Motorola V186 - Cell Phone - GSM, ACE3600 System Planner Manual

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System Planner

ACE3600 RTU

6802979C45-D

Draft 2

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DISCLAIMER NOTE

The information within this document has been carefully checked and is believed to be entirely reliable. However, no responsibility is assumed for any inaccuracies. Furthermore Motorola reserves the right to make changes to any product herein to improve reliability, function, or design. Motorola does not assume any liability arising out of the application or use of any product, recommendation, or circuit described herein; neither does it convey any license under its patent or right of others.

All information resident in this document is considered copyrighted.

COMPUTER SOFTWARE COPYRIGHTS

The Motorola products described in this Product Planner include copyrighted Motorola software stored in semiconductor memories and other media. Laws in the United States and foreign countries preserve for Motorola certain exclusive rights for copyrighted computer programs, including the exclusive right to copy or reproduce in any form the copyrighted computer program.

Accordingly, any copyrighted Motorola computer programs contained in Motorola products described in this Product Planner may not be copied or reproduced in any manner without written permission from Motorola, Inc. Furthermore, the purchase of Motorola products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the copyright, patents, or patent applications of Motorola, except for the normal non-exclusive, royalty free license to use that arises by operation in law of the sale of a product.

TRADEMARKS

MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners.

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Table of Contents

TABLE OF CONTENTS...............................................................................................................I

ACE3600 SYSTEM OVERVIEW................................................................................................ 1

ACE3600 RTU CONSTRUCTION.............................................................................................. 3

POWER SUPPLY MODULES....................................................................................................6

12V BACKUP BATTERY............................................................................................................... 7

CPU MODULES............................................................................................................................ 8

I/O MODULES............................................................................................................................ 10

DIGITAL INPUT MODULES................................................................................................... 13

DIGITAL OUTPUT RELAY MODULES................................................................................ 22

ANALOG INPUT MODULES................................................................................................... 31

ANALOG OUTPUT MODULES............................................................................................... 39

DIGITAL OUTPUT AND DIGITAL INPUT FET MODULES............................................. 45

MIXED I/O MODULES ............................................................................................................. 52

MIXED ANALOG MODULES.................................................................................................. 54

I/O EXPANSION......................................................................................................................... 56

EXPANSION POWER SUPPLY MODULE............................................................................ 60

EXPANSION MODULE............................................................................................................. 61

MODULE FIRMWARE AND OPERATION MODES......................................................................... 62

EXPANSION LAN SWITCH..................................................................................................... 65

RTU I/O EXPANSION - POWER CONSIDERATIONS........................................................ 67

ORDERING INFORMATION .................................................................................................. 70

ACE3600 RTU ORDERING FLOW: ............................................................................................ 70

LIST OF ACE3600 MODELS....................................................................................................... 80

LIST OF ACE3600 OPTIONS ...................................................................................................... 82

GENERAL ORDERING REQUIREMENTS ...................................................................................... 85

ACE3600 INSTALLATION GUIDELINES............................................................................. 86

DIMENSIONS.............................................................................................................................. 86

GENERAL SAFETY INFORMATION: .................................................................................. 87

MOUNTING THE ACE3600 FRAME ON A WALL ........................................................................ 88

INSTALLING THE ACE3600 IN A 19" RACK............................................................................... 90

HOUSING INSTALLATION........................................................................................................... 91

COMMUNICATIONS................................................................................................................ 93

MDLC PROTOCOL..................................................................................................................... 94

COMMUNICATION LINKS........................................................................................................... 98

RS232 PORTS ............................................................................................................................ 98

RS485 PORTS ............................................................................................................................ 99

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IP PORTS (MDLC OVER IP)..................................................................................................... 101

RADIO COMMUNICATIONS ...................................................................................................... 120

COMMUNICATION NETWORK .................................................................................................. 129

MDLC ENCRYPTION ............................................................................................................... 135

CLOCK FUNCTIONS AND SYNCHRONIZATION........................................................... 140

RTU CLOCK ............................................................................................................................ 140

TIME ADJUSTMENT AND SYNCHRONIZATION ......................................................................... 140

NTP CLOCK SYNCHRONIZATION ............................................................................................ 142

GLOBAL POSITIONING SYSTEM (GPS) .................................................................................... 144

SCADA SYSTEM COMPONENTS ........................................................................................145

CONTROL CENTER – SCADA MANAGER................................................................................ 145

M-OPC.................................................................................................................................... 145

IP GATEWAY ........................................................................................................................... 147

LEGACY MODBUS FEP ........................................................................................................... 147

APPENDIX A - ACE3600 SPECIFICATIONS...................................................................... 149

POWER SUPPLY MODULE SPECIFICATIONS ............................................................................. 152

CPU 3610/CPU 3640 MODULE SPECIFICATIONS.................................................................... 155

DI MODULE SPECIFICATIONS.................................................................................................. 156

DO/DI FET MODULE SPECIFICATIONS ................................................................................... 159

DO RELAY MODULE SPECIFICATIONS .................................................................................... 161

AI MODULE SPECIFICATIONS.................................................................................................. 163

AO MODULE SPECIFICATIONS ................................................................................................ 164

MIXED I/O MODULE SPECIFICATIONS..................................................................................... 165

MIXED ANALOG MODULE SPECIFICATIONS............................................................................ 167

EXPANSION POWER SUPPLY MODULE SPECIFICATIONS ......................................................... 169

EXPANSION MODULE SPECIFICATIONS ................................................................................... 170

EXPANSION LAN SWITCH SPECIFICATIONS............................................................................ 171

APPENDIX B - FCC INFORMATION SPECTRUM AND REGULATO RY UPDATE... 172

FCC RULES UPDATE ............................................................................................................... 172

LICENSING OF FIXED DATA SYSTEMS..................................................................................... 175

SPECTRUM AVAILABLE FOR FIXED DATA SYSTEMS............................................................... 175

APPENDIX C: ACE3600 MAXIMUM POWER RATINGS................................................ 178

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ACE3600 System Overview

The purpose of ACE3600 system is typically to provide some degree of automatic operation to a new or existing customer process. The process may be found in water pump stations, sewage lift stations, communication system monitoring, security, public notification control, electrical substation monitoring, distribution automation, demandside management, automated meter reading, or other applications. This automation is provided by a combination of hardware.

• Remote Terminal Unit (RTU):

RTU

The field sites are equipped with ACE3600 RTUs that collect data from on-site sensors, add data from off-site sources, and use this data aggregate to make decisions regarding how the process is operating. Changes to the local process may be made; messages may be initiated that send data elsewhere to influence the operation of off-site equipment or to advise the SCADA Manager of some important change.

INPUTS

Communication

System

OTPUTS

• Communications:

The multiple sites in the system may communicate among themselves by utilizing a variety of communication choices: IP

STS

FEP

networks, two-way conventional, trunked, or data radio or any other communication network. MDLC, the main communication protocol employed by ACE3600, is based

SCADA Manager

on the seven-layer OSI recommendation, and is designed to be totally functional on variety of communication media. MDLC includes a store-&-forward capability that permits different communication media links to be incorporated into the total system, i.e. conventional radio and trunked radio and microwave radio and LAN all interconnected by ACE3600 into a single communication system. Data may be passed from any site to any other site in the system (peer-to-peer) either directly or by multiple hops through intermediate ACE3600 sites. This peer-to-peer communication capability enables system designs that use a distributed-intelligence operating philosophy; central-intelligence-only systems may also be implemented if the load on the communication system permits it.

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ACE3600 System Overview

• The Front End Processor (FEP):

The Front End Processor is used at the central site(s) to provide a two-way path to the communication system and the distant RTUs from the SCADA Manager hardware and software. The FEP converts MDLC protocol data from the RTUs to a protocol used by the SCADA Manager vendor: when the OPC or ModBus protocol is used, the FEP will maintain a local database of all the data from the multiple in-field sites; when TCP/IP gateway is used, the FEP is simply a gateway between the two different protocols. The FEP always acknowledges all RTU-initiated messages. The FEP can also provide a twoway path between the ACE3600 STS and the field RTUs for those functions unique to ACE3600 that are not provided by the SCADA Manager software (over-the-air programming download, diagnostics upload, and more.)

• SCADA Manager:

The SCADA Manager provides the operator with the display and report tools necessary to view and manage the associated process(es). The SCADA Manager obtains data from the FEP according to its needs and typically presents that data on custom-created display formats; control messages may also be initiated from these custom screens. Security is typically implemented via permission levels activated by the operator’s sign-on password. Microsoft Windows is becoming the operating system of choice because it easily supports the desired graphic symbols used on the custom screens. The report capability may be provided by the SCADA software or a data export to Microsoft Excel or equivalent may be utilized. The end result is an easy to use pictorially-described representation of the field status of key equipment items plus the means to make changes in how those pieces of equipment operate.

• System Tools Suite (STS):

The ACE3600 STS is a software program that allows the system engineer to set up and maintain the ACE3600 system in accordance with system-specific requirements. The STS computer (PC) may be connected to any RTU/FEP or to the other network points in the system and have connectivity established

with any other site through the store-&-

forward capability of the MDLC protocol; all the capabilities available during a local connection may then be enjoyed by the remotely-connected system engineer: the communication network topography may be defined; the application(s) for each site may be created and downloaded into the RTUs; run-time and diagnostic data may be uploaded.

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ACE3600 RTU Construction

The ACE3600 RTU is a universal device that may serve as an RTU, a Programmable Logic Controller (PLC), or as the system FEP. It is placed at the system’s field sites to collect data from on-site sensors, add data from off-site sources, and use this data aggregate to make decisions regarding how some process is operating. The RTU may make changes to the local process; messages may be initiated that send data elsewhere to influence the operation of off-site equipment or to advise the SCADA Manager of some important change.

The ACE3600 is available in various structures:

 Frame which can accommodate a varied number and type of modules  Metal chassis which accommodates the frame, and optional radios, backup battery

and communication interfaces

 Protective housing which accommodates the frame, and optional radios, backup

battery and communication interfaces (suitable for outdoor installation)

The ACE3600 frame consists of the following elements:

 Plastic slots which accommodate the power supply, CPU and I/O modules, and

backplane bus motherboard

 Mounting plate for attaching the plastic slots together and mounting the frame on

a wall

 Backplane bus motherboard which connects the modules to each other via the

signal buses and connects the modules with operating voltages

 Power junction box for AC or DC power source and ground connections

A frame can be mounted on the wall or installed in a 19" rack or customer enclosure.

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ACE3600 RTU Construction

Each RTU can include a number of options, including portable and mobile radios, and plastic boxes with interface card for communication, etc.

Housing/Mounting Type Capacity/Options Illustration

No I/O slot frame Basic (default) model.

Can be installed on a wall.

3 I/O slot frame Can be installed on a wall.

5 I/O slot frame Can be installed on a wall.

7 I/O slot frame Can be installed on a wall.

Power supply and CPU Can be ordered with metal

chassis or housing options.

Power supply and CPU, up to 3 I/Os

Can be ordered with metal chassis or housing.

Power supply and CPU, up to 5 I/Os

Can be ordered with large metal chassis or housing.

Power supply and CPU, up to 7 I/Os

Can be ordered with large metal chassis or housing.

8 I/O slot frame Can be installed on a wall

or in 19" rack/enclosure.

Small metal chassis Enables installation of

radio, backup battery and other accessories.

Can be installed on a wall or in housing.

Power supply and CPU, up to 8 I/Os

Can be ordered with metal chassis option for accessories: 6.5 or 10 Ah Lead-Acid backup battery up to 2 radios; up to four plastic boxes.

