SCD5200 Hardware User Manual

Hardware User Manual
for the: SCD5200
Document ID: Revision:

I/A Series Intelligent SCADA System
2005662 1.2
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Hardware User Manual for the SCD5200 2005662 - Rev. 1.2
Document Revision History:

Rev. 1.1 1.2 Date 27 Mar, 2003 12 Nov, 2003 Comments Initial writing Add the 8 x 10 Amp Digital (Relay) Output Module (8DO) Prepared By D. Krautz L. Murray D. Krautz L. Murray
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Hardware User Manual for the SCD5200 2005662- Rev. 1.2
Contents
1. Introduction .............................................................................................................. 9 1.1 1.2 1.3 1.4 1.5 2. 3. 4. 5. Scope ............................................................................................................................. 9 Audience........................................................................................................................ 9 Product Overview .......................................................................................................... 9 Definitions and Abbreviations....................................................................................... 9 Referenced Documents .................................................................................................. 9
File and Module Arrangement ............................................................................... 10 100 Watt Power Supply Module ............................................................................ 12 CPU / OptoNet / Power Supply / Ethernet Module (COPE) ................................. 14 Communication Modules....................................................................................... 21 5.1 Dual Communications Modules .................................................................................. 21 5.1.1 5.1.2 5.1.3 5.1.4 5.2 V.28 Dual Communications Module ..................................................................22 V.23 Dual Communications Module ..................................................................23 V.11 Dual Communications Module ..................................................................25 Glass Optical Dual Communications Module ....................................................26
Eight Channel Serial Module....................................................................................... 27 5.2.1 Eight Channel RS-485/RS-232 Communications Module .................................27
6.
Input/Output Modules ............................................................................................ 31 6.1 6.2 6.3 6.4 6.5 6.6 6.7 Identification of I/O Module front termination assembly features and parts............... 32 32 Digital Input / 4 Analog Input Module (32 DI / 4 AI)............................................ 35 20 Channel Analog Input Module (20 AI) .................................................................. 37 4 Channel Analog Output Module (4 AO) .................................................................. 39 12 Digital (Relay) Output Modules (12 DO)............................................................... 40 8 x 10A Digital (Relay) Output Module (8 DO) ......................................................... 42 Multi Input/Output Module (24DI/6AI/6DO, 24DI/6AI/8DO)................................... 43
7. 8.
Power Supply Connection and Disconnection.................................................... 47 Installation, Grounding, and Wiring Guidelines .................................................. 48
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8.1 8.2 8.3 8.4 9. 10. 11.
Installing the Ten I/O Slot File .................................................................................... 48 Installing the Five I/O and One I/O Slot File............................................................... 49 Earthing of the File ...................................................................................................... 50 I/O Wiring Guidelines ................................................................................................. 51
Preventative Maintenance and Inspection ........................................................... 52 File, Backplane Slot Identification, and SYSFAIL Alarm .................................... 53 Appendices ............................................................................................................. 55 Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H Appendix I Definitions and Abbreviations.............................................................. 55 Referenced Documents......................................................................... 56 Summary of Part Numbers ................................................................... 57 Environmental Specification ................................................................ 58 Calibration ........................................................................................... 59 Electromagnetic Compatibility............................................................. 63 Safety Compliance ............................................................................... 64 Non-compliance with the Australian Telecommunications Labelling Notice 2001 [5]..................................................................................... 65 COPE Error Codes ............................................................................... 66
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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.
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Blank Page
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1 Introduction
1.
1.1
Introduction
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 1.5
Definitions and Abbreviations

Definitions and abbreviations found in this document are listed in Appendix A.
Referenced Documents
Documents referenced in this manual are listed in Appendix B.
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2 File and Module Arrangement
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.
10 I/O SLOT FILE 19" Rack
I/O slot 10
I/O Module can go from I/O slot 1 to I/O slot 10 Communication Modules can go from I/O slot 1 to I/O slot 10 CPU/Etherent/Optonet Module in second slot 100W Power Supply Module in first slot
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.
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2 File and Module Arrangement
5 I/O SLOT FILE Half 19" Rack
I/O slot 5 I/O Modules (5 maximum) Communication Modules (5 maximum) Power Supply/CPU/Etherent/Optonet Module in first slot
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).
1 I/O SLOT FILE 1/6 of 19" Rack
Communication or I/O Module Power Supply/CPU/Etherent/Optonet Module in first slot
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.
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3 100 Watt Power Supply Module
3.
100 Watt Power Supply Module

