Control Microsystems 5604 Hardware Manual

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5604 Input/Output (I/O) Module

Hardware Manual

CONTROL MICROSYSTEMS

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5604 Input/Output (I/O) Module - Hardware Manual

Trademarks

TeleSAFE, TelePACE, SmartWIRE, SCADAPack, TeleSAFE Micro16 and TeleBUS are registered trademarks of Control Microsystems Inc.

All other product names are copyright and registered trademarks or trade names of their respective owners.

Material used in the User and Reference manual section titled SCADAServer OLE Automation Reference is distributed under license from the OPC Foundation.

5604 Input/Output (I/O) Module - Hardware Manual October 19, 2007

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Table of Contents

1 OVERVIEW .................................................................................................... 5

2 IMPORTANT SAFETY INFORMATION ......................................................... 6

3 FIELD WIRING CONNECTORS .................................................................... 7

4 POWER SUPPLY .......................................................................................... 8

4.1 Overview and Requirements..................................................................... 8

4.2 Power Supply Input Connections .............................................................. 8

4.2.1 Recommended AC Power Supply Configuration ................................. 9

4.2.2 Recommended 24V Power Supply Configuration ............................. 10

4.2.3 Recommended Battery Configuration ............................................... 11

4.2.4 Recommended 5103 Power Supply Configuration............................ 12

4.3 System Grounding .................................................................................. 13

4.4 Power Management Features ................................................................ 13

4.4.1 DC/DC Converter Control .................................................................. 13

4.4.2 VLoop Power Control ........................................................................ 14

4.4.3 VLoop Over-Current Protection ......................................................... 14

5 ANALOG INPUTS ........................................................................................ 15

5.1 Current or Voltage Mode ........................................................................ 15

5.2 Range and Resolution ............................................................................ 16

5.3 Wiring ..................................................................................................... 17

5.3.1 Wiring Examples ............................................................................... 17

5.4 Filtering and Response Timing ............................................................... 18

6 ANALOG OUTPUTS .................................................................................... 19

6.1 Current Outputs ...................................................................................... 19

6.2 Voltage Outputs ...................................................................................... 20

6.3 Range and Resolution ............................................................................ 20

7 DIGITAL I/O ................................................................................................. 21

7.1 Digital Inputs ........................................................................................... 21

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7.2 Digital Outputs ........................................................................................ 21

7.3 Internal DIO ............................................................................................ 21

7.4 Wiring Examples ..................................................................................... 23

8 SERIAL COMMUNICATION ........................................................................ 24

8.1 COM3 RS-232 Serial Port ...................................................................... 24

8.2 RJ-45 Modular Connector for RS-232 .................................................... 24

8.3 RS-232 Wiring Examples ....................................................................... 25

8.4 RS-232 Cables ....................................................................................... 25

8.4.1 RJ-45 to DE-9S DTE ......................................................................... 25

8.4.2 RJ-45 to DE-9P DCE ......................................................................... 27

9 OPERATION ................................................................................................ 28

9.1 LED Indicators ........................................................................................ 28

10 SPECIFICATIONS ....................................................................................... 29

10.1 General ................................................................ ................................... 29

10.2 Communications ..................................................................................... 29

10.3 Visual Indicators ..................................................................................... 30

10.4 Power Supply .......................................................................................... 30

10.5 Analog Inputs .......................................................................................... 30

10.5.1 Inputs 0-7 .......................................................................................... 30

10.5.2 Input 8 ............................................................................................... 31

10.6 Analog Outputs ....................................................................................... 31

10.7 Digital Inputs ........................................................................................... 32

10.8 Digital Outputs ........................................................................................ 33

11 APPROVALS AND CERTIFICATIONS ....................................................... 34

Index of Figures

Figure 1: 5604 I/O Module Layout ...................................................................................... 7

Figure 2: Recommended AC Power Supply Configuration ................................................. 9

Figure 3: Recommended 24V Power Supply Configuration...............................................10

Figure 4: Recommended Battery Configuration ................................................................11

Figure 5: Recommended 5103 Power Supply Configuration .............................................12

Figure 6: Power Management ...........................................................................................13

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Figure 7: Analog Input Mode Settings ...............................................................................16

Figure 8: Analog Input Wiring ...........................................................................................18

Figure 9: Analog Output Wiring .........................................................................................19

Figure 10: Digital Input/ Output Wiring ................................ ..............................................23

Figure 11: Front View of an RJ-45 Connector ...................................................................25

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1 Overview

The 5604 I/O module is an integrated component of a SCADAPack Series controller and not available as a standalone unit. The following controllers support the 5604 I/O module:

 SCADAPack P1A - A 520x controller board with an integrated 5604 I/O Module.  SCADAPack P4A - A 5232 controller board with an integrated 5604 I/O module.

The 5604 I/O module increases the I/O and communication capacity of a SCADAPack controller by providing 9 single ended analog inputs, 32 digital inputs/outputs, two analog outputs (optional) and one RS-232 serial communication port. This I/O module also has a 12V to 24V boost converter power supply capable of generating 24V at 0.25A for up to twelve 20mA transmitters or loads. Note that this I/O module is not available as a standalone unit.

The analog inputs can be configured for current or voltage mode with a measurement ranges of 020mA or 0-10V respectively. Analog inputs can also be configured with a 20% offset in the measuring range. In current mode, a 250 current sense resistor appears across each analog input channel. The 250 resistor produces a voltage drop of 5V for a 20mA of current flow. All analog input channels are transient protected, optically isolated from the main logic supply and share a common return (COM) that is connected to the chassis.

This I/O module uses a 16-bit successive approximation A/D converter and provides 15 bit resolution over the range of the analog input. Analog Input 8 is a 0 to 32.768-volt input that measures with 10-bit resolution and can be used to monitor a power supply or battery voltage. There is one internal analog input that is used in application programs to monitor the DC/DC converter voltage used for VLOOP.