Power supply and CPU, up to 3 I/Os, 1 mobile/portable radio, 1 plastic interface box,

6.5 Ah Lead-Acid backup battery

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ACE3600 RTU Construction

Housing/Mounting Type Capacity/Options Illustration

Large painted metal chassis Enables installation of

radio, backup battery and other accessories.

Can be installed on a wall or in housing.

Small NEMA 4/IP65 housing

Enables installation of radio, backup battery and other accessories.

Can be installed on a wall.

Large metal NEMA 4/IP65 housing

Enables installation of radio, backup battery and other accessories.

Can be installed on a wall.

Power supply and CPU, up to 7 I/Os, 1 plastic interface box, up to 2 mobile/portable radios,

6.5 or 10 Ah Lead-Acid backup battery

Power supply and CPU, up to 3 I/Os, 1 mobile/portable radio, 1 plastic interface box,

6.5 Ah Lead-Acid backup battery

Power supply and CPU, up to 7 I/Os, 1 plastic interface box, up to 2 mobile/portable radios,

6.5 or 10 Ah Lead-Acid backup battery

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ACE3600 RTU Construction

Power Supply Modules

The ACE3600 power supply module provides the other modules in the RTU with their operating voltages via the motherboard bus.

The following power supply options are available:

 DC power supply low-tier (10.8-16V)  DC power supply (10.8-16V) – provided as default  DC power supply (18-72V)  DC power supply (18-72V) with battery charger  AC power supply- 100-240V  AC power supply- 100-240V with battery charger

Common characteristics of all power supply modules: (except the DC power supply low-tier)

 On/Off switch on the front panel  Controlled auxiliary voltage outputs  Heat convection cooling (no need for fans)  Short protection outputs  Over heating protection  The module operation is monitored by the CPU module.  Status LEDs on the front panel  The PS module is always located in the leftmost slot of the frame.  Input current protection fuse  Controlled power line enables centralized disabling of Electrically Energized and

Magnetically Latched relay outputs in selectable DO modules.

Note: The DC power supply low-tier does not support radios that require input power other than 10.8-16V. Do not use portable radios which require 7.5V input with this option.

Note: The low limit of the DC power supply (10.8-16V) can be configured to 10.5V. The default is 10.8.

Common characteristics of power supply modules with battery charger:

 Automatic switchover to battery on power fail  Automatic switchover to main power on power return  Temperature compensated charging  Over-charging protection

Characteristics of the DC power supply low-tier:

 Two auxiliary voltage outputs

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ACE3600 RTU Construction

 Short circuit protection outputs  PS located on the leftmost slot of the frame  Overvoltage protection for CPU and I/Os  Reverse voltage protection

Power supply modules with a battery option support a 6.5 or 10 Ah Lead-Acid battery. The power supply automatically switches to the backup battery as a 12V DC power source for the RTU and communications when the main AC or DC power source fails.

Power supply modules with battery charger option charge the backup battery when not in use, and protect the battery from over-discharge. The charger performs battery tests/diagnostics, including controlled battery discharge, when requested by the user. If the battery is failed, the charger will not charge it and will send a failed status signal to the CPU. If the battery is remotely located, long battery cables can be used.

The charging voltage of the Lead-Acid battery is controlled by the charger as a function of the battery temperature. The charging profile is set to comply with the temperaturecompensated float-voltage of the ACE3600 battery.

A battery test can be performed on the Lead-Acid battery, either from the ACE3600 STS Hardware Test utility or from the user application program. The battery test includes disabling the battery charger, discharging the battery and measuring the capacitance.

Note: An additional power supply module for use with I/O expansion frames is described in the Expansion Power Supply Module section below.

12V Backup Battery

The ACE3600 backup 12V Lead-Acid battery provides backup for the main input power. The battery is available in two capacities: 6.5 Ah and 10 Ah. Switching from main input power to the battery and charging of the battery is performed by the ACE3600 power supply module. Sealed Lead-Acid technology batteries can be recharged and discharged at a temperature range of -30º to +60ºC. Storage and operating temperatures affect the battery capacity and lifespan. ACE3600 power supply modules include a special charging power supply designed to fit the specific temperature-compensated float-voltage-charging curve of the battery.

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CPU Modules

The main element of the ACE3600 is the CPU module. It controls the I/O modules, processes the gathered data and communicates with the outside world. The core of the module is Freescale’s MPC8270 32-bit microprocessor which has extended communication capabilities, high speed core, DMA and floating point calculation support. The module includes on-board memory, communication ports, I/O bus interface and other circuits. The firmware is based on Wind River’s VxWorks operating system.

Module Location: The CPU is a removable module located in a dedicated slot in the RTU rack. The CPU module must be plugged into the wide slot to the right of the Power Supply module.

The CPU module includes several communication ports:

On Board ports:

 Serial 1 (SI1) – RS232/RS485 serial port (configurable)  Serial 2 (SI2) – RS232 serial port  Eth1 (E1) - 10/100BaseT Ethernet port (CPU 3640 only)

Plug-in ports bays, where different types of ports can be installed:

 Plug-in 1 (PI1) – fits RS232, RS485, 10 MB Ethernet, 10/100 MB Ethernet, or

Radio Modem Plug-in option

 Plug-in 2 (PI2) – fits RS232, RS485, 10 MB Ethernet, or Radio Modem Plug-in

port option.

Note: For information on the ACE3600 Ethernet port and Auto-Negotiation, see the Auto-Negotiation Note at the end of the IP Ports (MDLC over IP) section below.

The ACE3600 CPU memory includes FLASH, SDRAM, and optional SRAM Plug-in memory. The FLASH stores the firmware, the user application program, and the user data. The SDRAM memory stores the temporary data. The optional SRAM memory expansion is used for logging user data. The SRAM data is retained using an on-board rechargeable lithium battery.

Model 3610 Model 3640 Flash memory

SDRAM memory: User FLASH: User SDRAM: SRAM Plug-In

16 Mb 16 Mb

32 Mb 32 Mb

3 Mb 3 Mb

10 Mb 10 Mb

4 Mb 4 Mb

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CPU Modules

The CPU has a low drift RTC. The date and time are retained using an on-board rechargeable lithium battery. The CPU date and time can be set using the ACE3600 STS. The CPU can also be synchronized with other RTUs in the system, using the system clock.

The CPU’s rechargeable lithium battery provides backup power and data retention for the SRAM and RTC. Typically, the battery will preserve the data stored in the SRAM and RTC for 60 continuous days without power. When the SRAM option is not used, the Lithium battery will keep the Real Time Clock (RTC) running for a longer period of time.

The CPU module also includes:

 Buzzer (audio indication), which is used to indicate task completion (such as end

of download/upload, restart etc.) and can also be controlled from the user application program.

 Pushbuttons on the front panel, PB1 and PB2. These pushbuttons are used for

activating and testing the module LEDs, restarting the unit, erasing the user Flash memory and activating memory test. The pushbuttons can also be monitored by the user application program (when it is running) for the application purposes.

 Status LEDS which indicate the CPU status during startup (boot), run-time or

when there is a failure. Communication LEDs are used to indicate the communication port status. User LEDs can be used by the user application program.

The CPU’s firmware is a real-time multitasking operating system, based on the Wind River VxWorks OS. The CPU is shipped from the factory with the most recent firmware version, and it can be updated/replaced using a remote or local connection. Downloading firmware updates is performed using the STS. (See Downloading to a Site in the ACE3600 STS User Guide.) If the new firmware download stops or fails, the CPU will restart with the existing firmware.

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I/O Modules

The ACE3600 RTU can include up to eight I/O modules, depending on the frame size. A variety of I/O modules is available. The I/O modules can be positioned in the slots to the right of the CPU. As with all ACE3600 modules, the I/O modules can be replaced while the power is on (hot swap.)

Each I/O module includes an ERR status LED, individual I/O status LEDs, an array of I/O connectors, and a coding mechanism for the terminal cable connector or TB holder option. The ERR LED indicates an I/O module fault and errors. It will remain lit until all the errors have been eliminated. Diagnostic and error messages can be retrieved from the module using the ACE3600 STS Error Logger or SW Diagnostics.

The I/O status LEDs in Digital Input (DI) and Digital Output (DO) modules indicate ON and OFF (LED lit when the I/O is ON.) In Analog Input (AI) modules, each input has two LEDs, indicating Overflow (OF) and Underflow (UF). In Analog Output (AO) modules, each output has three LEDs, indicating voltage output (Vout), current output (Iout), and calibration (Cal).

Each I/O module can be ordered either with a set of two, three or four TB connectors or with a TB holder. TB connectors have a fixed female side on the module and a male plug for the sensor/device wire connection. The TB male side in all modules is screw type for up to 1mm (18 AWG) wire in modules with two/four TBs (3.5 mm pitch) or 1.6 mm (14 AWG) wire in modules with three TBs (5 mm pitch). Two TB extractor tools (FHN7063A) are provided for easy removal of TBs, one for modules with two/four TBs and one for modules with three TBs.

The TB holder secures the male TBs neatly in place and forms a single connector plug per module. The wires connected to the TBs are concealed in the holder. The module and the TB holder provide a coding mechanism to prevent cabling errors. Ejector handles enable easy release of the TB holder connector from the module. An optional three-meter cable braid, completely wired with holder and cable, is available. A TB holder kit is available to enable self-assembly of cables. User assembled cables should use wires of up to 0.4mm (26 AWG) in modules with two/four TBs (3.5 mm pitch) or wires of up to 0.8 mm (20 AWG) in modules with three TBs (5 mm pitch). The TB holder kit does not include a cable.

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I/O Modules

Terminal Block (TB)

Ejector Handles

Positioner

Screw

TB Holder

Terminal Blocks (TB)

I/O Module

Positioner

Terminal Block (TB)

Code Key

TB Holder

I/O Module

Code Key

Up to two 24V DC floating plug-in power supplies can be added to certain I/O modules,

as detailed in the table below.

Up to four 24V DC floating plug-in power supplies can

be added per rack.

Module Type Number of Power Supplies

32 DI 2 16 DI 1 16 AI 1

8 AI 1

Mixed I/O 1

Mixed Analog 1

Available as of December 2007.

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I/O Modules

Spacers

Optional 24V

Floating Power Supply Plug-In

Motherboard Location PIN

Motherboard Connector

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Digital Input Modules

Low Voltage DI Modules:

The ACE3600 low voltage Digital Input (DI) module can have 16 or 32 inputs. The following DI modules are available:

 16 DI Fast 24V  32 DI Fast 24V  16 DI Fast 24V IEC TYPE 2  32 DI Fast 24V IEC TYPE 2

Two types of low voltage (“wet”) inputs are supported, IEC 61131-2 Type II compliant inputs and 24V “MOSCAD compatible” inputs.

In the 32 DI modules, the first 20 inputs can function as fast counters. In the 16 DI modules, all inputs can function as fast counters. A counter’s maximum rate is dependent on the module type (see the specifications below.)

All the inputs are optically isolated. The DI modules support optional 24V DC floating plug-in power supplies (for contact “wetting” or other purposes).

The 16 DI Fast 24V and 32 DI Fast 24V modules can handle AC and DC input signals. The user can select DC or AC operation per module. When AC configuration is selected, the Fast Capture, Counter Function and Input Filters (see below) are disabled.

120/230V (HV) DI module:

The ACE3600 high voltage Digital Input (DI) module has 16 inputs. All the inputs are IEC 61131-2 Type2 compliant and all are optically isolated.

This module supports high voltage AC or DC signals in the inputs. The Counter function is not supported in this module.

