseconds
Common mode withstand (contact to 2kVac rms / 1 minute
output and output to chassis)
One output circuit coil load 67mA nominal on +15V
Terminal wire range 12 to 22 AWG
Wire strip length 8 mm
1. The trackwork and relay contacts require external fuse protection

so that the printed circuit tracks do not burn out, or contact
damage occur, on extended overload conditions above 10A.
2. Do not remove the front termination assembly while DC load
current is passing through any relay contact. This will cause
connector arcing while the load current is broken.
3. The controls isolate feature of the 100W power supply permits
disconnection of the relay coil supply. This ensures that no relay contact
can be closed.
Figure 17

for the SCD5200
2005662 - Rev. 1.2
6.7 Multi Input/Output Module (24DI/6AI/6DO,

24DI/6AI/8DO)
A Multi Input/Output Module (Multi IO) provides 24 digital inputs which share
a single common, 6 non-isolated analog inputs, and either 6 paired pilot relay
outputs, or 8 mini-pilot relay outputs. A current to voltage resistor for each
analog input is mounted in locations R1 to R6 on the rear of the termination
assembly. Figure 18 shows the front panel of the 24DI/6AI/6DO Multi
Input/Output Module. Figure 19 shows the front panel of the 24DI/6AI/8DO
Multi Input/Output Module.
The Digital Input parameters and their permissible values are described in the
table below.
Digital Input Parameters Value
Input voltage range 18 to 32V, nominal 24V
Input current 5mA at 24V
5mA at 48V
4mA at 129V
On/Off time 2 milliseconds debounce
Common mode withstand 2kVrms / 1 minute
The analog input parameters and their permissible values are described in the
table below.
Input range +2V (+2.048V overrange)
0-20mA using a 100 resistor
+10mA using a 200 resistor
Conversion range +4000 counts (+4095 overrange)
Overall accuracy +0.25% (over temp and maxV common
mode)
+0.1% (25oC and 0V common mode)
Common mode rejection 80dB at 6V peak
Differential mode rejection 60dB at 60Hz
Common mode withstand 50V peak
(channel to chassis and
channel to channel)
Input update time (maximum 600 milliseconds
data age)
Figure 18

for the SCD5200
2005662 - Rev. 1.2








 





 



Digital Input



 
 


 


 









 


















Refer to Appendix E for scaling and calibration of analog input assemblies.
Figure 19

for the SCD5200
2005662 - Rev. 1.2
The 6 paired Pilot Relay Output parameters and their permissible values are
6 paired Pilot Relay Output Value
Parameters
A.C. contact rating 1,2 5A 250Vac cos = 0.4 (30,000
operations)
D.C. contact rating 1,2 5A 30Vdc, 0.5A 50Vdc L/R 40ms
(30,000 operations)
100mA 129Vdc L/R 40ms (30,000
operations)
Minimum switching load 10mA@10V (not previously having
switched heavy loads)
Relay on delay approximately 10 milliseconds
Relay off delay approximately 5 milliseconds
Common mode withstand 2kVac rms / 1 minute
(contact to contact and
contact to chassis)
The 8 mini-pilot Relay Output parameters and their permissible values are
8 mini-pilot Relay Output Value
Parameters
A.C. contact rating 1, 2 0.5A 125Vac cos = 0.4 (30,000
operations)
D.C. contact rating 1, 2 0.5A 30Vdc, 0.25A 50Vdc L/R 40ms
(30,000 operations)
50mA 129Vdc L/R 40ms (30,000
operations)
Minimum switching load 10 A@20mV
Relay on/off delay approximately 4 milliseconds
Common mode withstand 2000Vac rms / 1 minute
(contact to chassis only)
The controls isolate feature of the 100W power supply permits disconnection
of the relay coil supply. This ensures that no relay contact can be closed.