The 5604 I/O module can be equipped with an optional 5305 Analog Output Module that provides two 20mA outputs through a 12-bit D/A converter. The analog outputs are transient and over voltage protected. The output channels share a common return (GND) and with the analog input channels.

32 universal digital inputs/outputs are provided onboard this I/O module. Each digital I/O point can be used as an input or an output only. The inputs can be used to monitor the status of that output. In addition to the 32 universal digital input/outputs there are 3 internal digital inputs and 2 internal digital outputs that are used to monitor and control a DC/DC converter or VLOOP power supply as well as to monitor digital output mismatch status.

The inputs are intended for use with dry contacts such as switches, open collector transistors and relay contacts. Wetting current for the contacts is provided. All GND terminals on the I/O module are connected internally to the SCADAPack chassis.

Outputs are open-collector/open drain type for use with sustained DC loads of up to 1 ampere. Loads with high in-rush currents may exceed the 1A rating. The output circuit will tolerate these higher peak currents. Inductive load transient suppression is built into each digital output point. It is not necessary to add additional inductive load transient suppression unless highly inductive loads (greater than 1H) are operated continuously at greater than 0.5Hz.

Note: This manual covers the powering, wiring and configuration of a 5604 I/O module only. It is

meant to be used with the hardware manual of the respective controller board to which the I/O module is attached.

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2 Important Safety Information

WARNING !

EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2.

WARNING !

EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES.

WARNING !

EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS.

Power, input and output (i/o) wiring must be in accordance with Class I, Division 2 wiring methods Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in accordance with the authority having jurisdiction.

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3 Field Wiring Connectors

Digital I/O 24-31

Connector (P6)

Digital I/O 16-23

Connector (P7)

Digital I/O 8-15 Connector (P8)

Digital I/O 0-7

Connector (P9)

Power – Analog Out

Connector (P3)

Analog Inputs

Connector (P4)

RS-232 COM3

Connector (P5)

The 5604 I/O modules use screw termination style connectors for termination of field wiring. These connectors accommodate solid or stranded wires from 12 to 22 AWG.

CAUTION: Remove power before servicing unit. The 5604 I/O module has seven connectors for field wiring. Refer to Figure 1: 5604 I/O Module

Layout for connector locations.

 Primary power input connections, VLOOP output power connection and optional analog output

connections are wired to a six-pole connector labeled P3. Refer to section 4-Power Supply for details on wiring the power supply.

 The nine analog inputs are wired to a ten-pole connector labeled P4. Refer to section 5-Analog

Inputs for details on wiring analog input signals.

 The digital inputs and outputs are wired to four ten-pole connectors labeled P6, P7, P8 and P9.

Refer to section 7-Digital I/O for details on wiring digital input/output signals.

 The 5604 I/O Module has one RS-232 serial communication port that is wired to a black 8 pin

modular RJ-45 connector labeled P5. Refer to section 8-Serial Communication for details.

Figure 1: 5604 I/O Module Layout

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4 Power Supply

4.1 Overview and Requirements

The 5604 I/O module requires 11-24Vdc applied to the AC/DC PWR IN terminals on connector P3 of the I/O board to power the analog input and optional analog output circuitry.

The current requirement of the analog portion (input and optional output circuitry) on the 5604 I/O board can vary from a minimum of 10mA for basic operation of the analog circuitry to a maximum of 550mA if all analog inputs, optional analog outputs and the 24V boost converter requires full power to provide 6W (250mA @24V) of power.

The user has three options to supply 11-24V to the I/O board as outlined below but should thoroughly examine the application and supply the 5604 I/O Module with a suitable power source.

Note: Voltage referred to as Vrms (or VAC on some products) indicates AC power. Voltage

referred to as V indicates DC power.

4.2 Power Supply Input Connections

Power to DC PWR on the I/O board can be provided in several ways:

 With a 16Vac source supplying power to the controller board, 24V is available on the DC PWR

terminals on connector P5 of the controller board which can be used to power the lower I/O model. See the section 4.2.1-Recommended AC Power Supply Configuration for details.

 A 24Vdc source connected to the DC PWR terminals on the controller board and on the 5604

I/O module in a parallel configuration. See section 4.2.2-Recommended 24V Power Supply Configuration for details.

 With a 12Vdc source connected to the DC PWR terminals on the controller board and on the

5604 I/O module in a parallel configuration. See section 4.2.3-Recommended Battery Configuration for a wiring example.

 A 5103 UPS Power Supply supplies 5Vdc to the controller board through the IMC cable and

supplies 24Vdc to the 5604 I/O module through the 24Vdc output. See section 4.2.4Recommended 5103 Power Supply Configuration for an example of using the 5103 UPS Power

Supply.

CAUTION: Power can be applied to either the AC/DC power input OR the DC power input.

DO NOT apply power to both inputs. Damage to the power supply may result.

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4.2.1 Recommended AC Power Supply Configuration

120

Vrms

Class 2

Transformer

AC/DC

PWR IN

DC PWR

+ –

1 2 3 4 5

Controller Board

5604 I/O Module

DC PWR

+ –

1 2 3 4 5

AOUT

0 1 COM

Vloop +

Controller DC output

boosted to 24V

This configuration uses a single Class 2 16vac transformer to power the controller board and the 5604 I/O Module. 24V is available on the controller module connector P3. This is used to power the analog circuitry for the analog input and output circuits on the 5604 I/O module.

Notes on this configuration:

 The 24V-boosted output (VLOOP) can be switched on and off under the control of the

application program to save power to any loads connected to VLOOP.

 The DC output of the controller board is unregulated and can be boosted to a stable 24Vdc on

the 5604 I/O Module under the control of the application program.

 Only a limited amount of power is available from the controller. This configuration is not

recommended when a large amount of current is required at 24V.