Common Characteristics to all DI modules:

Each DI can be an event trigger (interrupt-driven) to a high priority fast process. The high priority fast process enables very fast activation of an output in response to an input trigger and logical conditions. This high priority fast process is not dependent on the I/O scan.

When the DI module is in DC mode, each DI can be configured as a Fast Capture DI. Fast capture causes the SCAN ladder output operation to get the first change that occurred since the previous scan. When fast capture is disabled, the scan gets the current value of the DI (in this case, any DI changes between scans are missed.)

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Digital Input Modules

When the DI module is in DC mode, each input has a HW input filter to make sure that the input reading is stable. The range of the HW DI filter is 0 to 50.8 millisecond (in 0.2 mS steps). The Fast Counter DI filter range is 0 to 12.75 millisecond (in 0.05 mS steps).

The DI module features which can be configured are listed in the table below. Some parameters are per module and some are per input.

Feature Parameter

Settings

Default Setting Per Module/

Input

Parameter Setup Location

DC or AC operation

Fast Capture Disabled

DI Filter (DC) 0-254 (x 0.2

Counter Filter (DC)

Event Time Tagging

Keep Last Value and Predefined Value

Mask No /Yes No Input User Program I/O

∗

AC/DC DC Module STS site

configuration

Disabled Input STS site

/Enabled

mS)

0-255 (x 0.05 mS)

Disabled/ Enabled

KLV/PDV PDV=0/1

50 (10 mS) Module STS site

20 (1 ms) Module STS site

Disabled Input User Program I/O

KLV Input User Program I/O

configuration

configuration; ‘C’ User Program

configuration ‘C’ User Program

link table

Note: In the 120/230V DI module, the minimum effective DI Filter parameter value is 7.0 mSec.

Each DI can be set in the user application program’s I/O link table to trigger recording of time tagged events upon any input change of state. The time tagged events are recorded in the CPU memory and can be retrieved for various purposes.

Each input can be configured to “Keep Last Value” (KLV) or to “Predefined Value” (PDV 0 or 1). This value is shown to the user application program in the event of DI module failure. The PDV can also be used during normal operation to force a value that masks the actual input value. In this case the user program will get the PDV instead of the actual input value.

∗

in Fast 24V IEC TYPE II modules –only DC

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Digital Input Modules

Each DI module can be switched by the user application program to Sleep Mode. In Sleep Mode, the module does not function and the power consumption is minimized. During Sleep mode, the user application program will get the predefined values (PDV) for each I/O.

The DI module can be diagnosed and monitored using the STS Hardware Test utility. This test verifies that the module is operational, presents the module configuration and shows the actual value of each input. It is also possible to change the input filter setup temporarily for the duration of the Hardware Test.

In the STS Hardware Test utility, it is possible to set the DI module to Freeze Mode. In this mode the user application program will get the predefined value of each input in the module, instead of the actual input value. Freeze mode enables testing the inputs while the user application program is running.

Connection of a dry contact sensor to the low voltage DI module requires “wetting” the contact with a voltage. This can be done using the 24V DC floating plug-in power supplies that can be added to the module. The 24V can be also used to power “wet” sensors. ** The 24V can be also used to power “wet” sensors. (Low voltage only)

Low Voltage DI I/O Circuit Diagram:

DI - Typical Input Circuit

DI Status

6.5 mA Current Limiter

33V

Full Diode Bridge Rectifier

250

Available as of December 2007.

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16 DI Module Block Diagram:

16 DI

Digital Input Modules

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32 DI Module Block Diagram:

Digital Input Modules

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Low Voltage DI I/O Connection Diagram:

Digital Input Modules

DI Module

External Wetting Source

Dry Contact Sensor

“Wet”

Sensor

DIx (input x) COM (common)

DI Module

DIx (input x)

COM (common)

DI Module

“Wet”

Sensor

Dry Contact Sensor

DIx (input x) +24V (Plug-in PS)

DI Module

+24V (Plug-in PS)

DIx (input x) COM (common)

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High Voltage DI I/O Circuit Diagram:

High Voltage DI - Typical Input Circuit

DI Status

10K

Digital Input Modules

1238

47nF

62V

Current

Circuit

COM

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16 DI 120/230V Module Block Diagram:

16 DI High Voltage

DI11

3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19 20

DI22 DI3

DI4

DI5 DI6

COM 1-6

DI7 DI8 DI9 DI10

DI11 DI12

COM 7-12

Input Circuit

Control

Digital Input Modules

Bus

Interface

DI13

DI14

DI15

DI16

24 25 26 27 28 29 30

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16 DI 120/230V I/O Connection Diagram:

AC / DC Signal Source

Digital Input Modules

DI 120/230V Module

DIx (input x)

COM (Common)

DI 120/230V Module

Ext. Relay / Switch

DIx (input x)

AC / DC Signal

Source

COM (Common)

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Digital Output Relay Modules

Low Voltage DO Relay Modules:

The DO Relay modules have 8 or 16 outputs. There are two types of DO relays:

 Electrically Energized (EE) - the outputs return to the non-energized state in case

of power off or module failure.

 Magnetic Latch (ML) - Relay outputs are magnetically latched, the outputs

maintain their state in case of power off or module failure.

The following DO relays modules are available:

 8 DO EE Relay 2A  16 DO EE Relay 2A  8 DO ML Relay 2A  16 DO ML Relay 2A

In the 8 DO modules, the relays of outputs 1 through 5 are Single Pole Single Throw (SPST) normally open (NO) and are referred to as the “Form A” relays. The relays of outputs 6 through 8 are Single Pole Double Throw (SPDT) and are referred to as the “Form C” relays.

In the 16 DO modules, the relays of outputs 1 through 5 and 9 through 13 are Single Pole Single Throw (SPST) normally open (NO) “Form A” relays. The relays of outputs 6 through 8 and 14 through 16 are Single Pole Double Throw (SPDT) “Form C” relays.

120/230V DO Relay Modules:

The ACE3600 DO Relay 120/230V (High Voltage DO) modules have 12 outputs. Each output is switched by a relay.

There are two types of DO relays:

 Electrically Energized (EE) - the outputs return to the non-energized state in case

of power off or module failure.

 Magnetically Latched (ML) - Relay outputs are magnetically latched, the outputs

maintain their state in case of power off or module failure.

The following DO relays modules are available:

 12 DO EE Relay 120/230V 3A  12 DO ML Relay 120/230V 3A

DO Modules Common Characteristics:

The physical position of each relay is monitored by the module logic, using a back indication signal which is connected to the relay’s second contact set. Any contradiction

Page 27

Digital Output Relay Modules

between the required position and the back indication signal is reported to the CPU and is available to the user program.

In some applications it is necessary to inhibit relay output operation when attending the site for safety reasons. In all DO relay modules, it is possible to inhibit all relays per DO module.

When a module is configured to enable relay inhibiting, the power to the relays is provided from the power supply via a dedicated power line (12V DO), controlled from the “12V DO” input (TB located on the power supply module front panel). When the input’s terminals are shorted, the relays are operational. When the input’s terminals are open, the relays are inhibited (EE relays in 0 position and ML relays do not change state.) The user program can monitor the relay inhibiting status and act accordingly. Also, when the module’s relays are inhibited, any mismatch between the relay position and the output logical state is ignored.

Each output can be configured to “Keep Last Value” (KLV) or to a “Predefined Value” (PDV 0 or 1). This value is executed when the user program stops or when the module has no communication with the CPU module. Also, the PDV can be used during normal operation to force a value on the output by ignoring the user program value (mask).

In the ML relay modules, it is possible to configure the module to reset all the ML relays positions on startup. This is set in the STS site configuration.

Parameter Selection Default Setup Per Module/

Input

Parameter Setup Location

DO Keep Last Value & PreDefined Value

DO Mask No /Yes No Output Application

Reset DO at Startup

Relay Inhibiting (SW selectable)

KLV/PDV PDV = 0/1

Disable/Enable Disable Module Site

KLV Output Application

Programmer I/O link table

configuration

Each DO module can be switched by the user program to Sleep Mode. In Sleep Mode, the module does not function and the power consumption is minimized.

The DO module can be diagnosed and monitored using the STS Hardware Test utility. This test verifies that the module is operational, presents the module configuration and shows the actual value of each output. It is also possible to change the DO’s value. In the Hardware Test utility, it is possible to set the module to Freeze Mode. In this mode, the

Page 28

Digital Output Relay Modules

DOs will keep the last value they had at the time they were frozen. Freeze mode enables testing the inputs and outputs while the user program is running.

Note: In systems with I/O expansion, the power supplies on I/O expansion frames can be attached via DC cable to the power supply on the previous I/O expansion frame in a daisy-chain manner, or directly to the main power supply. In this case, the 12V DO control on the main power supply can control all DO EE relays in the entire RTU that were configured by dip switch for 12V DO. This enables the user to inhibit all DO EE relays in the entire RTU simply by removing the plug from the 12V DO control in the main power supply.

Page 29

Low Voltage I/O Circuit Diagrams:

DO EE Relay (SPST) - Typical Output Circuit

Digital Output Relay Modules

12V

Back Indication

DO Set Control

CO NO

DO Control

DO ML Relay (SPST) - Typical Output Circuit

12V

COM NO

DO Reset Control

Page 30

Digital Output Relay Modules

DO EE Relay (SPDT) -Typical Output Circuit

12V

Back Indication

DO Set Control

COM NO

DO Control

DO ML Relay (SPDT) - Typical Output Circuit

12V

NC CO

DO Reset Control

Page 31

8 DO Module Block Diagram

Digital Output Relay Modules

Page 32

16 DO Module Block Diagram:

Digital Output Relay Modules

Page 33

120/230V DO I/O Circuit Diagram:

HV DO EE Relay (SPST) -Typical

12V

Digital Output Relay Modules

Output

ircuit

Back Indication

DO Control

HV DO ML Relay (SPST) -Typical Output Circuit

12V

DO Set Control

DO Reset Control

Page 34

120/230V DO Module Block Diagram:

Digital Output Relay Modules

12 V 12 V DO (User Controlled)

11 12

13 14

15 16 17

18 19

3 4

5 6

7 8

NO1

NO2

NO3

NO4

NO5

NO6

NO7

NO8

Back Indication

Module

Control

Bus

Interface

21 22

23 24

25 26

27 28

29 30

NO9

NO10

NO11

NO12

Page 35

Analog Input Modules

The Analog Input (AI) modules have 8 or 16 inputs. The modules sample and convert analog data into digital format and transfer the digital data to the CPU module.

The following modules are available:

 8 AI, ±20 mA (supports 4-20 mA)  16 AI, ±20 mA (supports 4-20 mA)  8 AI, ±5 V (supports 0-5 V and 1-5 V)  16 AI, ±5 V (supports 0-5 V and 1-5 V)

The module’s analog-to-digital conversion resolution is 16 bit (including sign). Each input is fully isolated from the other inputs on the module and also optically isolated from the module internal circuits. The modules are fully calibrated and can be tested and recalibrated in the field.

The measured values are digitally filtered to reduce 50 or 60 Hz noise. The user can select the filtering frequency per module. The measured values can be smoothed by digital filtering.

Smoothing is accomplished by calculating the running average values of a defined number of converted analog values (samples). The user can select the level of smoothing per module. The higher the smoothing level chosen, the more stable the smoothed analog value and the longer it takes until the smoothed analog signal is applied after a step response.

The user can select how the analog values are represented to the user application program, as unit-less numeric values or as scaled values that represent certain Engineering Units (EGU).

Each AI module can include an optional plug-in floating 24V DC power supply to power external devices.