for the SCD5200
2005662 - Rev. 1.2
1. A pair of pilot relays share a single common, but the eight mini-
pilot relays together share a single common. The trackwork and
relay contacts require external fuse protection so that the printed
circuit tracks or contacts are not damaged on extended overload
conditions. Protect the pilot relay pair with a 5A fuse on the
common, and protect the mini-pilot relays with a 3A fuse on the
common.
2. When inductive loads are switched (particularly when the relay
contact breaks the current) sparking across the contact will cause
EMC problems and contact degradation unless the energy is
suppressed. Ensure a snubbing diode is fitted across the inductive
load when breaking capacity is required. For A.C. inductive loads
use a varistor.
3. The 18mA per relay load permits up to 50 relays to be held
simultaneously, using the COPE +15V power output rated at
1Amp.
The 24DI/6AI/8DO module using 8 mini-pilot relays, also has

+15V control voltage available on the terminal assembly. This
power may be used to energise external interposing relays via the
mini-pilot relay contacts. Consider current consumption
requirements of external relays using the internal +15V control
supply, so as not to exceed the COPE +15V supply rating of
1 Amp, with all other loads considered as well.





 


 



 


 




 



 

 








The 1.25A fuse F1 is located on the Only use the +15V control
rear of the terminal assembly (type F voltage for local
20 x 5mm quick blow). energisation of external
interposing relays. Local
means within the same or
adjacent cubicles within an
installation.

Hardware User Manual 7 Power Supply Connection
for the SCD5200 and Disconnection
2005662 - Rev. 1.2
7. Power Supply Connection and

Disconnection
In order to comply with the European Safety Standard IEC 61010-1 [4],
external means for disconnecting the power supply must be provided, if the
applied voltage exceeds 70Vdc.
The power supply ON/OFF switch, on the 100W module and the COPE
module, does not disconnect power from all internal circuits. This is
because the actual load power is switched electronically, the front panel
switch controls the electronic switch.
The external disconnect device which is provided to control the supply to the
SCD5200 shall have the following characteristics (in the context of Safety
Standard IEC 61010-1):
1. If a switch or a circuit breaker is used, it shall meet the compliance
standards for that kind of device, i.e. for CE compliance, IEC/EN 60947.
2. Be physically located within the cubicle where the SCD5200 is installed,
and be within easy reach.
3. Be clearly marked for the purpose.

Hardware User Manual 8 Installation, Grounding,
for the SCD5200 and Wiring Guidelines
2005662 - Rev. 1.2
8. Installation, Grounding, and Wiring

Guidelines
8.1 Installing the Ten I/O Slot File

The Ten I/O slot file may be installed in a 19” rack, or it may be rear-mounted.
The change is effected by relocating the mounting angle brackets from the front
to the rear of the file.
Ten I/O Slot File for

mounting in a 19”
rack.
Ten I/O Slot File for

rear mount.
For door open

add an extra Ten I/O Slot rear mount pattern.
30mm.

2005662 - Rev. 1.2
8.2 Installing the Five I/O and One I/O Slot

File
The Five I/O and One I/O slot files are rear-mounted since they are not wide
enough to fit into a 19” rack.
Five I/O Slot file rear mount
Five I/O Slot rear mount pattern
One I/O Slot file rear mount
One I/O Slot rear mount pattern
For door open, add

an extra 30mm

2005662 - Rev. 1.2
8.3 Earthing of the File

The earthing of the file is important for safety. Be sure to follow these
guidelines. Do not assume that an adequate earth is maintained by using file
mounting bolts only. Use 2.5mm2 (50/0.25mm) earthing wire.
M5 Earth Stud on
side of File
minimum size 2.5mm2 (50 / 0.25mm) (AWG 13)
Run this earth wire directly to the safety earth bar.

Note 1: Logic 0V is connected to the file frame via the backplane. Therefore
logic 0V will be earthed.
Note 2: Some installations may stipulate an isolated shield bar separately
earthed, and an alternate, normally non-isolated safety earth bar. The
SCD5200 file should be connected to the safety earth bar. This dual
bar configuration is not the preferred arrangement for High Frequency
EMC performance (refer to Appendix F).