 The Controller Board DC Power terminal must be connected to the same power supply as the

5604 I/O Module DC Power terminals.

Figure 2: Recommended AC Power Supply Configuration

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4.2.2 Recommended 24V Power Supply Configuration

24Vdc Power

Supply

–

5604 I/O Module

DC PWR

+ –

1 2 3 4 5

AOUT

0 1 COM

Vloop +

AC/DC

PWR IN

DC PWR

+ –

1 2 3 4 5

Controller Board

24V switched

This configuration uses a 24V power supply to power the controller board and the 5604 I/O module. This 24V is used to power the analog circuitry for the analog inputs and output circuits on the 5604 I/O module.

Notes on this configuration:

 The 24V output (VLOOP) can be switched on and off under the control of the application

program to save power to any loads connected to VLOOP.

 It is unnecessary to boost the 24V power in the 5604 I/O Module. The 24V output (VLOOP) on

the 5604 I/O Module can be switched under control of the application program.

 This configuration is recommended when a large amount of current is required at 24V. Refer to

section 10-Specifications and the section outlining sample power calculations in the manual of your respective controller board to determine the power required from the 24V power supply.

 The Controller Board DC Power terminal must be connected to the same power supply as the

5604 I/O Module DC Power terminals.

Figure 3: Recommended 24V Power Supply Configuration

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4.2.3 Recommended Battery Configuration

12V battery

5604 I/O Module

DC PWR

+ –

1 2 3 4 5

AOUT

0 1 COM

Vloop +

AC/DC

PWR IN

DC PWR

+ –

1 2 3 4 5

Controller Board

12V boosted to 24V

This configuration uses a 12V battery to power the controller board and the 5604 I/O Module. This 12V is used to power the analog circuitry for the analog inputs and output circuits on the 5604 I/O Module.

Notes on this configuration:

 The 24V-boosted output (VLOOP) can be switched on and off under the control of the

application program to save power to any loads connected to VLOOP.

 The DC input (battery voltage) to the 5604 I/O Module can be boosted to 24Vdc on the 5604 I/O

Module under the control of the application program.

 This configuration is recommended when a large amount of current is required at 24V. Refer to

the specifications and the sample calculations to determine the power required from the 12V battery.

 The 5232 Controller Board DC Power terminal must be connected to the same power supply as

the 5604 I/O Module DC Power terminals.

Figure 4: Recommended Battery Configuration

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4.2.4 Recommended 5103 Power Supply Configuration

AC/DC

PWR IN

DC PWR

+ –

1 2 3 4 5

Controller Board

1 2 3 4 5

5103 Power Supply

120 Vrm

24 Vrms

Class 2

Transformer

AC/DC

+ BATT

+ 24V

Optional 12 Volt

Gel Cel Battery

5604 I/O Module

DC PWR

+ –

1 2 3 4 5

AOUT

0 1 COM

Vloop +

When additional power is required by the system, 5000 Series 5103 power supplies can be used in combination with the SCADAPack controllers. Refer to the System Configuration Guide for more information.

The 5103 power supplies can be connected anywhere downstream (to the right) of the controller. They will supply power to the modules downstream of them.

Note: The Sleep Mode feature of the controller applies only to those modules powered by the

controller.

The 5103 power supply may also be connected upstream (to the left) of any SCADAPack Controller, but only if the following conditions are observed:

 No power is applied to the power inputs of the controller board.  A jumper is installed at position J5 (see the user manual of your respective controller board for

details.

 The sleep mode feature is not used.

This configuration uses a 5103 Power Supply module to power a SCADAPack controller. The 24VDC output from the 5103 powers the 5604 I/O module. The 5103 power supply provides a 5V output to power the 5604 I/O module, the controller board and 5000 Series modules through the IMC cables.

Note that no connection is made to the AC/DC PWR IN or DC PWR terminals on the controller board.

Figure 5: Recommended 5103 Power Supply Configuration

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4.3 System Grounding

12V to 24V boost

ON/OFF

Dout 32

Dout 33

5305 Analog Output Module

+ –

DC PWR

1 2 3 4 5

0 1 COM

AOUT

+ Vloop

In most applications, it is desirable to ground the system by connecting the system power supply common, to the chassis or panel ground.

On the 5604 I/O module, “-“ terminal of the 24V supply(DC PWR “-“) is already connected to the enclosure by the printed circuit board traces.

4.4 Power Management Features

The 5604 I/O board provides a number of special features to reduce power consumption. These power management features include:

 VLoop power control.  12V to 24V DC/DC Converter Control.

The 5604 I/O module provides two internal digital outputs that can be operated by the user application to manage the power saving features. Internal digital outputs 32 and 33 and the power management functions they control are described in the following sections.

Refer to Figure 6: Power Management for an overview of the power management features. Refer to the appropriate software manual for information on using and controlling the internal Digital Outputs. For TelePACE applications refer to the Register Assignment for the SCADAPack 5604 I/O module and for ISaGRAF applications refer to the I/O Complex Equipment for SCADAPack 5604 I/O module.

Figure 6: Power Management

4.4.1 DC/DC Converter Control

The 12V to 24V DC/DC converter is used to provide 24 VDC for VLoop power and for the Analog Output module. The converter should be turned on if the 5604 I/O Module is equipped with analog

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outputs for which 24V-drive capability is required. Otherwise, the DC/DC converter can be turned off to conserve power.

 Turn on Digital Output 32 to turn ON the 12V to 24V DC/DC converter. When the converter is

turned on 24Vdc is provided to the VLoop power and to the Analog Output module.

 Turn off Digital Output 32 to turn OFF the 12V to 24V DC/DC converter. When the converter

is turned off VLoop power and the Analog Output module use is the applied input power.