Each analog input has two status LEDs:

 UF - indicates Underflow when lit  OF - indicates Overflow when lit

Page 36

Analog Input Modules

The AI Module Configuration includes:

 50/60 Hz Filtering - This parameter enables the user to configure the module to

use 50 or 60 Hz filter on all inputs.

 AI Filter (Smoothing) - This parameter enables the user to configure the level

smoothing (averaging) on all inputs. It can be set to 1, 2, 4, 8, 16, 32, 64,128 samples.

 Change Of State (COS) Delta - This parameter sets a delta value for each input.

This enables the user application program to get an indication when the input value change is more than ± delta value.

 Input Range - This parameter sets the input overflow and underflow LEDs limits

(refer to AI Module value representation below). In the current input modules, the ranges that can be selected are: ±20 mA (default) and 4-20 mA. In voltage input modules, the ranges that can be selected are ± 5V (default), 0-5 V and 1-5 V.

 “Keep Last Value” (KLV) and “Predefined Value” (PDV) - Each input can be

configured to KLV or to a PDV. This value is shown to the user application program in the event of AI module failure. The predefined value can also be used during normal operation to force a value that masks the actual input value. In this case the user program will get the PDV instead of the actual input value.

 I/O Legacy Resolution Parameter - In systems with both ACE3600 RTUs and

legacy (MOSCAD/MOSCAD-L) RTUs, some MOSCAD/MOSCAD-L applications can be upgraded to ACE3600 without modifying the references to analog values in the applications (‘C’ or ladder). The I/O Legacy Resolution STS advanced parameter sets the Analog I/O bit resolution to either Actual (ACE3600) or Legacy (MOSCAD/MOSCAD-L).

Parameter Selection Default setup Per Module/

Input

Parameter Setup location

50/60 Hz Filtering

AI Filter (Smoothing)

Input Range Current: ±20 mA/

COS Delta value 0 (disabled) Input Application

KLV & PDV KLV/PDV

Mask No /Yes No Input Application

50/60 50 Hz Module STS Site

configuration

1/2/4/8/16/32/64/128 (x10 mS)

4-20 mA Voltage: ±5 V/0-5V/ 1-5V

PDV=value

32 Module STS Site

configuration

Current: ±20 mA Voltage: ±5 V

KLV Input Application

Module STS Site

configuration

Programmer I/O link table

Page 37

Analog Input Modules

In the event of AI Module failure, the I/O module ERR LED will be lit. The event is registered by the CPU in the Error Logger. AI Module failure status is also visible to the user application program.

In addition to the ERR LED, the module includes an Underflow (UDF) and Overflow (OVF) LED for each input.

 When the UDF LED is lit, it indicates that the signal level in the corresponding

input is below the nominal range.

 When the OVF LED is lit, this indicates that the signal level in the corresponding

input is above the nominal range.

 If both the UDF and OVF LEDs of the same channel are lit, the channel is

uncalibrated.

The AI module can be diagnosed and monitored using the STS Hardware Test utility. The Hardware Test verifies that the module is operational, presents the module configuration and shows the actual value of each input, including overflow and underflow. It is also possible to change the input filter setup for the duration of the Hardware Test.

In the Hardware Test utility, it is possible to set the AI module to Freeze Mode. In this mode, the program user will get the KLV or PDV of each input in the module instead of the actual input value. Freeze mode enables testing the inputs while the user application program is running.

Page 38

Analog Input Modules

AI Module Value Representation:

In ± 20 mA current inputs Decimal Value Input Current Indication

< -32256 < -20.16 mA Underflow LED ON

-32000 -20 mA 0 0 mA

Rated range (no LED active)

32000 +20 mA > 32256 > +20.16 mA Overflow LED ON

In 4 - 20 mA current inputs Decimal Value Input Current Indication

< 6144 < 3.84 mA Underflow LED ON 6400 +4 mA 0 0 mA

Rated range (no LED active)

32000 +20 mA > 32256 > +20.16 mA Overflow LED ON

In ± 5 V current inputs Decimal Value Input Voltage Indication

< -32256 <-5.04V Underflow LED ON

-32000 -5 V 0 0 V

Rated range (no LED active)

32000 +5 V > 32256 > +5.04 V Overflow LED ON

In 0 - 5 V current inputs Decimal Value Input Voltage Indication

< -256 < -0.04 V Underflow LED ON 0 0 V 32000 +5 V

Rated range (no LED active)

> 32256 > +5.04 V Overflow LED ON

In 1 - 5 V current inputs Decimal Value Input Voltage Indication

< 6144 < 0.96 V Underflow LED ON 6400 1 V 32000 +5 V

Rated range (no LED active)

> 32256 > 5.04 V Overflow LED ON

Page 39

I/O Circuit Diagram:

Analog Input Modules

I ±20 mA - T ypical Input Circuit

N+

A/D

Channel Select

A/D

124

15V

I ±10 V - Typical Input Circuit

15V

PGND

AN+

PGN

Channel Select

Page 40

8 AI Module Block Diagram:

Analog Input Modules

Page 41

16 AI Module Block Diagram:

Analog Input Modules

Page 42

Analog Input Modules

I/O Connection Diagrams:

There are two types of current sensors/transmitters, namely 2-wire and 4-wire. The 2wire transmitters require a serial power feed for the current loop, whereas 4-wire transmitters have a separate power supply connection. As a result, with 4-wire transmitters a single power supply may be used to provide power to several sensors; the diagram below describes the connection of the two types of current sensors to the analog input module.

AI Module

Shield

AI+ (input x)

AI - (input x)

AI Module

AI+ (input x)

AI - (input x)

2 Wire Current Sensor

4 Wire

Current

Sensor

The diagram below describes the connection of 2-wire and 4-wire current sensors using the 24V PS plug-in on the Analog Input module. Note: 24V Plug-in is a future option.

AI Module

+24V (Plug-in PS)

4 Wire

Current

Sensor

Shielded Wire

AI+ (input x) AI - (input x)

2 Wire Current Sensor

COM (common)

AI Module

Shielded Wire

AI+ (input x) +24V (Plug-in PS)

AI- (input x) COM (common)

Page 43

Analog Output Modules

The Analog Output (AO) modules have four optically-isolated analog output channels for controlling user devices (see Figure 1). Each channel has two possible outputs: 0-20 mA Interface industry standard current output and 0-5 V Interface industry standard voltage output. Only one of the outputs can be enabled in a particular channel - either current or voltage.

The module’s digital to analog converter resolution is 14 bit. The Analog Output channels are optically isolated from the module internal logic circuits. The modules are fully calibrated and can be tested and recalibrated in the field.

Each analog output has three status LEDs, Vout, Iout, and CAL which represent the calibration status of each output for voltage/current.

The AO Module Configuration includes:

 AO Type - The analog outputs can be set to voltage, current, or raw data.  AO Value - The analog outputs can be set to a numeric value (in the range of 0 to

16000) or either in voltage or current according to the output type. The values for voltage are 0 to 10 V and the values for current are 0 to 20 mA.

 AO Calibration - The upper and lower limits of analog outputs can be calibrated -

either as current (20mA upper limit and 4mA lower limit) or voltage (10V upper limit and 2V lower limit). Default upper and lower calibration limits are provided from the factory.

 “Keep Last Value” (KLV) and “Predefined Value” (PDV) - Each output can be

configured to KLV or to a PDV. This value is maintained in the event of AO module failure or communication failure with the CPU. The predefined value can also be used during normal operation to force a value that masks the actual output value.

 Sleep Mode - Each AO module can be switched by the user application program

to Sleep Mode. In Sleep Mode, the module does not function and the power consumption is minimized. During Sleep mode the user application program will get the predefined values for each output.

 I/O Legacy Resolution Parameter - In systems with both ACE3600 RTUs and

Page 44

Analog Output Modules

Parameter Selection Default setup Per

Module / Output

AO Type Voltage/Current User Defined Output STS HW

AO Value Voltage - 0 to 10 V

Current - 0 to 20 mA

AO Calibration

KLV & PDV

Mask No /Yes No Output Application

Voltage - 2 to 10 V Current - 4 to 20 mA

KLV/PDV PDV=value

User Defined Output STS HW

Voltage - 2 to 10 V Current - 4 to 20 mA

KLV Output Application

Output STS HW Test

Parameter Setup location

Test/User application program

Programmer I/O link table

In the event of AO Module failure, the I/O module ERR LED will be lit. The event is registered by the CPU in the Error Logger. AO Module failure status is also visible to the user application program. In addition to the ERR LED, the module includes a voltage output (Vout), current output (Iout), and calibration (CAL) LED for each output.

CAL Vout Iout Indication

On On On Neither output is calibrated. On Off On Iout is uncalibrated. On On Off Vout is uncalibrated. Off On On Both outputs are defined by the user, either using HW

test or user application program to send raw data.

Off On Off Vout is defined by the user, either using HW test or user

application program.

Off Off On Iout is defined by the user, either using HW test or user

application program.

The AO module can be diagnosed and monitored using the STS Hardware Test utility. The Hardware Test verifies that the module is operational, shows the type and actual value of each output, enables calibration, and presents the ROM data calibration factors. The AO type can be set either in the user application program or in the Hardware Test.

Page 45

Analog Output Modules

To set the output value in the Hardware test, the user application program must be stopped or the AO module frozen. To calibrate the output in the Hardware test, the user application program must be stopped or the AO module frozen.

In the Hardware Test utility, it is possible to set the AO module to Freeze Mode. In this mode, the AOs will keep the last value they had at the time they were frozen. Freeze mode enables testing the inputs and outputs while the user program is running.

AO Module Value Representation:

In 0-20 mA current outputs

0 0 4000 5 mA 8000 10 mA 16000 20 mA

Decimal Value Output

Current

In 0- 10 V voltage outputs

Decimal Value Output

Voltage

0 0 V

4000 2.5 V

8000 5 V

16000 10 V

Page 46

I/O Circuit Diagram:

12V

Floating

Voltage

Converter

AO - Typical Output Circuit

Variable

Current source

20V

D/A Control

330

30V

30V 26V

Analog Output Modules

Iout

PGN

RET

Variable

Voltage source

Vout

Page 47

4 AO Module Block Diagram:

Analog Output Modules

Page 48

I/O Connection Diagram:

Analog Output Modules

Devi ce /

Load

Devi ce /

Load

Current Output wiring

Voltage O ut put w iring

Shield

Shie ld

AO Module

Iout x Ret x

AI Module

Vout x

Ret x

Page 49

Digital Output and Digital Input FET Modules

The Digital Output/Digital Input (DO/DI) FET modules have 16 or 32 configurable user connections, organized in groups. Each group can be configured as an 8 DO group or as an 8 DI group.

The outputs are optically isolated current sink FET type with back indication. The inputs are optically isolated Dry Contact type with internal “wetting” voltage.

In the 32 DO/DI module, the following I/O combinations can be configured in the ACE3600 STS site configuration:

I/O combination DI location DO location

32 DO - 1-32 8 DI + 24 DO 1-8 9-32 16DI + 16 DO 1-16 17-32 24 DI + 8 DO 1-24 25-32 32 DI 1-32 -

In the 16 DO/DI module, the following I/O combinations can be configured in the ACE3600 STS site configuration:

I/O combination DI location DO location

16 DO - 1-16 8 DI + 8 DO 1-8 9-16 16 DI 1-16 -

The appropriate combination is selected as the I/O module type, when configuring the I/Os in the ACE3600 STS site configuration.

Each DI can be configured as Fast Capture DI in the STS advanced I/O configuration. Fast capture causes the SCAN ladder output operation to get the first change that occurred since the previous scan. When fast capture is disabled (default), the scan gets the current value of the DI (in this case DI changes between scans are missed).