Figure 4 shows the 100 Watt Power Supply Modules 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. 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. 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. 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. 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.
3.
4. 5.
6.
7.
IN OK 15V OK
Green ON
The input voltage is high enough for operation. The +15V and 15V outputs are above their under voltage limits.
Green ON
8.
Due to hazardous voltages, authorised personnel only should access and maintain this module. Part identification number. (0399131)
Figure 4
9.
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3 100 Watt Power Supply Module
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. 130 Watts input for 100 Watts output. Maximum loading of 100 Watts
Efficiency Output loading
> 75 % +5V @ 10A +15V @ 3A 15V @ 0.45A 7.2A @ 18V 0.75A @ 164V 2000 Vac rms for 1 minute 4 milliseconds at 100W output
Input current Isolation Shorted input hold up time
At maximum loading of 100 Watts Primary to chassis, and primary to secondary isolation. A shorted input event can occur 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. Interruption in input supply.
Open input hold up time On board Fuse
20 milliseconds 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 rating Part Number 200mA at 30Vdc, 3VA maximum 0399131 Contact to chassis isolation is 1000 Vac rms. 100 Watt power supply 35mm module.
Table 1. 100 Watt Power Supply Module Specification
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4 CPU / OptoNet / Power Supply / Ethernet Module (COPE)
4.
CPU / OptoNet / Power Supply / Ethernet Module (COPE)

A singe module incorporates four major functions:
Part Number
0399129 includes power supply
CPU / OptoNet / Power Supply / Ethernet functions in a 35mm module.
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
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4.
RUN (Green)
! FAIL ! RUN
RUN ON FAIL OFF
The CPU has correctly started normal operations when the Green RUN indication is ON. CPU in the reset condition, at an incomplete initialisation stage, or in Bootstrap mode, when the Red FAIL indication is ON. The input voltage is high enough for power supply operation when the Green indication is ON. The +15V and 15V outputs are above their under voltage limits when the Green indication is ON.
FAIL (Red) IN
OK
RUN OFF FAIL ON
ON
15V OK
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.
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down
Reset the SCD5200.
down up
Reset the SCD5200 and hold the toggle in the up position until the first beep, to put into Bootstrap mode. Enable or disable the flash memory file system. Status indicated by the 3rd most significant diagnostic LED.
up
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 LED 8 (MS) 7 6 (3rd most significant) 5 4 Meaning 10ms timer interrupt 10s timer interrupt Flash memory enabled/disabled Flash memory write in progress Flash memory read in progress Expected State Pulses on every 250 milliseconds. Pulses on every 10 seconds. On for flash memory file system disabled. Off when enabled, writing to the flash memory may be in progress. On while erasing. Flashing slowly while writing data to flash file. On while reading flash memory.
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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 2 3
COM1 RS232 DB9 Male Connector
Data Carrier Detect Receive Data Transmit Data Data Terminal Ready Signal ground Data Set Ready Request to Send Clear to Send Ring Indicate Connected to chassis of SCD5200
DCD RXD TXD DTR DSR RTS CTS RI -
Input Input Output Output Input Output Input Input -
4 5 6 7 8 9 Frame 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 8 2
COM2 RS232/RS485 DB9 Male Connector
Connected to an RS-232 input RS-485 VA receive signal RS-485 VB receive signal Connected to an RS-232 output Signal ground Connected to an RS-232 input RS-485 VA transmit signal RS-485 VB transmit signal Connected to an RS-232 input Connected to chassis of SCD5200
Input Input Output Output -
4 5 6 3 7 9 Frame
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COM2 RS-485 2 wire mode (LK1 not fitted) This table only applies to COM2, since COM2 can be set to RS-485 mode.
1 3
Location of COM2 Port Mode control link LK1
Connected to an RS-232 input RS-485 VA transmit/receive signal RS-485 VB transmit/receive signal Connected to an RS-232 output Signal ground Connected to an RS-232 input Connected to a disabled input Connected to a disabled input Connected to an RS-232 input Connected to chassis of SCD5200
Input / Output Input / Output -
7 4 5 6 2 8 9 Frame
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 MT-RJ
LNK1 ACT1 LNK2 ACT2
Port 1 fibre link is established Port 1 link is receiving
Port 2 Port 2 fibre link is established Port 2 link is receiving MT-RJ
The MT-RJ fibre optic transceivers use the 840nm wavelength. Either 50/125m or 62.5/125m 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
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is also indicated by the arrows on the port. The outward arrow (that is, the arrow pointing towards the boards 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 50/125m or 62.5/125m 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 Off
On Off
Receive connection broken Transmit connection broken
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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 Efficiency Output loading 18 to 164 Vdc > 65% +5V @ 4.5A +15V @ 1A 15V @ 0.15A 3.3A @ 18V 0.34A @ 164V 2000 Vac rms for 1 minute 4 milliseconds at 40W output A higher voltage will damage components, a lower voltage and the power supply will not start. 60 Watts input for 40 Watts output. Maximum loading of 40 Watts output.
Input Current Isolation Shorted input hold up time
At maximum loading of 40 Watts output. Primary to chassis and Primary to Secondary isolation. A shorted input event can occur when the power 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. Input supply interruption.
Open input hold up time On board fuse
10 milliseconds 6.3A / 250V Type T
Replace with same Type T, Foxboro part number. 1009140. Only replace while unpowered. On board memory and clock backup battery (20mm Li/MnO2 cell) 6 months in storage. 7 years in use. Replace with 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
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5 Communication Modules
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 0399111 0399112 0399119 0399120 0399121 0399122 0399126 0399127 0399132
Interface Type 2 x V.23 2 x V.28 2 x V.23 2 x V.28 2 x V.11 2 x Optical 2 x V.28 2 x Optical 8 x RS 485 / RS 232
Protocol Conitel/Baker/C300 Conitel/Baker/C300 DNP3 DNP3 DNP3 DNP3 IEC 60870-5-101 IEC 60870-5-103 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.
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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 DCBs 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.
Pin 1 2 3 Function Connected to frame Transmit Data Receive Data Request to Send Clear to Send reserved (do not connect) Signal ground Data Carrier Detect +12V (50mA maximum fused) -12V (50mA maximum fused) reserved (do not connect) Data Terminal Ready Receive Clock Transmit Clock Out Transmit Clock In Connected to chassis of SCD5200 DTR RXCLK TXCLK OUT TXCLK IN DCD TXD RXD RTS CTS Direction Output Input Output Input Input Output Output Output Input Output Input -
RS232 Voltage signal DB15 Female Connector
4 5 6 7 8 9 10 11 12 13 14 15 Frame
4. Figure 7
Due to hazardous voltages on adjacent modules, and the possibility of physical contact, authorised personnel only should access and maintain the module in situ.
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5.1.2