Internal Digital Input 32 indicates the status of the 12V to 24V DC/DC converter. Digital Input 11 is set when the 12V to 24V DC/DC converter is on and is cleared when the 12V to 24V DC/DC converter is off.

The 12V to 24V DC/DC converter is turned on when the LED power is enabled. This feature is provided for service and diagnostics. Refer to the LED Power Control section in the hardware manual of your respective controller board for further information on this feature

4.4.2 VLoop Power Control

The DC/DC converter output can be used to power analog input current loops or other instrumentation. This output, VLoop, is controlled for intermittent or continuous operation. Turning the VLoop output off when it is not required can save considerable electrical power.

The switched VLoop power source is the output of the DC-DC 12/24V converter if it is turned on. See the DC/DC Converter Control section for converter information. The VLoop power source is the applied input power if the DC-DC converter is turned off.

 Turn on Digital Output 33 to turn ON the VLoop output.  Turn off Digital Output 33 to turn OFF the VLoop output.

Note: When VLoop is first turned on, the user application program must wait at least one second

for input readings to stabilize. This time may be increased depending on field sensors and transmitters. Documentation for these devices should be consulted.

The VLoop output is turned on when the LED power is enabled. This feature is provided for service and diagnostics. Refer to the LED Power Control section in the hardware manual of your respective controller board for further information.

4.4.3 VLoop Over-Current Protection

When VLoop output is turned on, it is monitored for excessive current consumption caused by field wiring or instrumentation problems. If sustained over-current is detected (100 ms), VLoop is turned off even though internal Digital Output 33 is turned on. This protection prevents unnecessary fuse blowing, circuitry damage and rapid battery depletion.

When VLoop output is turned on, using internal Digital Output 33, and a short circuit is detected VLoop will turn off. VLoop will turn on to try again 5 seconds after turning off. If the fault condition still exits VLoop will again turn off and retry after a 5 second delay. While the fault condition exists internal Digital Input 34 will be ON.

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5 Analog Inputs

The 5604 I/O module enhances the capacity of a SCADAPack controller by providing an additional nine single ended analog inputs on connector P4, that can be configured for current or voltage mode. Refer to Figure 1: 5604 I/O Module Layout for the location of this connector.

Analog Inputs 0-7 can be configured for current or voltage mode using jumper switches. Please refer to section 5-Analog Inputs on how to select input modes.

 In voltage mode, these analog inputs are single ended and the measurement range is 0-10V. The

range is selected via the configuration DIP switches. Refer to section 5.2- Range and Resolution below for details.

 In current mode, a 250 current sense resistor appears across each analog input channel.

Measurement range in current mode is 0-20mA or 4-20mA selectable via the configuration switches. The 250 resistor produces a voltage drop (input reading) of 5V for a 20mA of current flow.

All analog input channels are transient protected, optically isolated from the main logic supply and share a common return (COM) that is connected to the chassis.

The controller uses a 16-bit successive approximation analog to digital (A/D) converter and provides 15 bit resolution over the range of the analog input.

Analog Input 8 is a 0 to 32.768-volt input that measures with 10-bit resolution and can be used to monitor a power supply or battery voltage.

There is one internal analog input that is used in application programs to monitor the DC/DC converter voltage used for VLOOP.

 For TelePACE applications use the SCADAPack 5604 I/O Module register assignment to read

the nine external and the internal analog inputs.

 For ISaGRAF applications use the sp5604 I/O connection to read the nine external and the

internal analog inputs.

Please refer to the respective TelePACE and ISaGRAF software manuals on how to assign the above registers to read these input ports.

5.1 Current or Voltage Mode

Analog Inputs 0-7on connector P4 can be configured for either voltage or current mode using jumper links. The jumper links reside on the lower I/O board itself. To access the jumper links, the main cover and controller board will have to be taken off by removing the retaining screws.

Note: Analog Input channels 0-7 are configured for current mode by default.

To select current mode, install the jumpers on the side labeled 20mA on the I/O board as shown in the figure below for analog inputs 0-5. In current mode a 250 resistor appears across the input channel.

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AIN0

20mA

J10

AIN1

J11

AIN2

J12

AIN3

J13

AIN4

J14

AIN5

J15

AIN6

J16

AIN7

J17

Current (mA) Channel 0-7

Voltage (V) Channel 0-7

Voltage (V) Channel 8

A/D Output

0V 0 1.22mA

0.305mV

NA 1 4

1.0

3.277

3277

2.5

8.192

8192

5.0

16.38

16384

39.999

9.9997

32.767

32767

Figure 7: Analog Input Mode Settings

To select voltage mode, install the jumpers on the side labeled 5V. In the figure above, Analog inputs 6 and 7 are configured for voltage mode.

5.2 Range and Resolution

Analog inputs channels 0 – 7 use a16-bit, unipolar, analog to digital (A/D) converter that measures input voltages from 0 to 10V or currents from 0-20mA. In voltage mode, the input is represented by a 15 bit unsigned real number. In current mode, the input is represented by a 14 bits unsigned real number

Input resolution for channels 0-7 is:

 0.305mV/count in voltage mode  1.22µA/count in current mode. There is 100% over range.

The following table shows the typical A/D output value for several input signals.

Analog input 8 is configured for voltage mode only. Voltage ranges of up to 32.768V are measurable using a 10 bit A/D converter and represented with 15 bits of data. The input resolution on this channel approximately 0.03V/count.

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5.3 Wiring

The analog inputs support loop powered and self powered transmitters. Loop powered transmitters are two terminal devices that connect between a power supply and the analog input. The loop current continues from the power supply, through the transmitter and to ground through a 250 resistor built into the 20mA input circuit. Self-powered transmitters have three terminals called power in, signal out and common. Self-powered transmitters can have a current or voltage output. The signal out connects to the Analog Input Channel, the common connects to GND and the power in connects to a power supply.