Each input has a hardware input filter to make sure that the input reading is stable. The hardware DI filter range is 0 to 50.8 mS (in 0.2 mS steps). Counter DI filter range is 0 to

12.75 mS (in 0.05 mS steps). The DI filter can be set in the STS advanced I/O configuration. Note: In this module, the minimum effective filter value is 1 mS.

Page 50

Digital Output and Digital Input FET Modules

Each DI can be set in the Application Programmer I/O link table to trigger recording of time tagged events upon any input change of state. The time tagged events are recorded in the CPU memory and can be retrieved for various purposes.

Each input can be configured to KLV or to a PDV (0, 1) in the Application Programmer I/O link table. This value is shown to the user application program in the event of DI module failure. Also, the predefined value can be used during normal operation to force a value that masks the actual input value. In this case the user application program will get the PDV instead of the actual input value.

Each output can be configured to “Keep Last Value” KLV or to a “Predefined Value” PDV (0, 1). This value is executed when the user application program stops or when the module has no communication with the CPU module.

Also, the predefined value can be used during normal operation to force a value on the output by ignoring the user application program value.

The DO/DI FET module features which can be configured are listed in the table below. Some parameters are per module and some are per input.

Parameter Selection Default

Setup

Per Module/ Input

Parameter Setup Location

DI Fast Capture Disabled /Enabled Disabled Input RTU configuration DI Filter* 0-254 (x 0.2 mS) 50 (10 mS) Module RTU configuration;

‘C’ Program

DI Counter Filter* 0-255 (x 0.05 mS) 20 (1 ms) Module RTU configuration;

‘C’ Program

DI Event Time Tagging

DI Keep Last Value & Predefined Value

DI Mask No /Yes No Input Application

DO Keep Last Value & Predefined Value

Disabled /Enabled Disabled Input Application

Programmer I/O link table

KLV/PDV PDV = 0/1

KLV Input Application

Programmer I/O link table

KLV Output Application

Programmer I/O link table

The counters are limited to 1Khz; therefore filtering is relevant from 1mS and above. In this module the

minimum relevant value for DI Filter is 5 and the minimum value for DI Counter Filter is 20.

Page 51

Digital Output and Digital Input FET Modules

Parameter Selection Default

Setup

DO Mask No /Yes No Output Application

Per Module/ Input

Parameter Setup Location

Programmer I/O link table

Each DO/DI module can be switched by the user application program to Sleep Mode. In Sleep Mode, the module does not function and the power consumption is minimized. During Sleep mode, the user application program will get the KLV or PDV per each DI.

In the event of a DO/DI module failure, the ERR LED on the module will be lit. This event is registered by the CPU in the Error Logger. DO/DI module failure status is also visible to the user application program.

The DO/DI module can be diagnosed and monitored using the STS Hardware Test utility. The Hardware Test verifies that the module is operational, presents the module configuration and shows the actual value of each input and output. It is also possible to change the input filter setup for the duration of the Hardware test and change the value of the DOs.

In the Hardware Test utility, it is possible to set the module to Freeze Mode. In this mode the user application program will get the KLV/PDV of each input in the module instead of the actual input value. The DO values will keep the last value they had when the module was switched to Freeze Mode. Freeze mode enables testing the inputs and outputs while the user application program is running.

Page 52

I/O Circuit Diagram:

12V

Floating

Voltage

Converter

Digital Output and Digital Input FET Modules

DO/DI - Typical I/O Circuit

20K

DI Status/ DO Back Indication

DO Control

Self Recovery Fuse

33V

DO/DI

COM

* FET Always “OFF” in DI configuration

“”

Page 53

16 DO/DI Module Block Diagram:

Digital Output and Digital Input FET Modules

Page 54

32 DO/DI Module Block Diagram:

Digital Output and Digital Input FET Modules

Page 55

I/O Connection Diagram:

Digital Output and Digital Input FET Modules

DI wiring

Dry Contacts Switch / Sensor

DO wiring

DC Source

DO/DI FET Module

DIx (input x)

COM (Common)

DO/DI FET Module

Load

Diode (Inductive load)

DOx (Output x)

COM (Common)

Page 56

Mixed I/O Modules

The ACE3600 Mixed I/O modules include a mixture of Digital Inputs, Relay Outputs and Analog Inputs on the same module.

The available Mixed I/O modules are:

 16 Digital Inputs + 4 EE DO Relay Outputs + 4 Analog Inputs ( ±20 mA)  16 Digital Inputs + 4 ML DO Relay Outputs + 4 Analog Inputs ( ±20 mA)

For operation, description, and configuration of the DIs, refer to the Digital Input Modules chapter. For operation, description, and configuration of the DOs, refer to the Digital Output Relay Modules chapter. For operation, description, and configuration of the AIs, refer to the Analog Input Modules chapter. For operation, description, and configuration of the AOs, refer to the Analog Output Modules chapter.

Page 57

Mixed I/O Module Block Diagram:

Mixed I/O Modules

Page 58

Mixed Analog Modules

The ACE3600 Mixed Analog modules include a mixture of Analog Inputs and Analog Outputs on the same module.

The available Mixed Analog modules are:

 4 Analog Outputs + 8 Analog Inputs (0-20 mA)  4 Analog Outputs + 8 Analog Inputs (0-10V)

For a description of the AIs in the Mixed Analog modules, see the Analog Input Modules chapter. For a description of the AOs in the Mixed Analog modules, see the Analog Output Modules chapter.

The Mixed Analog modules support an optional 24V DC floating plug-in power supply to power external devices.

Page 59

Mixed Analog Module Block Diagram:

Mixed Analog Modules

Page 60

I/O Expansion

The ACE3600 RTU includes the option of expanding the number of I/O modules controlled by a single CPU module on the main frame. The I/O expansion frames can be co-located with RTU on the main frame (installed in the same 19” rack or cabinet) or distributed in the same site (up to 50 meters from the main frame.)

I/O expansion is based on a 100 Base-T full duplex Ethernet connection between the CPU module and the expansion modules. This type of connection enables the user program application to control and monitor the I/O modules on the expansion frames transparently as if they are located on the main frame.

The user can diagnose all the modules on the expansion frames using the STS connected to the CPU on the main frame (locally or remotely.) The STS can also be connected locally to the expansion module’s RS232 (STS1) port.

I/O expansion is based on three modules:

 Expansion LAN Switch: This module is part of the expansion frame. It is

installed in the main frame in an I/O module slot. Up to seven expansion frames can be connected through a single expansion LAN switch. (For one expansion frame, the switch is not required.) Eight to thirteen expansion frames can be connected using a combination of two expansion LAN switches.

 Expansion Power Supply: This module is installed in the I/O expansion frame. It

extends power (and 12V DO control) from the power supply on the RTU’s main frame to the I/O expansion frame, or from one I/O expansion frame to another. This module can be replaced by another ACE3600 power supply option per power requirements or when the expansion frame is not co-located with the main frame.

 Expansion Module: This module is part of the expansion frame. It is installed in

the I/O expansion frame next to the power supply. It is connected via LAN to the RTU’s main frame, either to the CPU module or to the expansion LAN switch, depending on the configuration. For more information, see Expansion Module below.

Note: Only a dedicated LAN with ACE3600 components should be used by the main CPU and expansion modules to communicate with each other. Connecting other elements

as routers and other devices

to the LAN may disrupt the I/O expansion system operation.

Note: The main CPU must include an Eth1 Ethernet port. Therefore, only the CPU 3640 can be used for I/O expansion on the main frame.

The figure below provides a general view of an ACE3600 CPU with a single I/O expansion frame. The expansion module on the I/O expansion frame is connected using a crossed LAN cable to the CPU3640 on the main frame (Port Eth1.) The expansion power supply on the I/O expansion frame is attached via DC cable to the power supply on

such

Page 61

I/O Expansion

the main frame. Accessories such as a mobile radio, battery, etc. are attached to a separate optional 19” chassis.

Main Frame

Radio/Batt. Chassis

(optional)

Main PS (AC/DC) CPU3640

DC Cable

Crossed LAN Cable

Expansion PS

Expansion Module

I/O Frame

ACE3600 I/O Expansion – Single Frame Example

Main Rack

Radio/Batt. Chassis

(optional)

Main PS (AC/DC) CPU (3640) Expansion Switch Communication

Cable

Expansion PS (DC)

Expansion Module

ACE3600 I/O Expansion – Multi-Frame Example

LAN Cable

LAN CableLAN CableDC

I/O Rack #7I/O Rack #2I/O Rack #1

Page 62

I/O Expansion

Note: The number of expansion power supplies that can be cascaded to the power supply on the main frame is limited. When required, optional DC or AC power supplies should be installed on the expansion frames to meet the accumulated power consumption and voltage level requirements.

In the maximal configuration, up to 110 I/Os can be connected to the ACE3600, by using two expansion Ethernet switches on the main frame and thirteen I/O expansion frames. See the figure below.

Main PS (AC/DC) CPU 3640 Expansion Switch 1 Expansion Switch 2 Communication

Cables

Main Rack

LAN Cable PS (AC)

Expansion Module

Radio/Batt. Chassis

LAN Cable

I/O Rack #13I/O Rack #8I/O Rack #7

DC Cable

Expansion PS (DC) Expansion Module

LAN Cable

LAN CableLAN Cable

I/O Rack #6I/O Rack #2I/O Rack #1

ACE3600 I/O Expansion – Maximal I/O Configuration

The following table shows the various configurations per required number of I/O slots:

Number of I/O Slots

Main Frame F75xx

LAN Switch option

Exp. Frame F7510

LAN Cable 0 0 2 3 4 5 6 7 8 9 10 11 12 13 LAN Crossed

Cable

0-8 9-16 17-23 24-31 32-39 40-47 48-55 56-63 64-70 71-78 79-86 87-94 95-102 103-110

1 1 1 1 1 1 1 1 1 1 1 1 1 1

0 0 1 1 1 1 1 1 2 2 2 2 2 2

0 1 2 3 4 5 6 7 8 9 10 11 12 13

0 1 0 0 0 0 0 0 0 0 0 0 0 0

Note: This table assumes the main frame and expansion frames have 8 I/O slots (use option V108).

Page 63

I/O Expansion

I/O Expansion Frame

An I/O expansion frame always includes an expansion module to enable the CPU in the main frame to communicate with and control the expansion frame and its I/O modules. The expansion module is provided with each expansion frame (model F7510). Like the ACE3600 main frame, the I/O expansion frame can contain 3, 5, 7 or 8 I/O slots. The expansion frame is compatible with the chassis and housing options.

I/O Expansion Power

The choice of power supplies for a system with I/O expansion is determined by the specific configuration and the power requirements of the system. In a co-located system where the power supply on the main frame feeds the I/O expansion frame, a low-tier power supply cannot serve as the main power supply. In a distributed system where the power supply on the I/O expansion frame is not connected to the main frame, any power supply modules can be used which suit the power requirements of the system. When applicable, it is recommended to have an external single power on/off switch to control all the power supplies simultaneously. Similarly, it is very important to have a single on/off switch for all 12V DO controls.

Power-up/Restart/Power-down

In a system where the power supply on the main frame feeds the I/O expansion frame, powering up/restarting the main power supply will power-up/restart the expansion frames as well. Power down of the main power supply will power-down the expansion frames as well. In a system where the power supply on the I/O expansion frame is not connected to the main frame, powering down or restarting the main power supply will not impact the I/Os on the expansion frame I/Os. However, these expansion I/Os may be reset after a period of time as a result of this action. If the expansion frame loses communication with the main frame for more than a certain number of seconds (configurable), it will restart. For information on configurable timeouts which may cause the expansion module to restart, see the ACE3600 STS User Guide - Appendix A: Site Configuration Parameters.