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 DCBs front panel, and its components are described below. 1. Module identification number. Determined by the protocol firmware installed (refer to Table 3). 2. Run (Green) or Fail (Red) indicator. 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. Channel activity indicators.
RTS TXD DCD RXD
Request To Send means the carrier has been turned on. Transmit Data means that a Space is being transmitted. Data Carrier Detect means that the carrier is being received. 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.
Contact rating
1 Amp at 30 Vdc maximum 10A at 10mV minimum
Radio key use, and turn on parameters, are set using the System Configurator [1].
Figure 8
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5. Communication line terminals.
Transmit Tx/Rx 600R 2W 4W 4W Rx 600R 2kV rms isolation 600R LOZ Link Receive
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 Channel 2 LK5
1 2 3
Configuration 4 wire mode (default setting) 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 Channel 2 LK5 Configuration 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.
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5.1.3

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 DCBs front panel, and its components are described below. 1. Module identification number. Determined by the protocol firmware installed (refer to Table 3). 2. Run (Green) or Fail (Red) indication. For normal running conditions 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.
Pin 1 2 Function (per ISO 4903) Connected to Frame Transmit data VA Transmit data VB Request to send VA Request to send VB Transmit clock VA Transmit clock VB Signal ground Receive clock VA Receive clock VB Receive data VA Receive data VB Data carrier detect VA Data carrier detect VB reserved connected to chassis Direction Output Output Output Output Output Output Input Input Input Input Input Input -
V.11/RS485 Voltage signal DB15 Male Connector
9 3 10 7 14 8 6 13 4 11 5 12 15 Frame
Figure 9
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 of physical contact, authorised personnel only should access and maintain the module in situ.
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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 DCBs front panel, and its components are described below. 1. Module identification number. Determined by the protocol firmware installed (refer to Table 3). 2. Run (Green) or Fail (Red) indication. For normal running conditions the indicator will be green. At reset of the RTU the indicator will be red until the module has correctly initialised. 3. Channel activity indicators.
TXD RXD
Data being transmitted 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 50/125m or 62.5/125m multimode cable, up to 2000m in length, can be used. 5. Due to hazardous voltages on adjacent modules, and the possibility of physical contact, authorised personnel only should access and maintain the module in situ.
Figure 10
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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 Configurations
RS-232 Configurable
1 to 4 5 to 8
1500 Vrms nil
<= 38,400 <= 38,400
2 wire 2 or 4 wire
no yes
Figure 11 shows the Eight Channel Communications Modules (part number 0399132) front panel, and its components are described below.
1. Channel activity indicators.
TX RX
Data being transmitted Data being received
Figure 11
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2. Isolated RS-485 Channels 1 to 4. 8 Terminal Connector (Removable)

Terminal Function Direction
1 2 3 4 5 6 7 8
Transmit/Receive data on VB Transmit/Receive data on VA Signal Ground Chassis connected to SCD5200 Frame Chassis connected to SCD5200 Frame Signal Ground Transmit/Receive data on VA Transmit/Receive data on VB
In/Out In/Out In/Out 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 LK2 LK3 LK4
Channel 1 Channel 2 Channel 3 Channel 4
Typical terminations to the RS-485 connector.

LINK Isolation Barrier 120R B A GND 2 WIRE 120R
100R
RTU Chassis
120R
Isolated
LINK Isolation Barrier 120R B A GND
3 WIRE
120R
Optional connection
100R
RTU Chassis
Isolated
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3. Run (Green) or Fail (Red) indication. For normal running conditions the indicator will be green. At reset of the 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 LK6 LK7 LK8
Channel 5 Channel 6 Channel 7 Channel 8

RS232/RS485 DB9 Male Connector
Channel in RS-232 mode (Default setting)

1 2 3 4 5 6 7 8 9 Frame
Data Carrier Detect Receive Data Transmit Data Data Terminal Ready Signal Ground Data Set Ready Request to Send Clear to Send Ring Indicate Connected to Chassis of SCD5200
DCD RXD TXD DTR
DSR RTS CTS RI
Input Output Input Input -
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Channel in RS-485 4 wire mode.