2005662 - Rev. 1.2
8.4 I/O Wiring Guidelines (3.5mm terminals)

Terminal pitch 3.5mm
3.5mm
Solid conductor size 0.14 – 1.5mm2 (28-16 AWG)

Stranded conductor size 0.14 – 1.5mm2 (28-16 AWG)
Stranded with ferrule (with plastic collar) 0.25 – 0.5mm2
Stranded with ferrule (without plastic collar) 0.25 – 1.5mm2
Multiple (2) solid conductor 0.14 – 0.5mm2
Multiple (2) stranded conductor 0.14 – 0.75mm2
Multiple (2) stranded with TWIN ferrules 0.5mm2
(with plastic collar)
Multiple (2) stranded with ferrules (without 0.25 – 0.34mm2
plastic collar)
Stripping length 7mm
Screw torque 0.22 – 0.25Nm
Screwdriver size 0.4 mm x 2.5 mm
Cable tie width through termination up to 3.5mm
assembly base side wall
Maximum wire size for a bundle of 50 wires 0.5mm2
inside one closed termination assembly
50 x 0.5mm2 (AWG 20)

Shielded drain wire termination To signal earth bar at enclosure entry point





















Wire segregation It is recommended that analog I/O signal wires be

physically separated from status input and relay output
wiring within ducting internal to the enclosure.

Hardware User Manual 9 Preventative Maintenance
for the SCD5200 and Inspection
2005662 - Rev. 1.2
9. Preventative Maintenance and

Inspection
From a safety perspective, in accordance with the requirements of
safety standard IEC61010-1 [4] the following items should be
periodically checked as follows.
1. That each module is 2. That the earth wire is tightly

inserted fully, and that attached to the earth stud on the
the four captive screws side of the file (indicated by 2
(indicated by 1 in the in the figure above), and that the
above figure) that fix the cubicle earth termination is
module to the file frame secure.
are tight.
3. That accumulations of dust and soot be removed so that electrical safety

clearances are not jeopardised.
4. That on routine maintenance these items are checked as a matter of course,
on completion of the maintenance.

Hardware User Manual 10 File, Backplane Slot
for the SCD5200 Identification, and SYSFAIL
2005662 - Rev. 1.2 Alarm
10. File, Backplane Slot Identification,

and SYSFAIL Alarm
Part Number File Assembly

2003098 Ten I/O Slot Card File (Fully covered for CE compliance)
2003100 Five I/O Slot Card File (Fully covered for CE compliance)
2003104 One I/O Slot Card File (Fully covered for CE compliance)
Slot identification is shown in Figures 20, 21, and 22.
         
 
 

Figure 20. Ten I/O Slot File 2003098

10 I/O Slot backplane does not have a SYSFAIL alarm. It is provided on the
100W power supply module.
If the 10 I/O Slot backplane is to be used without a 100W power supply (that is,
it is powered by the COPE module), position LK1 on the 10 I/O Slot backplane
must be shorted. This will permit control output operation using the COPE
module power supply. However, LK1 must be removed if the 100W power
supply is installed at a later time.

Hardware User Manual 10 File, Backplane Slot
for the SCD5200 Identification, and SYSFAIL
2005662 - Rev. 1.2 Alarm
Access to the SYSFAIL alarm on the Five I/O Slot and One I/O Slot backplanes
is shown in Figures 20 and 21 respectively. Terminal block X7 (5 I/O slot file)
or X3 (1 I/O slot file) is located on the left end side of the backplane, near the
CPU slot.
     
Figure 21. Five I/O Slot File 2003100
 
Figure 22. One I/O Slot File 2003104

If the controls isolate function is required with the 5 I/O Slot file and 1 I/O
Slot file, it is necessary to connect to terminal positions 4 and 5 of
backplane terminal block X7 (5 I/O Slot file) or X3 (1 I/O Slot file). This
optional feature requires installation of an additional two-way 3.81mm pitch
terminal block in this position (or direct soldering of wires). Normally
terminal locations 4 and 5 are bridged on the rear of the backplane.
Therefore it is necessary to remove the bridge located on the rear of the
backplane. This connection must then be shorted to permit Control Output
(Relay) operation.