Status and Diagnostics

Status and diagnostics information can be retrieved from the expansion module, LAN switch, and power supply using the STS Hardware Test utility and SW Diagnostics and Loggers, via the CPU on the main frame. In a system where the expansion frames are not co-located with the main frame, status and diagnostics information on the expansion components can be retrieved by connecting a PC running STS directly to any expansion module RS232 port.

Page 64

Expansion Power Supply Module

The expansion power supply module (10.8-16V DC) extends power from the power supply on the RTU’s main frame to the I/O expansion frame, or from one I/O expansion frame to another.

Note that this module is provided as default power supply in each I/O expansion frame unless replaced with the other power supply options.

Characteristics of the expansion power supply module:

 Located on the leftmost slot of the expansion frame  Provides overvoltage protection for the I/O expansion

frame

The expansion power supply can only be connected to the power supply on the ACE3600 RTU main frame and to other expansion power supply modules. If all the power supplies on I/O expansion frames are attached via DC cable to the power supply on the previous I/O expansion frame in a daisy-chain manner, the main power supply controls the entire RTU. This enables the user to turn off the entire RTU simply by turning off the main power supply. If the main power supply does not control all other power supplies in the RTU (e.g. when the total power consumption required does not allow all frames to be daisy chained), it is recommended that the main power provided to the power supplies be connected to a single external on/off power switch.

Important: When adding expansion power supplies, make sure that you do not exceed the total power limit of the main power supply, as all connected expansion power supplies drain energy from it. Also make sure that the voltage provided to each power supply (when connected in a daisy-chain manner) does not fall below the minimum operating voltage (see RTU I/O Expansion - Power Considerations below).

The power supply on each expansion frame must be connected to the grounding strip of its frame.

The expansion power supply includes two slow blow fuses, one 4A fuse for overcurrent protection for the I/O expansion frame and one 8A fuse for maximum current via the Power in/out circuit.

The expansion power supply module is connected to another ACE36000 power supply using a DC power cable (FKN8559A/3002360C26).

Page 65

Expansion Module

The expansion module provides an interface from the CPU module (either directly or via the expansion LAN switch) on the ACE3600 main frame to the I/O modules on the expansion frame. This enables the CPU on the main frame to control the I/O modules on the expansion frame and process the gathered data.

This module is installed in the I/O expansion frame in the CPU slot, second slot from the left and is connected via dedicated LAN to the RTU’s main frame.

The expansion module includes two on board communication ports:

 Exp Eth1 (E1) - 10/100BaseT Ethernet port, used to connect to

the expansion Ethernet switch or to the main CPU

 STS 1 (STS1) – RS232 port, used to connect a PC running the

ACE3600 STS to perform diagnostics and other STS operations (for distributed I/O), as if it is connected directly to the main CPU.

The expansion module includes a (rotary) selector switch which enables the user to determine the frame number in the expanded RTU. The frame number is used during communication with the main CPU, with the STS, etc. The expansion frame number range is 1 to 13. On the selector switch, A, B, C and D refer to 10,11,12 and13.

Note: Changing the selector position when the expansion frame is running, takes effect

only after the next restart.

The expansion module shipped from the factory is set by default to 1. In a multiexpansion frame configuration, the settings of additional I/O expansion frames must be changed accordingly to provide each frame with a unique number.

The expansion module can be connected to the main frame in two ways:

Single expansion frame - Direct connection:

In a system with a single expansion frame, connect the Eth1 port on the expansion module directly to the Eth1 port on the main CPU, using a crossed LAN cable (V665/FKN8525A).

Switch connection:

 In an RTU with more than one expansion frame, the Eth1 port on the expansion

module is connected to one of the Ethernet ports Eth2-Eth8 on the expansion Ethernet switch (situated on the main frame). Note: The Eth1 port in the expansion Ethernet switch is reserved for connection to the main CPU.

 If two switches are used, the Eth1 port on the expansion module is connected to one

of the Ethernet ports (Eth3-Eth8) on the first expansion Ethernet switch or to one of

Page 66

I/O Expansion

the Ethernet ports (Eth2-Eth8) on the second switch. (The Eth2 port on the first switch is connected to the Eth1 (M) port on the second switch Ethernet LAN.)

Expansion frames are provided without cables. For connection, use one of the cables listed below or use any other standard Category 5E shielded (FTP) LAN cable (up to 50 meter length).

Three different Ethernet cables are available for this purpose. Choose the cable length based on the distance from the main frame to the expansion frame.

 60 cm (Motorola p/n V529 / FKN8561A) - This cable is used for local connection

of the main CPU to the expansion switch, or connection of the first LAN switch to the second, if such exists.

 2 meter (Motorola p/n V648 / FKN8562A)  3 meter (Motorola p/n V666 / FKN8563A)

Module Firmware and Operation Modes

The expansion module firmware extends the main CPU control to the I/O modules located in the expansion frame. The expansion module (expansion CPU) is shipped from the factory with a dedicated firmware called Expansion Loader. After connecting to the main CPU (MCPU), the expansion module loads the Expansion Firmware Image from the main CPU to ensure that all modules use the same firmware version.

The following diagram describes the initiation process of an expansion module after power-up/restart and during run-time.

Page 67

yes

The Expansion module discovers the main

CPU (MCPU) via UDP/IP (broadcast).

1. Loads the Firmware Image into RAM from the MCPU (using TCP).

2. Turns off all LEDs and runs the loaded Expansion Firmware Image.

3. Auto-recognizes actual I/O modules.

Discovery succeeded-

obtained self and MCPU IP address?

yes

I/O Expansion

Expansion Loader

Loads user files from the MCPU (using TCP) and saves in FLASH:

1. Configuration, if such exists

2. Application database, if such exists

3. Predefined input and output values and I/O link (if such exist)

4. Encryption files, if such exist

yes

1. Registers its actual I/O modules information in the MCPU (using TCP).

2. Initializes the Expansion Image (system startup).

3. Negotiates Ethernet addresses (MAC) and starts EMI with the MCPU via TCP.

yes

Running:

1. Monitor EMI communication with the MCPU.

2. Monitor the MCPU status via TCP.

3. Monitor actual I/O modules change (hot-swap) and update the MCPU.

Failed to load one or more files?

Failed to negotiate or start EMI?

Expansion Firmware Image

yes

Has the MCPU restarted, or disconnected for

more than fail time (60 seconds)?

Page 68

I/O Expansion

Expansion Module Power-up and Restart

The MCOM LED on the expansion module indicates the connection status between the expansion module and the main CPU and expansion frame initialization progress.

The main CPU expects the expansion frames to complete the initialization within a configurable period of time (60 seconds default). After this period of time elapses, the main CPU will operate normally with the connected frames and their I/O modules. Any expansion frame that has not completed initialization within that time (e.g. because it was connected later to the RTU) will be ignored until the next main CPU restart.

Note that after the main CPU starts up, it waits for the expansion modules to complete the initialization process. The wait time is derived from the number of expansion frames configured in the RTU. After all the expansion frames have completed the initialization, the main CPU will continue its system startup. The main CPU will wait 60 seconds (default) for all expansion frames to connect.

Expansion Module during Run-Time

The expansion module constantly exchanges I/O data and status data with the main CPU, using the Ethernet Micro-code Interface (EMI). The EMI enables the main CPU to be updated by all the expansion modules every very short period of time via the expansion Ethernet LAN. The main CPU constantly synchronizes the expansion module date and time, and periodically polls the errors, pushbuttons and time tagged data from all the connected expansion modules.

If the connection between the expansion module and the main CPU is lost (e.g. due to main CPU restart, cable disconnection, etc.) for a configurable period of time (1 minute default), the expansion module will restart and the initialization process will begin again.

After the expansion frames have initialized, it is possible to download to the RTU a user program or other user defined files. After successful download, the main CPU automatically updates each expansion module. Note that if the main CPU tries to download a user program or other files to an expansion module during initialization, the expansion module is restarted.

Page 69

Expansion LAN Switch

The expansion Ethernet switch provides an interface from the ACE3600 CPU (on the master RTU frame) to up to seven expansion frames, or up to 13 expansion frames when two switches are used. This enables up to 110 I/O modules in a single RTU. The expansion modules can be co-located with the switch (installed in the same 19” frame or cabinet) or distributed in other locations.

The switch is installed only in the RTU’s main frame, in either of the first two I/O module slots.

The ACE3600 expansion LAN switch is configured to prioritize different Ethernet data frame types. A special protocol, used for communication between the expansion LAN switch and the main CPU, quickly collects I/O information from the expansion frames to the main CPU and adds the highest priority and special tags to these Ethernet frames. The switch recognizes these frames and gives them the highest priority in the buffer queue, higher than the frames of the standard protocols (MDLC, TCP/IP) used for communication in the ACE3600 system. For this reason, only the ACE3600 expansion LAN switch can be used in an I/O expansion system.

IMPORTANT: When an expansion LAN switch is used on an I/O expansion LAN, only the main CPU and the expansion frames (expansion modules) can be connected to the expansion switch(es). Any attempt to connect other devices to the expansion switch(es) may result in unpredictable communication delays between the main CPU and the expansion frames and malfunction of the expanded RTU.

The expansion LAN switch includes eight 100BaseT Ethernet communication ports:

The expansion LAN switch can be inserted and extracted while the system is powered up.

LAN switch status and diagnostics information can be retrieved via the main CPU using the STS Hardware Test utility. LAN switch warnings and errors are logged in the main frame CPU memory. The RTU error logger information can be retrieved using the STS Error Logger utility.

The expansion LAN switch option includes a 60 cm Ethernet cable (Motorola p/n V529/FKN8561A). Use this cable to connect from the Eth1 port on the main CPU to the Eth1 (M) port on the expansion switch. For the second switch in a system (if such exists), use this cable to connect from the Eth2 port on first switch to the Eth1 (M) port on the second switch.

Page 70

I/O Expansion

One of three Ethernet cables can be used to connect an Ethernet port on the expansion LAN switch to an expansion module in an expansion frame. If the system includes one switch (for up to seven frames), ports Eth2-Eth8 are available. If the system includes two switches (for up to thirteen frames), ports Eth3-Eth8 are available on the first switch and ports Eth2-Eth8 are available on the second switch. Note: The Eth.1 (M) port on the expansion LAN switch is reserved for connection to the main CPU. For details on the Ethernet cables, see Expansion Module above.

In systems with several expansion frames, the ACE3600 STS can be used to provide automatic switch connection configuration. The following physical connections are assumed:

 A system with one expansion frame is connected directly to the main CPU.  A system with 1-7 frames (frame IDs 1-7) is connected via one switch (to

expansion LAN switch ports Eth2-Eth8 respectively.)

 A system with 1-13 frames is connected via two switches (frame IDs 1-6 connected

to expansion LAN switch 1 ports Eth3-Eth8 respectively and frame IDs 7-13 connected to expansion LAN switch 2 ports Eth2-Eth8 respectively.)

If the expansion frames are not physically connected as described above, the switch connection must be manually configured in the STS Switch Connections dialog. For more information, see the ACE3600 STS User Guide.

Page 71

RTU I/O Expansion - Power Considerations

When planning a co-located multi-I/O expansion frame configuration (where all frames are located in the same enclosure or 19” rack), it is possible to cascade the power supplies of the expansion frames to the power supply in the main frame. In the system design stage (before ordering), it is critical to calculate the maximal accumulated power consumption from the main frame power supply (or from a power supply located on an expansion frame which is not an expansion power supply) to make sure it is not overloaded. It is also critical to consider the voltage drop due to the cascading of power supplies.