There are three options for the user when selecting the power source. In all cases it is important for the user to ensure that the transmitter has enough voltage for proper operation. The transmitter manufacturer supplies the minimum operating voltage specification of the transmitter. The analog input requires a minimum of 5V.

The first option is to use the 5604 I/O Module VLOOP Supply that boosts the input voltage to 24V with a 12V to 24V DC/DC converter. The stepped up voltage is available on connector P3 and is labeled VLOOP. There is sufficient power available for the eight analog inputs and four analog outputs all operating at 20mA. Significant power saving is possible by switching the VLOOP supply off when measurements are not being made.

The second option is similar to the first except that the power supply is not boosted up to 24V. This can be used with low voltage transmitters or when the input voltage is sufficiently high that further boosting is not necessary. It is still possible to switch the supply off under program control. When the step up is turned off, VLOOP is approximately 0.5V less that the power input voltage.

5.3.1 Wiring Examples

Several wiring examples for loop and self powered transmitters are illustrated in Figure 8: Analog Input Wiring. The transmitters are wired as follows:

 Channel 0 has a loop powered current transmitter connected to VLOOP.  Channel 1 has a self-powered voltage transmitter connected to the external power supply.  Channels 2 through 6 are unused.  Channel 7 has a self-powered current transmitter connected to the external power supply.  Channel 8 is used to monitor the external power supply.

If a 12V external power supply or battery is used the application can boost this voltage to 24V at VLOOP using the internal DC/DC converter. If a 24V external power supply is used it is unnecessary to boost this voltage.

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External 12 or

24Vdc Power

Supply

Voltage

+Vdc – Vloop 0 1 GND

7 6 5 4 3 2 1

0 1 2 3 4 5 6 7 8 GND

Current

P4 - Analog Inputs

PWR

Voltage O/P

COM

PWR

Current O/P

COM

J1 J2 J3 J4 J5 J6 J7 J8

10 6 5 4 3 2 1

P3 – Power and Analog Outputs

Filter Setting

Response Time

Digital Output 35

Digital Output 34

< 3 Hz

155ms at 60Hz 185ms at 50Hz

OFF

Maximum filter setting

6 Hz

85ms at 60Hz 85ms at 50Hz

OFF

Medium filter setting

11 Hz

45ms at 60Hz 55ms at 50Hz

OFF

Minimum filter setting

30 Hz

30ms at 60Hz 30ms at 50Hz

No filter

Figure 8: Analog Input Wiring

5.4 Filtering and Response Timing

The 5604 I/O Module also provides internal digital outputs to control the filtering and response times of the analog to digital conversion. Theses digital outputs can be controlled by the user application to either maximize the filtering in noisy environments or minimize the filtering in applications that require the fastest response times.

The following chart shows the response timing for the selectable filter settings. Internal digital outputs 34 and 35 control the filter setting. The 5604 I/O module may select 50 or 60 Hz line frequency for digital and analog input processing.

The Controller board Option Switch 3 selects the line frequency option.

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6 Analog Outputs

External 12 or

24Vdc Power

Supply

L O A D

+Vdc – Vloop 0 1 GND

6 5 4 3 2

P3 – Power and Analog Outputs

DC/DC

boost converter

24Vdc output

Aout0

Aout1

L O A D

The 5604 I/O Module may include two channels of analog output if this option was requested at time of purchase.

 For TelePACE applications use the SCADAPack AOUT I/O Module register assignment to

write to the two analog outputs.

 For ISaGRAF applications use the aout2pt I/O connection to write to the two analog outputs.

Please refer to the respective TelePACE and ISaGRAF software manuals on how to assign the above registers to read these input ports.

6.1 Current Outputs

The 5604 I/O Module can be equipped with an optional 5305 Analog Output Module that provides two 20mA analog outputs. Analog output resolution is 12 bits. The outputs are transient and over voltage protected. The outputs share a common return (GND) with each other and the 5604 I/O Module analog inputs.

The 12V to 24V DC/DC boost converter powers the analog outputs. The boost converter is used to boost the DC input power to 24V. The application program may control the boost converter.

Figure 9: Analog Output Wiring

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6.2 Voltage Outputs

Resistance

Output Range

Voltage Range

250

0-20mA

0 to 5V

500

0-20mA

0 to 10V

Raw Count

Current (0% offset)

Current (20% offset)

0 mA

4 mA

4.88 µA

4 mA

1500

0.92 mA

4.73 mA

3200

1.95 mA

5.56mA

6552

4 mA

7.2 mA

7000

4.27 mA

7.42 mA

10000

6.11 mA

8.88 mA

16384

10 mA

12 mA

24576

15 mA

16 mA

32760

19.995 mA

To obtain voltage outputs, connect a load resistor as shown in Figure 9: Analog Output Wiring above. Connect the voltage device across the load resistor. The table below list resistance values and output range settings for common voltage ranges. The resistance value listed is the parallel resistance of the device and the load resistor.

6.3 Range and Resolution

The optional analog output module installed on the 5604 I/O Module has a 12-bit, unipolar, digital to analog (D/A) converter. These analog outputs can be configured for a 0% (0-20mA) or 20% (420mA) range. There are 4096 D/A counts in the output signal range and one D/A count represents a value of 8 raw counts. Raw counts are displayed or issued from the application program.

The 0-20mA output range resolution is 4.88µA/count, such that 8 raw counts represent 4.88 µA. For a 0% offset, use the following relationship to determine the output current based on your raw counts:

Output Current [mA] = (20 * Raw Count) / 32760

For a 20% offset, use the following relationship:

Output Current [mA] = ( (16 * Raw Count) / 32760 ) + 4

The table below shows the output current for several raw counts, when the analog output is configured for a 0% and 20% offset.

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7 Digital I/O

The 5604 I/O module has 32 universal digital inputs/outputs. Each digital I/O point can be used as an input or an output only. The inputs can be used to monitor the status of that output.