Hardware User Manual 11 Appendices
for the SCD5200
2005662 - Rev. 1.2
11. Appendices
Appendix A Definitions and Abbreviations

The following terms and acronyms are defined here within the context of this
document.
TERM DEFINITION
A Amps
AC Alternating Current
AI Analog Input
AO Analog Output
AWG American Wire Gauge
C Common
CE Compliance Europe
COPE CPU, OptoNet, Power Supply and Ethernet combined board for the SCD5200
CPU Central Processing Unit
CTS Clear To Send
dB decibel
DC Direct Current
DCB Dual Communications Board
DCD Data Carrier Detect
DI Digital Input
DNP3 Distributed Network Protocol V3.0
DO Digital Output
DSR Data Set Ready
DTR Data Terminal Ready
EMC Electro Magnetic Compatibility
ESD Electro Static Discharge
HLSI High Level Serial Interface
Hz Hertz
IED Intelligent Electronic Device
I/O Input/Output
LED Light Emitting Diode
LS Least Significant
MS Most Significant
NC Normally Closed
RI Ring Indicate
rms Root Mean Square
RTS Request To Send
RTV Remote Terminal Viewer
RX Receive
RXCLK Receive Clock
RXD Receive Data
SCADA Supervisory Control And Data Acquisition
SCD Station Computing Device
SCD5200 Foxboro Australia’s Station Computing Device product
TX Transmit
TXCLK Transmit Clock
TXD Transmit Data
V Volt
W Watt

for the SCD5200
2005662 - Rev. 1.2
Appendix B Referenced Documents
[1] System Configurator User Manual for the RTU50 and SCD5200
Foxboro Australia
Document No. 2005663
[2] SALL High Level Serial Interface User Manual for the RTU50, RTU10,
SCD5200 and CLS
Foxboro Australia
Document No. 2005167
[3] Remote Terminal Viewer Software Release Note

Foxboro Australia
Document No. 1101192-RN
[4] Safety requirements for electrical equipment for measurement, control, and
laboratory use – Part 1: General requirements
International Electrotechnical Commission
IEC 61010-1, Second Edition 2001-02
[5] Telecommunications Labelling (Customer Equipment and Customer Labelling)

Notice 2001 as amended.

for the SCD5200
2005662 - Rev. 1.2
Appendix C Summary of Part Numbers

Part Number Module or Assembly
0399131 100W Power Supply Module
0399129 CPU/OptoNet/Power Supply/Ethernet Module (COPE)
0399132 8 Channel Serial Module RS-485 / RS-232
0399111 Dual Communications Module V.23 Conitel/Baker/C300
0399112 Dual Communications Module V.28 Conitel/Baker/C300
0399119 Dual Communications Module V.23 DNP3
0399122 Dual Communications Module Optical DNP3
0399126 Dual Communications Module V.28 IEC 60870-5-101
0399127 Dual Communications Module Optical IEC 60870-5-103
0399090 32 Digital Input (24V)/4 Analog Input (non-isolated) Module
0399081 32 Digital Input (24V)/4 Analog Input (1kV isolated) Module
0399093 20 Analog Input (non-isolated) Module
0399085 20 Analog Input (1kV isolated) Module
0399084 4 Analog Output Module
0399086 12 Digital (Relay) Output Module
0399087 12 Magnetically Latched Relay Output Module
0399136 8 x 10 Amp Digital (Relay) Output Module
0399089 24 Digital Input (24V)/6 Analog Input/6 Pilot Relay Output Module
0399088 24 Digital Input (24V)/6 Analog Input/8 Mini-Pilot Relay Output Module
2003098 Ten I/O slot card file (CE compliant)
2003100 Five I/O slot card file (CE compliant)
2003104 One I/O slot card file (CE compliant)
0399134 35mm Blanking Panel (CE compliant)
0399138 Empty Termination Slot Blanking Module
The shaded Dual Communications Modules are currently supported by the System
Configurator, and can therefore be configured for the SCD5200. All I/O modules listed are
supported.

for the SCD5200
2005662 - Rev. 1.2
Appendix D Environmental Specification
Temperature -40 to +70 oC