Power Consumption

The first step in the design is to calculate the number of expansion frames that can be cascaded per the power supply specifications.

The following power consumption information should be accumulated for the RTU:

 Maximal accumulated power consumption of the main frame (CPU, I/O modules,

24 V floating power supplies on modules, radio, etc.)

 Maximal accumulated power consumption of the each expansion frame (expansion

module, I/O modules, floating power supplies on modules) Note: The power consumption information is described in the ACE3600 Owner’s Manual and in this document in Appendix C: ACE3600 Maximum Power Ratings.

The accumulated power consumption from the main power supply (located in the main frame) should not exceed its maximum current output specifications. Consider the following example:

 An expanded RTU requires five expansion frames.  The accumulated power consumption of all frames exceeds the main power supply

specifications.

 The accumulated power consumption of the main frame and the four first frames

exceeds the main power supply specifications.

 The accumulated power consumption of the main frame and the three first frames

does not exceed the main power supply specifications.

 This means that from the power consumption perspective the first three expansion

frames can be cascaded to the power supply in the main frame, the expansion power

supply on the fourth expansion frame should be replaced with AC or DC power

supply option and the fifth expansion power supply can be cascaded to this added

power supply.

Voltage Drop

The second step is to calculate the number of expansion power supplies that can be cascaded per the allowable input voltage to the expansion power supply.

Page 72

I/O Expansion

Each cascaded expansion power supply gets a lower input voltage from the preceding power supply. The voltage drop is a function of the expansion power cable resistance and the current flowing through the cable (which is the accumulated current of the expansion frame and all the following expansion frames cascaded to it.)

The paragraph below shows how the input voltage of a cascaded expansion frame can be calculated.

Below is a block diagram of cascaded power supplies.

 n the number of expansion frames  Vo the output voltage of the main power supply  Ix

the maximal power consumption of expansion frame #x (x = 1,2,3..n)

 Vx the voltage in the input of expansion power supply #x (x = 1,2,3..n)

The equivalent electrical circuit diagram of such system is:

The values of V1, V2…..Vn must be calculated.

For example: Assume n= 4

V1 = Vo - 0.15(I1+I2+I3+I4) - 0.15(I1) V2 = Vo - 0.15(I1+I2+I3+I4) - 0.15(I2+I3+I4) - 0.15(I2) V3 = Vo - 0.15(I1+I2+I3+I4) - 0.15(I2+I3+I4) - 0.15(I3+I4) - 0.15(I3) V4 = Vo - 0.15(I1+I2+I3+I4) - 0.15(I2+I3+I4) - 0.15(I3+I4) - 0.15I4 – 0.15(I4)

Page 73

The general equation for Vx is:

I/O Expansion

Vo depends on the power supply configuration. Vo should be 13 V DC when the backup battery option is not used. If the battery option is used with the main power supply, during power fail Vo depends on the battery voltage (which may be below 13 V DC). It is highly recommended to use at least 11 V DC for input voltage Vx.

Consider the following example:

 An expanded RTU includes five expansion frames.  The maximal accumulated current consumption of each expansion frame

(expansion module, I/O modules, floating power supply on modules, etc.) is

calculated.

 The input voltage Vx of each expansion power supply (V1-V5) is calculated as

described above.

 The input voltage at the first three expansion power supplies (V1,V2, V3) is above

11 V DC.

 The input voltage at the last two expansion power supplies (V4, V5) is below 11 V

DC.

 This means that from the voltage drop perspective, the first three expansion frames

can be cascaded to the power supply in the main frame, the expansion power supply

on the fourth expansion frame should be replaced with an AC or DC power supply

option and the fifth expansion power supply can be cascaded from the fourth frame

power supply.

IMPORTANT: Design note: The design must take into account the worst case result of both the power consumption calculation and voltage drop calculations.

Page 74

Ordering Information

ACE3600 RTU Ordering Flow:

For RTUs without I/O expansions, follow only the ordering steps for Main Frame below.

Main Frame - Step 1

Select ACE3600 model

Note: CE countries (Western Europe) can only order ACE without radio (F7509)

Model F7509

Radio Installation

Add Radio

Installation

Kit option

regional option

Need

Kit?

Yes

CM200/EM200/ CM140/GM3188

Add the

required

V85X

Without Radio

Conventional radio

Specify

Conventional

Radio model in

the main row

What Radio

model selected?

HT750/GP320/ GP328/RO5150

Add the

required

regional option

V95X

Model Type?

Select

Radio Type

CDM750

With Radio

Analog Trunk

Radio model in

the main row

Trunked radio

Specify

! You must specify

frequency in the

order

Select

Trunking Type

Digital Trunk

(IV&D)

Specify

Digital Trunk

Radio model in

the main row

Go to

Main Frame - Step 2

Page 75

! The default

frame includes

CPU3610 and

12V DC PS

Main Frame - Step 2

Set # of I/O Modules Slots

and add I/O modules

Need slots

for I/O modules or

Exp. switch?

Ordering Information

8 I/O Slots fits wall mount and 19” rack only

The number of

modules MUST

match the number

of available I/O

slots

Expansion LAN

Switch occupies

I/O module slot

Cables

Yes

Add the required

Option to

set the frame to

3,5,7 or 8

I/O module slots

Add the required

I/O and Exp. Switch

modules options

Add the required

I/O modules

Accessories/

Options

Go to

Main Frame - Step 4

Page 76

! For models with

radio and/or

battery you

must add

metal chassis or

housing

Main Frame - Step 3

Select installation type

Need chassis,

housing or 19”

installation?

Yes

Ordering Information

0 or 3

Add

small / large

metal chassis

small / large

housing

option

How many

I/O slots?

5 or 7

Add

large

metal chassis

or large housing

option

Go to

Main Frame - Step 4

Add

19”

chassis

and/or

19” rack brackets

Page 77

! Default PS

12 V DC

Main Frame - Step 4 Select PS & Battery

Change

Default

Yes

Ordering Information

Large chassis /housing

Add

6.5 Ah or 10 Ah battery option

Yes

Add

AC PS or DC PS

with charger

option

What type of

Installation?

Needs

backup

battery?

Small chassis /housing

Add 6.5 Ah

battery option

Add

AC PS or DC PS

without charger

option

Expansion Frame - Step 5

Go to

Page 78

! Default CPU

CPU3610

I/O Expansion

Requires CPU3640

Main Frame - Step 5

Select CPU and Plug-in

Change

Default

CPU

Yes

Add

CPU3640 option

Ordering Information

Please note!

Conventional Radio Installation Kit includes radio modem plug-in

Need Plug-in

option

Yes

Add CPU

Plug-in option

Go to

Main Frame - Step 6

Page 79

Main Frame - Step 6

Miscellaneous

Ordering Information

Tamper switch, RS485 Junction Box, dummy module, etc.

Need

miscellaneous

Options?

Yes

Add

miscellaneous

Options

Need

I/O

Expansion?

End

Yes

Go to

Expansion Frame - Step 1

Page 80

! The default

frame includes Expansion module and Expansion PS

Ordering Information

Expansion Frame – Step 1

Select model

Set # of I/O Modules Slots

and add I/O modules

Select model

F7510

8 I/O Slots fits wall mount and 19” rack only

The number of

modules MUST

match the number

of available I/O

slots

Cables

Need slots

for I/O modules or

Exp. switch?

Yes

Add the required

Option to

set the frame to

3,5,7 or 8

I/O module slots

Add the required

I/O modules options

Add the required

I/O modules

Accessories/

Options

Expansion Frame - Step 2

Go to

Page 81

! For models with

battery you

must add

metal chassis or

housing

Expansion Frame - Step 2

Select installation type

Need chassis,

housing or 19”

installation?

Yes

Ordering Information

0 or 3

Add

small / large

metal chassis

small / large

housing

option

How many

I/O slots?

5 or 7

Add

large

metal chassis

or large housing

option

Go to

Expansion Frame - Step 3

Add

19”

chassis

and/or

19” rack brackets

Page 82

! Default PS

Expansion PS

Change PS per

power

requirements or if

the expansion is

not located with

the main frame

Expansion Frame - Step 3

Select PS & Battery

Change

Default

Yes

Needs backup battery?

Ordering Information

Yes

Large chassis /housing

Add

6.5 Ah or 10 Ah battery option

Add

AC PS or DC PS

with charger

option

What type of

Installation?

Add

AC PS or DC PS

without charger

option

Small chassis /housing

Add 6.5 Ah

battery option

Go to

Expansion Frame - Step 4

Page 83

Expansion Fram e -Step 4

Miscellaneous

Ordering Information

Tamper switch, LAN cable, Dummy module, Driver license, etc.

Need

miscellaneous

Options?

Yes

Add

miscellaneous

Options

Need

additional

I/O Expansion?

End

Yes

Go to

Expansion Frame - Step 1

Page 84

List of ACE3600 Models

Note All RTU models include no I/O slots frame,

10.8-16 V DC PS and CPU3610.

No Radio Model

• ACE3600 Basic Model No Radio

I/O Expansion Model

• Expansion Frame

Conventional VHF Radio Models

• ACE3600 with CM200/CM140/EM200/GM3188 VHF

• ACE3600 with CDM750 136-174 MHz

• ACE3600 with HT750/GP320/GP328 /PRO5150 VHF

Conventional UHF Radio Models

• ACE3600 with CM200/CM140/EM200/GM3188 UHF

• ACE3600 with CDM750 403-512 MHz

• ACE3600 with HT750/GP320/GP328 /PRO5150 UHF

Analog Trunked VHF Radio Models

• ACE3600 with XTL2500 136-174 MHz Analog

• ACE3600 with XTL2500 136-174 MHz Digital

• ACE3600 with XTS2500 136-174 MHz Digital

Trunked UHF Radio Models

• ACE3600 with XTL2500 380-520 MHz Analog

• ACE3600 with XTL2500 380-520 MHz Digital

• ACE3600 with XTS2500 380-520 MHz Digital

Trunked 800MHz Radio Models

• ACE3600 with XTL2500 800MHz Analog

• ACE3600 with XTL2500 800MHz Digital

• ACE3600 with XTS2500 800MHz Digital

Software

• ACE3600 System Tool Suite (STS)

• ACE3600 C Toolkit (CTK)

• ACE3600 Enhanced PID

Ordering Information

F7509

F7510

F7573 F7563 F7553

F7574 F7564 F7554

F7533 F7593 F7543

F7534 F7594 F7544

F7538 F7598 F7548

F7500 F7600 FVN5680

Page 85

Ordering Information

Note: All radio models require Metal Chassis or Housing option. IMPORTANT: Only model F7509A and all its options, including radio installation kits, may be shipped to European Union (EU) countries. The installer must confirm that there are no emissions or harmful interference to the spectrum due integrating the radio into this model.

Page 86

List of ACE3600 Options

Ordering Information

Regional radio options CM200/CM140/EM200/CM3188

One of the following options must be ordered for models F7573 and F7574:

• CM 200

• CM140

• GM3188

• EM200

HT750/GP320/GP328/PRO5150

One of the following options must be ordered for models F7553 and F7554.