1 8 2 4 5 6 3 7 9 Frame
Connected to an RS-232 input RS-485 VA Receive signal RS-485 VB Receive signal Connected to an RS-232 output Signal ground Connected to an RS-232 input RS-485 VA transmit signal RS-485 VB transmit signal Connected to an RS-232 input Connected to Chassis of SCD5200
Channel in RS-485 2 wire mode.

Pin 1 3 7 4 5 6 2 8 9 Frame Function Connected to an RS-232 input RS-485 VA Transmit/Receive signal RS-485 VB Transmit/Receive signal Connected to an RS-232 output Signal ground Connected to an RS-232 input Connected to a disabled input Connected to a disabled input Connected to an RS-232 input Connected to Chassis of SCD5200 Direction Input/Output Input/Output -
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. 5. Due to hazardous voltages on adjacent modules, and the possibility of physical contact, authorised personnel only should access and maintain the module in situ.
6. Part identification number (0399132).
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6 Input/Output Modules
6.
Module
Input/Output Modules
Function, Capacity, and Operating Voltage Isolation Voltage (rms)
An Input/Output module is identified by I/O function and capacity, operating voltage, and isolation voltage; as shown in Table 4 below. Analog and Digital Input Modules (32DI / 4AI) 32 Digital Input (24V) / 4 Analog Input 32 Digital Input (48V) / 4 Analog Input 32 Digital Input (129V) / 4 Analog Input 32 Digital Input (24V) / 4 Analog (1 kV) Input 32 Digital Input (48V) / 4 Analog (1 kV) Input 32 Digital Input (129V) / 4 Analog (1 kV) Input Analog Input Modules (20 AI) 20 Analog Input 20 Analog Input (1 kV isolation) Analog Output Module (4 AO) 4 Analog Output Digital (Relay) Output Modules (12 DO, 8DO) 12 Pilot Relay Output 12 Magnetically Latched Relay Output 8 x 10 Amp Relay Output
0399090 0399091 0399092 0399081 0399082 0399083
2 kV digital / nil analog 2 kV digital / nil analog 2 kV digital / nil analog 2 kV digital / 1 kV analog 2 kV digital / 1 kV analog 2 kV digital / 1 kV analog
0399093 0399085
nil analog 1 kV analog
0399084
50 Vdc analog
0399086 0399087 0399136
2 kV output 2 kV output 2 kV output
Multi Input/Output Modules (24DI / 6AI / 6DO, 24DI / 6AI / 8 DO) 0399089 0399096 0399097 0399088 0399094 0399095 24 Digital Input (24V) / 6 Analog Input / 6 Pilot Relay Output 24 Digital Input (48V) / 6 Analog Input / 6 Pilot Relay Output 24 Digital Input (129V) / 6 Analog Input / 6 Pilot Relay Output 24 Digital Input (24V) / 6 Analog Input / 8 Mini-Pilot Relay Output 24 Digital Input (48V) / 6 Analog Input / 8 Mini-Pilot Relay Output 24 Digital Input (129V) / 6 Analog Input / 8 Mini-Pilot Relay Output 2 kV digital / nil analog / 2 kV output 2 kV digital / nil analog / 2 kV output 2 kV digital / nil analog / 2 kV output 2 kV digital / nil analog / 2 kV output 2 kV digital / nil analog / 2 kV output 2 kV digital / nil analog / 2 kV output
Table 4. Input/Output Modules