Humidity 10 to 95% RH (non-condensing)
Vibration 10 Hz to 57 Hz 0.075mm
57 Hz to 150 Hz 1.0g
Shock 15G 3 times (X,Y,Z directions)
Voltage withstand 2kVac rms 50Hz EN 60255-5
Fast Transients Level 3 2kV EN 61000-4-4
Lightning Level 3 2kV EN 61000-4-5
Impulse Level 3 5kV EN 60255-5
Ripple and D.C. Level X 15% EN 61000-4-17
High Freq. disturbance Level 3 2.5kV EN 60255-22-1
RF Immunity (Radiated) Level 3 10V/m EN 61000-4-3
RF Immunity (Conducted) Level 3 10V EN 61000-4-6
ESD Level 3 8kV EN 61000-4-2
Magnetic Field (50Hz) 300 A/m EN 61000-4-8

for the SCD5200
2005662 - Rev. 1.2
Appendix E Calibration
The Electrobus extender board (part number 1901042) may be used to assist in
calibration.
Calibration of the V.23 DCB

The V.23/Bell 202 DCB will need to be mounted on the extender board to
allow access to the potentiometers that adjust transmit and receive levels.
VR3 Adjust channel 1 transmit level

VR4 Adjust channel 1 receive level
VR1 Adjust channel 2 transmit level
VR2 Adjust channel 2 receive level
Use the SCD5200 Remote Terminal Viewer (RTV) [3] diagnostic facility to
transmit a continuous MARK for transmit calibration. A typical transmit level
is –10dBm into 600 ohm. –10dBm is 245mVrms across a 600 resistor wired
into the transmit terminal pair.
The detection level of the receiver is determined by observing the behaviour of
the DCD LED on the front of the module. A typical receive level is –35dBm
into 600 ohm and this level is applied to the receive terminal pair. For the given
input level, adjust the receive potentiometer so that the DCD LED turns off.
Then slowly readjust so that the DCD LED just turns on. This should be done
slowly.
A method of obtaining the receive signal is to use an attenuated transmit signal
(if no test set is available).
 




 




 







 
Using a –25dBm attenuator to adjust receive.

for the SCD5200
2005662 - Rev. 1.2
Calibration of the Analog Input Modules
32DI/4AI Module
Steps:
1. Permit warm up for one minute.
2. Adjust RV1 to measure 1.00000 +10 V across TP1 and TP2. (This will
achieve calibration within specification.)
3. Even more accurate calibration may be achieved. Connect a precision
2.00000 +10 V voltage source to channel 1 input.
4. Adjust RV1 for a 4000 count reading on the RTV display.
32DI/4AI (1kV isolated) Module

Steps:
1. Permit warm up for one minute.
2. Install link LK1. This is the calibration link and its status is shown on the
RTV display.
3. Using a wire link, short out each analog input, 4 channels at once.
4. Using the RTV display, calibrate for zero.
5. Using a precision 2.00000 +10 V voltage source connect to each analog
input, 4 channels at once.
6. Using the RTV display calibrate for full scale.
7. Confirm on the RTV display that all channel calibrations are good (G).
8. Remove link LK1.
Multi I/O Modules

Steps:
1. Permit warm up for 1 minute.
2. Install link X5/8-10 calibration link. Check RTV display status.
3. Short analog input 1 using a wire link.
4. Using the RTV display calibrate for zero.
5. Connect a precision 2.00000 +10 V voltage source, connect to channel 1
analog input.
7. Confirm on the RTV display that calibration is good (G).
8. Remove link X5/8-10.

for the SCD5200
2005662 - Rev. 1.2
20 Channel AI Module
Steps:
2. Adjust VR1 to measure 1.00000 +10 V across TP1 and TP2. (This will
achieve calibration within specification.)
3. Even more accurate calibration may be achieved. Connect a precision
2.00000 +10 V voltage source to channel 1 input.
4. Adjust VR1 for a 4000 count reading on the RTV display.
20 Channel (1kV isolated) AI Module

Steps:
2. Install link LK2. This is the calibration link and its status is shown on the
RTV display.
3. There are five groups of 4 channels each. Calibration is performed on 1
group of 4 channels at a time. Using a wire link, short out each analog input
in a group.
4. Using the RTV display, calibrate for zero.
5. Repeat for the other groups.
6. Using a precision 2.00000 +10 V voltage source connect to a group of
inputs, 4 channels at once.
8. Repeat for the other groups.
9. Confirm on the RTV display that all channel calibrations are good (G).
10. Remove link LK2.