The 32 I/O points are organized into four groups of eight. Four connectors are used for wiring the digital inputs/outputs. These connectors are identified as P6 through P9. Refer to figure_37Figure 1: 5604 I/O Module Layout for the location of these connectors.

In addition to the 32 universal digital input/outputs there are 3 internal digital inputs and 2 internal digital outputs that are used to monitor and control the DC/DC converter or VLOOP power supply as well as to monitor digital output mismatch status. Refer to section 7.3-Internal DIO for information on these internal digital I/O.

 For TelePACE applications use the SCADAPack 5604 I/O Module register assignment to read

the digital inputs and write the digital outputs.

 For ISaGRAF applications use the sp5604 I/O connection to read digital inputs and write the

digital outputs.

Please refer to the respective TelePACE and ISaGRAF software manuals on how to assign the above registers to read these input ports.

7.1 Digital Inputs

The inputs are intended for use with dry contacts such as switches, open collector transistors and relay contacts. Wetting current for the contacts is provided. The input is connected from the I/O terminal to the terminal labeled GND. All GND terminals are connected internally to the SCADAPack chassis.

If LED power is enabled, there is a continuous 5mA wetting current for each input. Indicator LED’s will be at their maximum brilliance if on. This facilitates field service and diagnostics.

If LED power is disabled then the wetting current is turned on only when the digital inputs are scanned. Power consumption is reduced as the inputs are scanned only once every millisecond. Indicator LED’s are dim in this condition. This is normal.

7.2 Digital Outputs

Outputs are open-collector/open drain type for use with sustained DC loads of up to 1 ampere. Loads with high in-rush currents may exceed the 1A rating. The output circuit will tolerate these higher peak currents. The load is connected between this output point and a +DC power source. The negative side of the DC power source must be connected the terminal labeled GND. All GND terminals are connected internally to the SCADAPack chassis. This is the return path from –DC to the load.

Inductive load transient suppression is built into each digital output point. It is not necessary to add additional inductive load transient suppression unless highly inductive loads (greater than 1H) are operated continuously at greater than 0.5Hz.

7.3 Internal DIO

The 5604 I/O Module also provides internal digital outputs to enable the DC/DC boost converter, to switch on/off the boost converter output and control the analog input filtering. Theses digital outputs can be controlled by the user application to manage power savings and control the analog input response.

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Digital input 32 returns the DC/DC converter status.

0 = DC/DC converter off 1 = DC/DC converter on

Digital input 33 returns the DC/DC converter over current status.

0 = Over current not detected 1 = Over current detected

Digital input 34 returns the digital output mismatch status.

0 = No mismatch 1 = One or more digital outputs mismatch

Digital Output 32 is used to control the DC/DC converter.

0 = DC/DC converter off 1 = DC/DC converter on The 12V to 24V DC/DC converter is turned on when the LED power is enabled. This feature is provided for service and diagnostics.

Digital Output 33 is used to control the VLoop power supply.

0 = VLoop output off 1 = VLoop output on The VLOOP output is turned on when the LED power is enabled. This feature is provided for service and diagnostics.

Digital Outputs 34 and 35 control the SCADAPack 5604 I/O Module Analog Input filters.

Filter Setting Digital Output 35 Digital Output 34

< 3 Hz OFF OFF 6 Hz OFF ON 11 Hz ON OFF 30 Hz ON ON

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7.4 Wiring Examples

8 7 6 5 4 3 2

GND 7 6 5 4 3 2 1 0

P9 – Digital I/O 0-7

+ 24V Load –

P7 and P8 – Digital I/O 8-23 not shown.

12Vdc Power

Supply

24Vdc Power

Supply

+ 12V Load –

8 7 6 5 4 3 2

GND 31 30 29 28 27 26 25 24

P6 – Digital I/O 24-31

Various I/O point wiring examples are shown in Figure 10: Digital Input/ Output Wiring below. Inputs and outputs can be used on any of the I/O points.

 Digital I/O point 7 is shown connected to a 12V load and external 12V-power supply.  Digital I/O point 6 is shown connected to a 24V load and external 24V-power supply.  Digital I/O point 4 is shown monitoring a dry contact.  Digital I/O point 1 is shown monitoring an open collector contact.

Figure 10: Digital Input/ Output Wiring

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8 Serial Communication

Port

Type

Description

COM3

RS-232

RJ-45 connector designated P5 on the 5604 I/O Module.

Parameter

Supported Values

Baud Rate

1200, 2400, 4800, 9600, 19200, 38400, 57600 and

115200. Default: 9600

Duplex

Half Default: Half

Parity

Odd, None or Even Default: None

Data Bits

7 or 8 Bits Default: 8 Bits

Stop Bits

1 or 2 Bits Default: 1 Bit

Receive Flow Control

ModbusRTU or None Default: ModbusRTU

Transmit Flow Control

Ignore CTS or None Default: None

Station

1 to 65534 Default: 1

Protocol

None, Modbus RTU, Modbus ASCII and optionally DF1 Or DNP. Default: Modbus RTU

Addressing Mode

Standard or Extended Default: Standard

The 5604 I/O module enhances the serial communication ability of a SCADAPack controller by providing an additional RS-232 serial port identified as COM3. The RS-232 port is an 8-pin female RJ-45 connector configured as Data Terminal Equipment (DTE) and only supports a half-duplex serial communication. The recommended specification for RS-232 cable length is a maximum of 50 feet or 15.2 meters. Shielded cable must be used and the shield should be connected to chassis ground at one end.

8.1 COM3 RS-232 Serial Port

Connections to COM3 are made through a RJ-45. The wiring and pin connections for this connector are described in the section 8.2- RJ-45 Modular Connector for RS-232.