Page 31 of 66
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.
Page 32 of 66
F C
90
To open door: apply force (at F), outwards at top and bottom as required, and unlatch door clips (indicated by C), one at a time, by applying a sideways force on each clip using a screwdriver.
To remove door: open the door to 90o and pull outwards. The three retaining hinges will unclip.
Insert in the window above the clamp.
6. Removable screw termination blocks. A removable screw termination block is shown in Figure 12. Once the door 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 SZS 0.4 x 2.5. Do not use an oversized screwdriver as damage may result. 7. Cable tie facility (2). 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.
Do not insert in the window below the clamp.
Figure 12
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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 live voltages may be present on the terminations, such that the rear of the termination assembly is energised.
CAUTION: Avoid contact with the rear of adjacent modules.
Page 34 of 66
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 77 to 164V, nominal 129V 5 mA at 24V 5 mA at 48V 4 mA at 129V 2 milliseconds debounce 2kVrms / 1 minute
Input current
ON/OFF time Common mode withstand
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 + 4000 counts (+ 4095 overrange) + 0.25 % (over temp and maxV common mode) + 0.1 % (25oC and 0V common mode) 80 dB to 6V peak (non-isolated inputs) 120 dB to 1 kVrms (isolated inputs) 60 dB at 60 Hz 50V peak (non-isolated inputs) 1 kVrms (isolated inputs) 400 milliseconds (non-isolated inputs) 600 milliseconds (isolated inputs)
Conversion range Overall accuracy Common mode rejection Differential mode rejection Common mode withstand (channel to chassis and channel to channel) Input update time (maximum data age)
Figure 13
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Terminal Board IN
Common
4 groups of 8 Inputs each share a Common
Digital Input
Terminal Board IN + R1 IN
Filter
MUX
1 AMP 2
R1 Channel 1 R2 Channel 2 R3 Channel 3 R4 Channel 4
3 4
Non-isolated Analog Input
Filter
ADC
R1 Channel 1 R2 Channel 2 R3 Channel 3 R4 Channel 4
1kV isolated Analog Input (single isolated channel shown)
Refer to Appendix E for scaling and calibration of Analog Input assemblies.
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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.
Analog Input Parameters
Value
Input range
+ 2V (+ 2.048V overrange) 0-20mA using a 100 resistor + 10mA using a 200 resistor
Conversion range Overall accuracy
+ 4000 counts (+ 4095 overrange) + 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 Common mode withstand (channel to chassis and channel to channel) Input update time (maximum data age)
60 dB at 60 Hz 50V peak (non-isolated input) 1kVrms (isolated input) 65 milliseconds (non-isolated input) 600 milliseconds (isolated input)
Figure 14
Page 37 of 66
Filter
MUX
1 AMP 2 ADC
R1 Channel 1 R2 Channel 2 R20 Channel 20
20
Filter
ADC
R1 Channel 1 R2 Channel 2 R20 Channel 20
Isolated Analog Input
Refer to Appendix E for scaling and calibration of analog input assemblies.
Page 38 of 66
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 0-600 ohms 19-36V (nominal 24V) 40mA maximum/channel +0.1% at 25oC +0.25% over temp +0.5% over temp < 100 milliseconds / channel Yes per channel Yes per channel 50V dc or peak ac.
Loop resistance External loop power Accuracy 4-20mA Accuracy 0-10, 16mA Output update rate External power fail detection Loop open detection Common mode withstand (channel to channel and channel to chassis)
Terminal Board 24V (+) 24V (<40mA) Power Supply 24V ()
Loop Open Power OK
I+ LOAD ( 600R) I
Clock
DAC
Data
Latch
Offset Link
Figure 15 Refer to Appendix E for scaling and calibration of analog output assemblies.
Page 39 of 66
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
1, 2
A.C. contact rating
5A 250Vac cos = 0.4 (30,000 operations) 5A 30 Vdc, 1A 50Vdc L/R 40ms (30,000 operations) 200mA 129Vdc L/R 40ms (30,000 operations) 10mA@10V (not previously having switched heavy loads) approx. 5 milliseconds approx. 3 milliseconds 2kVac rms / 1 minute 27mA nominal
D.C contact rating 1, 2
Minimum switching load Relay on delay Relay off delay Common mode withstand (contact to contact and contact to chassis) Relay coil current 3
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. 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.
2.
Relay contact to be protected on Output module
Inductive load (interposing relay or contactors in the field)
Figure 16
Diode reverse breakdown voltage 3 x V, for example 1N5404 Varistor working voltage rating 1.2 x maximum Vac rms
3.
Where many relays are to be simultaneously operated, consider the
Page 40 of 66
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.
Page 41 of 66
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 described in the table below.
Relay Output Parameters
Value
A.C. contact rating
10A 130 Vac cos = 0.4 (30,000 operations) 10A 150 Vdc resistive (30,000 operations) 5A 150 Vdc L/R 40ms (30,000 operations) approx. 14 milliseconds approx. 5 milliseconds 2kVac rms / 1 minute 67mA nominal on +15V 12 to 22 AWG 8 mm
D.C. contact rating 1,2
Relay on delay Relay off delay Common mode withstand (contact to output and output to chassis) One output circuit coil load Terminal wire range Wire strip length
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. 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. 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.
2.
3.
Figure 17
Page 42 of 66
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 36 to 64V, nominal 48V 77 to 164V, nominal 129V 5mA at 24V 5mA at 48V 4mA at 129V 2 milliseconds debounce 2kVrms / 1 minute
Input current
On/Off time Common mode withstand
The analog input parameters and their permissible values are described in the table below.
Analog Input Parameters Value
Input range
+2V (+2.048V overrange) 0-20mA using a 100 resistor +10mA using a 200 resistor +4000 counts (+4095 overrange) +0.25% (over temp and maxV common mode) +0.1% (25oC and 0V common mode) 80dB at 6V peak 60dB at 60Hz 50V peak
Conversion range Overall accuracy
Common mode rejection Differential mode rejection Common mode withstand (channel to chassis and channel to channel) Input update time (maximum data age)
600 milliseconds
Figure 18
Page 43 of 66
Terminal Board IN
Common
2 groups of 12 Inputs each share the two Commons which are connected.
Digital Input
Filter
MUX
1 AMP 2 3 ADC
R1 Channel 1 R2 Channel 2 R3 Channel 3 R4 Channel 4 R5 Channel 5 R6 Channel 6
4 5 6
Refer to Appendix E for scaling and calibration of analog input assemblies.
Figure 19
Page 44 of 66
The 6 paired Pilot Relay Output parameters and their permissible values are described in the table below.
6 paired Pilot Relay Output Parameters Value
A.C. contact rating 1,2 D.C. contact rating 1,2
5A 250Vac cos = 0.4 (30,000 operations) 5A 30Vdc, 0.5A 50Vdc L/R 40ms (30,000 operations) 100mA 129Vdc L/R 40ms (30,000 operations) 10mA@10V (not previously having switched heavy loads) approximately 10 milliseconds approximately 5 milliseconds 2kVac rms / 1 minute
Minimum switching load Relay on delay Relay off delay Common mode withstand (contact to contact and contact to chassis) Relay coil current 3
18mA nominal
The 8 mini-pilot Relay Output parameters and their permissible values are described in the table below.
8 mini-pilot Relay Output Parameters Value
A.C. contact rating 1, 2 D.C. contact rating 1, 2
0.5A 125Vac cos = 0.4 (30,000 operations) 0.5A 30Vdc, 0.25A 50Vdc L/R 40ms (30,000 operations) 50mA 129Vdc L/R 40ms (30,000 operations) 10A@20mV approximately 4 milliseconds 2000Vac rms / 1 minute 18mA nominal
Minimum switching load Relay on/off delay Common mode withstand (contact to chassis only) Relay coil current 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.
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1.
A pair of pilot relays share a single common, but the eight minipilot 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. 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. The 18mA per relay load permits up to 50 relays to be held simultaneously, using the COPE +15V power output rated at 1Amp.
2.
3.
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.
Terminal Board
Relay 1 Relay 2 Relay 3 Relay 4
K1
K2
K3
4 Relay 10A output DIN Rail mount assembly 1025019