for the SCD5200
2005662 - Rev. 1.2
Calibration of the Analog Output Module

Various configuration options are provided by the System Configurator [1] for
the analog output module.
Digital value to be Analog output current Number of output steps

output in counts range actually available
0 – 4000 4 – 20mA 4000
800 – 4000 4 – 20mA 3200(2)
0 – 4000 0 – 10mA 2560(1)
0 – 4000 0 – 16mA 4000
0 – 2000 4 – 20mA 2000
400 – 2000 4 – 20mA 1600(2)
0 – 2000 0 – 10mA 1280(1)
0 – 2000 0 – 16mA 2000
Table 5
Note 1: Some counts output will not produce a change in current output, since
there are fewer steps available than counts.
Note 2: These ranges permit the transfer of an analog input value directly to
an analog output without scaling. For example, if 800-4000 is
selected, the analog input is 4 – 20mA across 100 then 4mA input
will give 800 counts internally, and transferred to the output will
produce 4mA without internal scaling being required.
4 Channel AO Module
Steps:
1. First configure the appropriate range (as shown in Table 5) using the
System Configurator [1].
2. Short out or load as required the current loop output (600 maximum).
3. Using RTV, output the low end of the range, e.g. 800 counts.
4. Adjust the offset for 4mA. If no offset is selected using the link, this
adjustment will have no effect.
5. Using the RTV display output the high end of the range, e.g. 4000 counts.
6. Adjust the gain for 20mA, 16mA, or 10mA as required (+10 A).

for the SCD5200
2005662 - Rev. 1.2
Appendix F Electromagnetic Compatibility

In order to remain compliant with the Emission and Immunity Standard to
which the SCD5200 has been tested, it is important that all panels and covers
remain in place as supplied. This includes rear, top and bottom covers, and the
front 35mm blank panels which are used to cover empty slots. This also ensures
compliance with the safety standard. The compliant EMC performance is
obtained by ensuring that the SCD5200 is enclosed in a metallic cabinet with
the correct optimum shielding termination arrangement for cables to a non-
isolated cabinet earth bar as illustrated.

for the SCD5200
2005662 - Rev. 1.2
Appendix G Safety Compliance
SCD5200 product used in European Union State shall not have voltages, in the
normal condition above 50 Vrms or 75 Vdc, connected to power, input or
output terminals.

for the SCD5200
2005662 - Rev. 1.2
Appendix H Non-compliance with the Australian

Telecommunications Labelling Notice
2001 [5]
Users within Australia:

The V.23 Dual Communications Board, when used within the SCD5200, has
not been qualified to the requirements of the Australian Telecommunications
Labelling Notice 2001, with respect to specific tests to technical standards as
detailed in Schedule 1 Part 2 Category A49 of the Notice.
This does not imply that the design does not conform to the technical
requirements necessary for compliance. Rather, the compliance has not been
confirmed by a recognised testing authority in this specific configuration of
assemblies.
It is therefore Foxboro’s lawful duty to present the following proforma
statement (Labelling Notice Schedule 9 Part 2).
DO NOT connect this item to any telecommunications network or

facility unless:
a) you have the written consent of the network or facility

manager; or
b) the connection is in accordance with a connection permit
issued for this item; or
c) a connection rule for this item has been made by the Australian
Communications Authority.
The connection of this item to any telecommunications network or

facility may cause a hazard or damage to the network or facility, or to
users of the network or facility, and may result in you being
consequentially liable to pay substantial compensation.

for the SCD5200
2005662 - Rev. 1.2
Appendix I COPE Error Codes

On startup the diagnostic display will flash through various codes as each area
is functionality checked. If an error occurs the diagnostic display will remain
fixed at this point, with the codes as listed in the table below.
MS is the most significant bit of the 8 bit error code.
LS is the least significant bit of the 8 bit error code.
Error Code (in hexadecimal) Description