The following table shows the serial and protocol communication parameters supported by COM1. These parameters are set from TelePACE, ISaGRAF Workbench or from an application program running in the controller. Default values are set when a Cold Boot or Service Boot is performed on the controller.

8.2 RJ-45 Modular Connector for RS-232

Serial communication port COM3 on the 5604 I/O module uses an 8-pin female RJ-45 connectors configured as Data Terminal Equipment (DTE). The following diagram shows the pin connections for the RS-232 (RJ-45) port connector for COM3.

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RJ-45 Modular Jack

1. +5V

2. DCD

3. DTR

4. GND

5. RxD

6. TxD

7. CTS

8. RTS

2187654

Function

Description

5V (Output)

This pin can be connected to the 5V power supply by installing a jumper at J4 on the SCADAPack controller board.

DCD (Input)

The DCD led is on for a MARK level.

DTR (Output)

This pin is normally at a MARK level. This pin is at a SPACE level when DTR is de-asserted.

GND

This pin is connected to the system ground.

RxD (Input)

The level is SPACE on standby and MARK for received data. The LED is lit for a MARK level.

TxD (Output)

The level is SPACE on standby and MARK for transmitted data. The LED is lit for a MARK level.

CTS (Input)

This level must be a MARK for the communication port to transmit data. When the attached device does not provide this signal, the controller keeps the line at a MARK.

When the attached device does provide this signal, it must set CTS to MARK to allow the controller to transmit data.

RTS (Output)

This pin is a MARK if full-duplex operation is selected for the port.

This pin is set to a MARK just before and during transmission of data if half-duplex operation is selected.

This pin is set to a SPACE when no data is being transmitted.

Figure 11: Front View of an RJ-45 Connector

The following table provides a description of the function of each pin of the RJ-45 connector. In this table a MARK level is a voltage of +3V or greater and a SPACE level is a voltage of –3V or less.

8.3 RS-232 Wiring Examples

See the chapter on Serial Communications in the hardware manual of your respective controller board for wiring examples.

8.4 RS-232 Cables

8.4.1 RJ-45 to DE-9S DTE

This cable is used to connect from an RJ-45 based RS-232 port on the 5604 I/O module to a DE-9P connector on a DTE such as a PC. A 10 ft. long cable is available from Control Microsystems as part number 297217.

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5604 Input/Output (I/O) Module - Hardware Manual

RJ-45 8 Pins

DTE Function

DE9S DTE Function

DE9S

Shield connects to shell

TxD

RxD

2 5 RxD

TxD

3 4 GND

GND

1, 2, 3, 7 and 8 are not connected at this end.

GND

No wires connected at this end.

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8.4.2 RJ-45 to DE-9P DCE

RJ-45

DTE Function

DE-9P DCE Function

DE-9P

Shield connects to shell

DTR

4 6 TxD

TxD

3 5 RxD

RxD

2 2 DCD

DCD

1 4 GND

GND

5 7 CTS

CTS

8 8 RTS

RTS

7 1 +5V

+5V

This cable is used to connect from an RJ-45 based RS-232 port on the SCADAPack P1A controller to DE-9S connector on a DCE such as a modem. A 15-inch long cable is available from Control Microsystems as part number 297218.

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9 Operation

LED

Function

On when receiving data COM3.

On when transmitting data on COM3.

CTS

On when CTS is asserted on COM3.

DCD

On when DCD is asserted on COM3.

DI/O

On when the corresponding input is on. On when the corresponding output is

on.

9.1 LED Indicators

This I/O module provides an additional 36 LEDs. All LED’s can be disabled by the controller board

to conserve power. Refer to the chapter on LED Indicators in the hardware manual of your respective controller board for details. The table below describes some of the LEDs on the 5604 I/O module.

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10 Specifications

I/O Terminations

6,8,9 and 10 pole, removable terminal blocks. 12 to 22 AWG 15A contacts

Dimensions SCADAPack

8.40 inch (213mm) wide

6.13 inch (155mm) high

2.80 inch (72mm) deep

Packaging

corrosion resistant zinc plated steel with black enamel paint

Environment

5% RH to 95% RH, non-condensing

–40oC to 70oC –40oF to 158oF

Communication Ports, 5203 controller board

2 RS-232 serial ports (COM1, COM2) Data Terminal Equipment (DTE) DE-9P male connector

Communication Ports, 5204 controller board

One RS-232 serial port (COM2) Data Terminal Equipment (DTE) DE-9P male connector

One RS-485 serial port (COM1) 2 wire half duplex 4 wire full or half duplex optional termination resistors

Communication Ports

5604 I/O Modulue

one RS-232 serial port (COM3) Data Terminal Equipment (DTE) DE-9P male connector

5604 I/O Module

one RS-232 serial port (COM3) Data Terminal Equipment (DTE) 8 pin modular jack

Baud Rates (COM1, COM2)

300, 600, 1200, 2400, 4800, 9600, 19200, 38400 default: 9600

Baud Rate (COM3)

Where applicable

1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 Default: 9600

Parity

none, even, or odd Default: none

Word Length

7 or 8 bits Default: 8 bits

Disclaimer: Control Microsystems reserves the right to change product specifications without notice. For more information visit www.controlmicrosystems.com .