+15V Control Voltage +15V Return 1.25A
K4
The 1.25A fuse F1 is located on the rear of the terminal assembly (type F 20 x 5mm quick blow).
Only use the +15V control voltage for local energisation of external interposing relays. Local means within the same or adjacent cubicles within an installation.
Page 46 of 66
7 Power Supply Connection and Disconnection
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.
Page 47 of 66
8 Installation, Grounding, and Wiring Guidelines
8.
8.1
Installation, Grounding, and Wiring Guidelines

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 30mm.
Ten I/O Slot rear mount pattern.
Page 48 of 66
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
Page 49 of 66
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).
Page 50 of 66
8.4
Terminal pitch
I/O Wiring Guidelines (3.5mm terminals)

3.5mm
3.5mm
Solid conductor size Stranded conductor size Stranded with ferrule (with plastic collar) Stranded with ferrule (without plastic collar) Multiple (2) solid conductor Multiple (2) stranded conductor Multiple (2) stranded with TWIN ferrules (with plastic collar) Multiple (2) stranded with ferrules (without plastic collar) Stripping length Screw torque Screwdriver size Cable tie width through termination assembly base side wall Maximum wire size for a bundle of 50 wires inside one closed termination assembly
0.14 1.5mm2 (28-16 AWG) 0.14 1.5mm2 (28-16 AWG) 0.25 0.5mm2 0.25 1.5mm2 0.14 0.5mm2 0.14 0.75mm2 0.5mm2 0.25 0.34mm2 7mm 0.22 0.25Nm 0.4 mm x 2.5 mm up to 3.5mm 0.5mm2
50 x 0.5mm2 (AWG 20) Shielded drain wire termination To signal earth bar at enclosure entry point
Card File
Drain Wire shortest length possible
Earth Bar
Closest to entry point as possible
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.
Page 51 of 66
9 Preventative Maintenance and Inspection
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 inserted fully, and that the four captive screws (indicated by 1 in the above figure) that fix the module to the file frame are tight. 3. 4.
2. That the earth wire is tightly attached to the earth stud on the side of the file (indicated by 2 in the figure above), and that the cubicle earth termination is secure.
That accumulations of dust and soot be removed so that electrical safety clearances are not jeopardised. That on routine maintenance these items are checked as a matter of course, on completion of the maintenance.
Page 52 of 66
10 File, Backplane Slot Identification, and SYSFAIL Alarm
10.
File, Backplane Slot Identification, and SYSFAIL Alarm