00 Reset, test registers, configure address decodes
C1 Identify board as COPE type 2 (AMD SC520)
C2 Configure SDRAM controller
C3 FAR jump to clear descriptor cache
C6 Configure PCI Host Bridge and Ethernet controllers
C7 Configure UART
C8 Configure Interrupt Controller (PIC)
C9 Pre-cache test code
1A CRC check bootstrap code
0B CRC check main firmware code
1E Base 64KB memory test 1 (basic pattern test)
3A Base 64KB memory test 2 (bit tests)
42 Initialise real-mode interrupt vectors
5E Protected mode test 1
60 PM Base memory test (960KB)
66 PM Extended memory test (beyond 1MB)
10 PM Memory Test readback failure
20 PM Memory Scan readback failure
0C Protected mode test 2
0D Copy high ROM to RAM
0E CRC test code in RAM
87 Power-on tests complete. Begin C50 bootstrap
90…A0 Protected Mode fault vectors 00...10
B0 Real-mode unexpected interrupt (unknown)
00…FF Real-mode unexpected interrupt (code = vector number)

Always include error codes in incident reports.

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for the: SCD5200

Document ID: 2005662

Foxboro Australia Pty Ltd The Foxboro Company

All other brand names may be trademarks of their respective owners.

Checked By & Date: Approved By & Date:

© Foxboro Australia Pty. Ltd. 2003–2010

I/A Series Intelligent SCADA System Page 2 of 66

Document Revision History:

Rev. Date Comments Prepared By

I/A Series Intelligent SCADA System Page 3 of 66

1.1 Scope ..............................................................................................................................9

1.2 Audience .........................................................................................................................9

1.3 Product Overview ...........................................................................................................9

1.4 Definitions and Abbreviations........................................................................................9

1.5 Referenced Documents ...................................................................................................9

2. File and Module Arrangement.............................................................................. 10

3. 100 Watt Power Supply Module ........................................................................... 12

4. CPU / OptoNet / Power Supply / Ethernet Module (COPE) ................................ 14

5. Communication Modules ..................................................................................... 21

5.1 Dual Communications Modules ...................................................................................21

5.2 Eight Channel Serial Module .......................................................................................27

6.2 32 Digital Input / 4 Analog Input Module (32 DI / 4 AI) .............................................35

6.3 20 Channel Analog Input Module (20 AI) ...................................................................37

6.4 4 Channel Analog Output Module (4 AO) ...................................................................39

6.5 12 Digital (Relay) Output Modules (12 DO) ...............................................................40

6.6 8 x 10A Digital (Relay) Output Module (8 DO) ..........................................................42

6.7 Multi Input/Output Module (24DI/6AI/6DO, 24DI/6AI/8DO) ....................................43

7. Power Supply Connection and Disconnection ................................................... 47

8. Installation, Grounding, and Wiring Guidelines ................................................. 48

I/A Series Intelligent SCADA System Page 4 of 66

8.1 Installing the Ten I/O Slot File .....................................................................................48

8.3 Earthing of the File .......................................................................................................50

8.4 I/O Wiring Guidelines ..................................................................................................51

9. Preventative Maintenance and Inspection .......................................................... 52

10. File, Backplane Slot Identification, and SYSFAIL Alarm .................................... 53

11. Appendices ........................................................................................................... 55

Appendix A Definitions and Abbreviations ..............................................................55

Appendix B Referenced Documents .........................................................................56

Appendix C Summary of Part Numbers ....................................................................57

Appendix D Environmental Specification .................................................................58

Appendix E Calibration ............................................................................................59

Appendix F Electromagnetic Compatibility .............................................................63

Appendix G Safety Compliance ................................................................................64

Appendix H Non-compliance with the Australian Telecommunications Labelling

Appendix I COPE Error Codes ................................................................................66

I/A Series Intelligent SCADA System Page 5 of 66

I/A Series Intelligent SCADA System Page 6 of 66

IMPORTANT: For the safety of the user and protection and

CAUTION: Risk of electric shock. A hazardous voltage may be present.

Safety Compliance: refer to Appendix G.

Users of the V.23 Dual Communications Board in Australia: refer to Appendix H.

I/A Series Intelligent SCADA System Page 7 of 66

I/A Series Intelligent SCADA System Page 8 of 66

1.3 Product Overview

1.4 Definitions and Abbreviations

1.5 Referenced Documents

I/A Series Intelligent SCADA System Page 9 of 66

2. File and Module Arrangement

Figure 1. Ten I/O Slot File

I/A Series Intelligent SCADA System Page 10 of 66

Figure 2. Five I/O Slot File

Figure 3. One I/O Slot File