10.1 General

10.2 Communications

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Stop Bits

1 or 2 bits Default: 1 bit

Duplex (COM1, COM2)

full or half with RTS/CTS control Default: full

Duplex (COM3)

half with RTS/CTS control

Cable Length

RS-232 –maximum 50 ft (15.2 m) RS-485 –maximum 4000 ft (1200 m)

Protocol 5203 and 5204 Controller Boards

TeleBUS (compatible with Modbus RTU and Modbus ASCII) DF1 and DNP Protocols optional

Default: Modbus RTU

Protocol Modes 5203 and 5204 Controller Boards

slave, master, master/slave, store and forward

10.3 Visual Indicators

Digital I/O (5604 I/O Module)

32 red LED’s

Push-button

LED power toggle

DC power Input

30V maximum 11V minimum 12V at 5mA during Sleep Mode 12V at 10mA with no loading on the boosted 24V Vloop 12V at 550mA with 88% efficiency 23V/0.25A loading

24Vdc Power Output

22.5 to 25.2 Vdc with 0 to 0.25A load. Shutdown current limiting typically 0.36A. Efficiency 88-92%, 12V on DC PWR input

5V power required

170mA with LED’s enabled and all I/O on 15mA with LED’s enabled and all I/O off 15mA with LED’s disabled

Input Points

8 at 10V/20mA: 250 resistance, user configurable with jumper link

Resolution

15 bits over the 10V measurement range 14 bits over the 20mA measurement range

Input Resistance

20k for 10V inputs 250 for 20mA inputs

Converter type

16 bit successive approximation

Accuracy

±0.1% of full scale at 25oC (77ºF) ±0.2% over temperature range

10.4 Power Supply

10.5 Analog Inputs

10.5.1 Inputs 0-7

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Type

single ended

Calibration

Calibration constants stored in on board microcontroller EEPROM.

Normal mode rejection

26 dB at 50/60 Hz Maximum filter setting 21 dB at 50/60 Hz Medium filter setting 14 dB at 50/60 Hz Minimum filter setting 5 dB at 50/60 Hz No filter

Over-scale Input Capacity

Measures up to 10V/40mA Inputs clamped between 12 and 17V Transient: 2.5kV surge withstand capability as

per ANSI/IEEE C37.90.1-1989

Isolation

Analog common side connected to Chassis Ground

Response Time

For 90% signal change, 60/50Hz. 155/185ms Maximum filter setting

85/ 95ms Medium filter setting 45/ 55ms Minimum filter setting 30ms No filter

Input Points

1 at 0-32.768V

Resolution

10 bits over the 32.768V measurement range

Input Resistance

600k for 32.768V inputs

Converter type

10 bit successive approximation

Accuracy

±0.25% of full scale at 25oC (77ºF) ±1% over temperature range

Type

single ended

Calibration

Calibration constants stored in on board microcontroller EEPROM

Over-scale Input Capacity (without damage)

Transient: 2.5kV surge withstand capability as per ANSI/IEEE C37.90.1-1989

Isolation

Analog common side connected to Chassis Ground

Response Time

30ms for 90% signal change.

Output Points

2 (when optional 5305 analog output module installed)

Output Signal Range

0-20mA

Maximum Load Resistance

925 with 24Vdcinput voltage or when internal 24V power supply is on.

375 with 12Vdc input voltage 250 with input voltage at power supply turnoff

Output Type

Single ended regulation on positive side with common negative return

10.5.2 Input 8

10.6 Analog Outputs

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Isolation

Analog common side connected to Chassis Ground.

Resolution

12 bits

Accuracy

Specified from 0.5-20mA ±0.15% of full scale at 25oC (77oF) ±0.25% of full scale over temperature range

Noise and Ripple

0.04% maximum

Transient Protection

Transient: 2.5kV surge withstand capability as per ANSI/IEEE C37.90.1-1989

I/O points

32 points in 4 group of 8. Each point is an input and an output.

Output Rating

1.0Adc maximum

0.35V maximum drop at 1.0A

0.05V maximum drop at 0.1A Open drain sinking when ON. 28V maximum when OFF.

Input Rating

Dry contact input. Wetting current typically 5mA, pulsed. Contact closure to ground is ON. Open input is OFF.

Digital Input Thresholds

0.9V typical turn on input voltage. Less than 0.4V guaranteed turn on input voltage.

1.5V typical turn off input voltage. Greater than 2.2V guaranteed turn off input voltage.

Transient Protection

2.5kV surge withstand capability as per ANSI/IEEE C37.90.1-1989

Isolation

Common ground return connected to Chassis Ground.

10.7 Digital Inputs

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10.8 Digital Outputs

I/O points

32 points in 4 group of 8. Each point is an input and an output.

Output Rating

1.0Adc maximum

0.35V maximum drop at 1.0A

0.05V maximum drop at 0.1A Open drain sinking when ON. 28V maximum when OFF.

Input Rating

Dry contact input. Wetting current typically 5mA, pulsed. Contact closure to ground is ON. Open input is OFF.

Digital Input Thresholds

0.9V typical turn on input voltage. Less than 0.4V guaranteed turn on input voltage.

1.5V typical turn off input voltage. Greater than 2.2V guaranteed turn off input voltage.

Transient Protection

2.5kV surge withstand capability as per ANSI/IEEE C37.90.11989

Isolation

Common ground return connected to Chassis Ground.

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11 Approvals and Certifications

Safety

Non-Incendive Electrical Equipment for Use in Class I, Division 2 Groups A, B, C and D Hazardous Locations.

Digital Emissions

FCC Part 15, Subpart B, Class A Verification EN61000-6-4: 2001 Electromagnetic Compatibility Generic

Emission Standard Part2: Industrial Environment C-Tick compliance. Registration number N15744.

Immunity

EN61000-6-2: 2001 Electromagnetic Compatibility Generic Standards Immunity for Industrial Environments

Declaration

This product conforms to the above Emissions and Immunity Standards and therefore conforms with the requirements of Council Directive 89/336/EEC (as amended) relating to electromagnetic compatibility.

P1 (5604) and P1B (5606 Models with digital inputs configured below 30Vdc/60Vac are eligible to bear the CE mark. The Low Voltage Directive is not applicable to these products in applications below 30Vdc/60Vac.

The Low Voltage Directive is not applicable to the P1A (5604) Model and is eligible to bear the CE mark.

5604 Input/Output (I/O) Module - Hardware Manual October 19, 2007