Part Number File Assembly
2003098 2003100 2003104
Ten I/O Slot Card File (Fully covered for CE compliance) Five I/O Slot Card File (Fully covered for CE compliance) One I/O Slot Card File (Fully covered for CE compliance)
Slot identification is shown in Figures 20, 21, and 22.
10
11
12
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.
Page 53 of 66
10 File, Backplane Slot Identification, and SYSFAIL 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.
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11 Appendices
11.
Appendices
Appendix A Definitions and Abbreviations
The following terms and acronyms are defined here within the context of this document.
TERM A AC AI AO AWG C CE COPE CPU CTS dB DC DCB DCD DI DNP3 DO DSR DTR EMC ESD HLSI Hz IED I/O LED LS MS NC RI rms RTS RTV RX RXCLK RXD SCADA SCD SCD5200 TX TXCLK TXD V W DEFINITION Amps Alternating Current Analog Input Analog Output American Wire Gauge Common Compliance Europe CPU, OptoNet, Power Supply and Ethernet combined board for the SCD5200 Central Processing Unit Clear To Send decibel Direct Current Dual Communications Board Data Carrier Detect Digital Input Distributed Network Protocol V3.0 Digital Output Data Set Ready Data Terminal Ready Electro Magnetic Compatibility Electro Static Discharge High Level Serial Interface Hertz Intelligent Electronic Device Input/Output Light Emitting Diode Least Significant Most Significant Normally Closed Ring Indicate Root Mean Square Request To Send Remote Terminal Viewer Receive Receive Clock Receive Data Supervisory Control And Data Acquisition Station Computing Device Foxboro Australias Station Computing Device product Transmit Transmit Clock Transmit Data Volt Watt
Page 55 of 66
11 Appendices
Appendix B
[1]
Referenced Documents
System Configurator User Manual for the RTU50 and SCD5200 Foxboro Australia Document No. 2005663 SALL High Level Serial Interface User Manual for the RTU50, RTU10, SCD5200 and CLS Foxboro Australia Document No. 2005167 Remote Terminal Viewer Software Release Note Foxboro Australia Document No. 1101192-RN 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 Telecommunications Labelling (Customer Equipment and Customer Labelling) Notice 2001 as amended.
[2]
[3]
[4]
[5]
Page 56 of 66
11 Appendices
Appendix C
Part Number 0399131 0399129 0399132 0399111 0399112 0399119 0399120 0399121 0399122 0399126 0399127 0399090 0399091 0399092 0399081 0399082 0399083 0399093 0399085 0399084 0399086 0399087 0399136 0399089 0399096 0399097 0399088 0399094 0399095 2003098 2003100 2003104 0399134 0399138
Summary of Part Numbers

Module or Assembly 100W Power Supply Module CPU/OptoNet/Power Supply/Ethernet Module (COPE) 8 Channel Serial Module RS-485 / RS-232 Dual Communications Module V.23 Conitel/Baker/C300 Dual Communications Module V.28 Conitel/Baker/C300 Dual Communications Module V.23 DNP3 Dual Communications Module V.28 DNP3 Dual Communications Module V.11 DNP3 Dual Communications Module Optical DNP3 Dual Communications Module V.28 IEC 60870-5-101 Dual Communications Module Optical IEC 60870-5-103 32 Digital Input (24V)/4 Analog Input (non-isolated) Module 32 Digital Input (48V)/4 Analog Input (non-isolated) Module 32 Digital Input (129V)/4 Analog Input (non-isolated) Module 32 Digital Input (24V)/4 Analog Input (1kV isolated) Module 32 Digital Input (48V)/4 Analog Input (1kV isolated) Module 32 Digital Input (129V)/4 Analog Input (1kV isolated) Module 20 Analog Input (non-isolated) Module 20 Analog Input (1kV isolated) Module 4 Analog Output Module 12 Digital (Relay) Output Module 12 Magnetically Latched Relay Output Module 8 x 10 Amp Digital (Relay) Output Module 24 Digital Input (24V)/6 Analog Input/6 Pilot Relay Output Module 24 Digital Input (48V)/6 Analog Input/6 Pilot Relay Output Module 24 Digital Input (129V)/6 Analog Input/6 Pilot Relay Output Module 24 Digital Input (24V)/6 Analog Input/8 Mini-Pilot Relay Output Module 24 Digital Input (48V)/6 Analog Input/8 Mini-Pilot Relay Output Module 24 Digital Input (129V)/6 Analog Input/8 Mini-Pilot Relay Output Module Ten I/O slot card file (CE compliant) Five I/O slot card file (CE compliant) One I/O slot card file (CE compliant) 35mm Blanking Panel (CE compliant) 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.
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11 Appendices
Appendix D
Temperature Humidity Vibration Shock Voltage withstand Fast Transients Lightning Impulse Ripple and D.C.
Environmental Specification
-40 to +70 oC 10 to 95% RH (non-condensing) 10 Hz to 57 Hz 0.075mm 57 Hz to 150 Hz 1.0g 15G 3 times (X,Y,Z directions) 2kVac rms 50Hz EN 60255-5 Level 3 2kV EN 61000-4-4 Level 3 2kV EN 61000-4-5 Level 3 5kV EN 60255-5 Level X 15% EN 61000-4-17 Level 3 2.5kV EN 60255-22-1 Level 3 10V/m EN 61000-4-3 Level 3 10V EN 61000-4-6 Level 3 8kV EN 61000-4-2 300 A/m EN 61000-4-8
High Freq. disturbance RF Immunity (Radiated) RF Immunity (Conducted) ESD Magnetic Field (50Hz)
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11 Appendices
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 VR4 VR1 VR2
Adjust channel 1 transmit level Adjust channel 1 receive level Adjust channel 2 transmit level 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).
DCB
Transmit continuous 1300Hz MARK
Tx 10dBm 536R
Set Link to 600R Receive
536R 68R
Rx 35dBm
Using a 25dBm attenuator to adjust receive.
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11 Appendices
Calibration of the Analog Input Modules 32DI/4AI Module

Steps: 1. Permit warm up for one minute. 2. Adjust RV1 to measure 1.00000 +10V across TP1 and TP2. (This will achieve calibration within specification.) 3. Even more accurate calibration may be achieved. Connect a precision 2.00000 +10V 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 +10V 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 +10V voltage source, connect to channel 1 analog input. 6. Using the RTV display calibrate for full scale. 7. Confirm on the RTV display that calibration is good (G).
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11 Appendices
8. Remove link X5/8-10.
20 Channel AI Module
Steps: 1. Permit warm up for 1 minute. 2. Adjust VR1 to measure 1.00000 +10V across TP1 and TP2. (This will achieve calibration within specification.) 3. Even more accurate calibration may be achieved. Connect a precision 2.00000 +10V 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: 1. Permit warm up for 1 minute. 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 +10V voltage source connect to a group of inputs, 4 channels at once. 7. Using the RTV display calibrate for full scale. 8. Repeat for the other groups. 9. Confirm on the RTV display that all channel calibrations are good (G). 10. Remove link LK2.
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11 Appendices
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 output in counts
Analog output current range
Number of output steps actually available
0 4000 800 4000 0 4000 0 4000 0 2000 400 2000 0 2000 0 2000
4 20mA 4 20mA 0 10mA 0 16mA 4 20mA 4 20mA 0 10mA 0 16mA
4000 3200(2) 2560(1) 4000 2000 1600(2) 1280(1) 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 (+10A).
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11 Appendices
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 nonisolated cabinet earth bar as illustrated.
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11 Appendices
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.
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11 Appendices
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 Foxboros 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) b) c) you have the written consent of the network or facility manager; or the connection is in accordance with a connection permit issued for this item; or 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.
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11 Appendices
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) 00 C1 C2 C3 C6 C7 C8 C9 1A 0B 1E 3A 42 5E 60 66 10 20 0C 0D 0E 87 90A0 B0 00FF Description Reset, test registers, configure address decodes Identify board as COPE type 2 (AMD SC520) Configure SDRAM controller FAR jump to clear descriptor cache Configure PCI Host Bridge and Ethernet controllers Configure UART Configure Interrupt Controller (PIC) Pre-cache test code CRC check bootstrap code CRC check main firmware code Base 64KB memory test 1 (basic pattern test) Base 64KB memory test 2 (bit tests) Initialise real-mode interrupt vectors Protected mode test 1 PM Base memory test (960KB) PM Extended memory test (beyond 1MB) PM Memory Test readback failure PM Memory Scan readback failure Protected mode test 2 Copy high ROM to RAM CRC test code in RAM Power-on tests complete. Begin C50 bootstrap Protected Mode fault vectors 00...10 Real-mode unexpected interrupt (unknown) Real-mode unexpected interrupt (code = vector number)
Always include error codes in incident reports.
Page 66 of 66

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Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

Document Revision History:

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662- Rev. 1.2

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

8.1 8.2 8.3 8.4 9. 10. 11.

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

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

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

Definitions and Abbreviations

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

2 File and Module Arrangement

File and Module Arrangement

10 I/O SLOT FILE 19" Rack

Figure 1. Ten I/O Slot File

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

2 File and Module Arrangement

5 I/O SLOT FILE Half 19" Rack

Figure 2. Five I/O Slot File

1 I/O SLOT FILE 1/6 of 19" Rack

Communication or I/O Module Power Supply/CPU/Etherent/Optonet Module in first slot

Figure 3. One I/O Slot File

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

3 100 Watt Power Supply Module

100 Watt Power Supply Module

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

3 100 Watt Power Supply Module

Power Supply Voltage

Efficiency Output loading

Input current Isolation Shorted input hold up time

Open input hold up time On board Fuse

20 milliseconds 10A / 250V Type T 20 x 5mm

Table 1. 100 Watt Power Supply Module Specification

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

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

CPU / OptoNet / Power Supply / Ethernet Module (COPE)

0399129 includes power supply

CPU / OptoNet / Power Supply / Ethernet functions in a 35mm module.

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

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

RUN ON FAIL OFF

RUN OFF FAIL ON

I/A Series Intelligent SCADA System

Hardware User Manual for the SCD5200 2005662 - Rev. 1.2

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

Reset the SCD5200.