• HT750

• GP320

• GP328

• PRO5150

Frames

• 3 I/O slots frame

• 5 I/O slots frame

• 7 I/O slot frame

• 8 I/O slots frame

• 19" rack brackets for 8 I/O slots frame

Metal Chassis

• 48 x 48 cm Metal Chassis (up to 7 I/O slots)

• 38 x 38 cm Metal Chassis (up to 3 I/O slots)

• 8 I/O (19") Metal Chassis

Housing

• 50x50 cm Metal Housing (up to 7 I/O slots)

• 50x50 cm Metal Housing with padlock accessory

• 40x40 cm Metal Housing (up to 3 I/O slots)

• 40x40 cm Metal Housing with padlock accessory

• Housing Tamper Switch

Power Supply, Battery Charger & Backup Battery

(Default PS is 10.8-16 V DC input)

• DC Power Supply Low-Tier 10.8-16V

• AC Power Supply 100-240 V

• DC Power Supply 18-72V

• AC PS 100-240 V with Battery charger

• DC PS 18-72V with Battery charger

• 6.5 Ah Backup Battery

V851 V852 V853 V854

V951 V952 V953 V954

V103 V105 V107 V108 V051

V056 V214 V269

V228 VA00405 V276 VA00406 V224

V149 V346 V251 V261 V367 V114

Page 87

Ordering Information

• 10 Ah Backup Battery

CPU Upgrade

(Default CPU is CPU3610)

• ACE CPU3640

• Plug-in SRAM

CPU Plug-in Ports

• Plug-in RS232 Port

• Plug-in RS 485 PORT

• Plug-in Ethernet 10M Port

• Plug-in Ethernet 10/100 M Port

• Plug-in Radio Port

Digital Input Modules

• 16 DI FAST 24V DC

• 32 DI FAST 24V DC

• 16 DI FAST 24V IEC TP2

• 32 DI FAST 24V IEC TP2

• 16 DI 120/230V

Relay Output Modules

• 8 DO EE relay 2A

• 16 DO EE relay 2A

• 8 DO ML relay 2A

• 16 DO ML relay 2A

• 12 DO EE relay 120/230V

• 12 DO ML relay 120/230V

Analog Input Modules

• 8 AI, ±20 mA

• 16AI, ±20 mA

• 8 AI, ±5 V

• 16AI, ±5 V

Analog Output Modules

• 4 AO, ±20 mA

Mixed Input/Output Modules

• 16 DI/DO FET

• 32 DI/DO FET

• 16 DI 4 DO EE 4 AI, ±20mA

• 16 DI 4 DO ML 4 AI, ±20mA

Mixed Analog Modules

• 4AO/8AI ± 20 mA

• 4AO/8AI ± 5 V

V328

V446 V447

V184 V440 V204 V212 VA00362

V265 V379 V117 V959 VA00331AA

V508 V616 V314 V516 VA00348 VA00332

V318 V463 V741 V742

V118

V480 V481 V245 V453

V562 V460

Page 88

Ordering Information

Blank Module

• Blank I/O module

I/O Module Cables

• 20-wire cable braid with TB holder 3 m

• 30-wire cable with TB holder 3 m

• 40-wire cable braid with TB holder 3 m

• 20-pin TB Holder kit

• 30-pin TB Holder kit

• 40-pin TB Holder kit

I/O Expansion

• ACE3600 Expansion LAN Switch

• LAN Cable 60cm length

• LAN Cable 2 Meter length

• LAN Cable 3 Meter length

• LAN Cross Cable

Communications Interface

V20

V253 V202 V358 V158 V203 V153

VA00226

V529 V648 V666 V665

RS485 Connection Box V186

Third Party Protocol Third party protocol license V377

Accessories

• ACT module

• 24V Plug-in Floating Power Supply

Software License (RTU Options)

• AGA 7+8 License

• DNP3+ License

• IEC 60870-5-101 License

V155 FPN1653A

V284 V283 V242

Page 89

Ordering Information

General Ordering Requirements

1. All orders must list the Model (F75XX) as a main line item.

2. Models F7573 and F7574, (CM200 / CM140 / EM200 / GM3188 conventional

radio models) require ordering option V85x (radio type by region).

3. Models F7553 and F7554 (HT750/GP320/GP328 /PRO5150 conventional radio

models) require ordering option V95x (radio type by region).

4. Entering a frequency is mandatory for all models with radio.

5. The default frame for all models is No I/O Slots Frame (CPU and PS slots only).

To change to 3, 5, 7 or 8 I/O slots, add the required Frame option to the order (V103, V104, V105, V107 or V108).

6. 8 I/O Slots Frame is provided with wall mount bracket. Installation on 19”rack

requires ordering 19” rack brackets option (V051). If V269 is used, two V051 units are required.

7. The Default Power Supply in all models excluding F7510 (expansion frame) is

DC 10.8-15.5 V (12 V DC PS), to change the power supply type, add the required PS option.

8. The default CPU module for all models (except F7510) is CPU 3610. To change

to CPU3640 type, add V446. For I/O expansion, V446 on the main frame is mandatory.

9. Model with conventional radio or analog trunked radio are provided with plug-in

radio modem installed in the CPU module.

10. Models with radio and orders that include battery option or accessories option

(such as RS-485 Junction Box) must be ordered with metal chassis or housing options (mandatory).

11. Model F7510 (I/O Expansion Frame) includes an expansion module (CPU),

expansion power supply and expansion power cable. To change the power supply type, add the required PS option to the order.

12. The expansion LAN switch occupies an I/O module slot. It is provided with a 60

cm LAN cable.

13. To connect a single expansion frame (for an RTU with up to 16 I/O module slots),

use a crossed LAN cable (3 meter length).

Page 90

ACE3600 Installation Guidelines

The ACE3600 RTU is shipped from the factory with the modules and plug-in ports assembled. The RTU frame is ready for mounting directly on a wall or in a customer’s enclosure. The 8 I/O frame can be installed on a 19" rack.

Note: For specific installation instructions, please refer to the ACE3600 Owner’s manual.

Dimensions

Frame Dimensions:

• No I/O slots - PS and CPU modules only, wall mount

117 W x 209 H x 198 D∗ mm (4.61" x 5. 30" x 7.80"), 0.95 Kg (2.1 lb)

• 3 I/O slots - PS, CPU and up to 3 I/O modules, wall mount

234 W x 244 H x 198 D∗ mm (9.21"x 9.61" x 7.80"), Approx. 1.9 Kg (4.19 lb)

• 5 I/O slots - PS, CPU and up to 5 I/O modules, wall mount

314 W x 244 H x 198 D∗ mm (12.36"x 9.61" x 7.80"), Approx. 2.4 Kg (5.3 lb)

• 7 I/O slots - PS, CPU and up to 7 I/O modules

391 W x 244 H x 198 D∗ mm (15.39" x 9.61" x 7.80"), 3. Kg (6.6 lb)

• 8 I/O slots - PS , CPU and up to 8 I/O modules, wall mount or 19" rack

435 W x 244 H x 198 D∗ mm (17" x 9.61" x 7.80"), Approx. 3.3 Kg (7.3 lb)

Metal Chassis Dimensions:

• Large - for PS, CPU and up to 7 I/O slot frame, two radios and 6.5 or 10 Ah

backup battery, wall mount , 448 x 468 mm x 200 D

mm (17.64"x 18.43" x

7.88")

• Small - for PS, CPU and up to 3 I/O slot frame, one radio and 6.5 Ah backup

battery, wall mount, 335 W x 355 H x 198 D

mm (17.64"x 18.43" x 7.80")

Housing Dimensions:

• Large NEM A4/IP66 painted metal - up to 7 I/O slot frame, two radios and 6.5 or

10 Ah, backup battery, 500 W x 500 H x 210 D mm (19.7" x19.7" x 8.26" )

• Small NEMA 4/IP66 painted metal - up to 3 I/O slot frame one radio and 6.5 Ah

backup, Battery, 380 W x 380 H x 210 D mm (15" x 15" x 8.26")

∗

Depth Including Module panel

Depth Including Frame and Module

Page 91

GENERAL SAFETY INFORMATION:

WARNING:

Installation of the ACE3600 should be done only by authorized and qualified service personnel in accordance with the US National Electrical Code. Only UL Listed parts and components will be used for installation.

Use UL Listed devices having an environmental rating equal to or better than the enclosure rating to close all unfilled openings. If the installation involves high-voltage connections, technicians must be specifically qualified to handle high voltage. If the I/O connections are powered by a hazardous voltage (>60VDC or >42Vpeak), all inputs should be defined as hazardous and the unit must be installed in a restricted access area for service personnel only.

If the I/O connections are powered by a safety extra low voltage (SELV) (<60VDC or <42Vpeak), all inputs should be defined SELV.

INSTALLATION CODES

ACE3600 Installation Guidelines

This device must be installed according to the latest version of the country’s national electrical codes. For North America, equipment must be installed in accordance to the applicable requirements in the US National Electrical Code and the Canadian Electrical Code.

INTERCONNECTION OF UNITS Cables for connecting RS232 and Ethernet Interfaces to the unit must

be UL-certified type DP-1 or DP-2. (Note- when residing in a non LPS circuit.)

OVERCURRENT PROTECTION A readily accessible Listed branch circuit over current protective

device rated 20 A must be incorporated in the building wiring.

Page 92

ACE3600 Installation Guidelines

Mounting the ACE3600 Frame on a Wall

WARNING:

Before drilling holes for mounting the frame, make sure there are no electrical wires installed inside the wall at the holes’ location.

CAUTION:

If the ACE3600 is subject to high levels of shock or vibration, you must take suitable measures to reduce the acceleration or amplitude. We recommend that you install the ACE3600 on vibration-damping materials (for example, rubber-metal anti-vibration mountings).

Wall Mount Installation

For convenient installation of the ACE3600 RTU on a wall, allow an additional 6 cm (2.4") (in W, H) and 7 cm (2.75") (in D) around the plate. Four holes are provided, one in each corner of the RTU metal chassis, for wall mounting the RTU. The figures below show the dimensions (in mm) of the various frames/metal chassis and the distances between the holes.

410 mm

295 mm

330 mm

443 mm

Small Metal Chassis Large Metal Chassis

Small/Large Metal Chassis Installation Dimensions and Screw Holes for Installation

Page 93

ACE3600 Installation Guidelines

117 mm

234 mm

82 mm

199.6 mm

124 mm

244 mm

209 mm

124 mm

0 I/O Frame 3 I/O Frame

No I/O and 3 I/O Frame Installation Dimensions and Screw Holes for Installation

314 mm

278.5 mm

391 mm

356.9 mm

244 mm

124 mm

5 I/O Frame 7 I/O Large Frame

5 I/O and 7 I/O Frame Installation Dimensions and Screw Holes for Installation

124 mm

The 8 I/O slots frame and the 8 I/O (19") Metal Chassis (V269) can be installed on a wall using two bracket that are shipped with the RTU. The figure below shows the required dimensions (in mm) for installation.

453 mm

450 mm

93 mm

128 mm

Page 94

ACE3600 Installation Guidelines

Installing the ACE3600 in a 19" Rack

The 8 I/O slot frame and the 8 I/O (19") Metal Chassis (V269) can be installed on 19" racks using the 19" rack brackets for 8 I/O slots frame (V051) as depicted in the pictures below.

Page 95

ACE3600 Installation Guidelines

)

12.6" (32.0 cm)

)

Housing Installation

For convenient installation of the ACE3600 RTU with the NEMA 4 housing, allow an additional 6 cm (2.4") (in W, H) and 7 cm (2.75") (in D) around the housing.

Four mounting brackets are provided, one in each corner of the RTU, for wall mounting the RTU housing (see the figures below). The figures below show the distances between the bracket holes.

17.40" (44.2 cm

20.86" (53.0 cm)

17.40" (44.2 c

Horizontal Bracket Installation Vertical Bracket Installation

Large NEMA 4 Housing - Installation Dimensions

16.2" (41.2 cm)

12.6" (32.0 cm

Small NEMA 4 Housing - Installation Dimensions

Page 96

MOUNTING BRACKET

ACE3600 Installation Guidelines

PRE±INSTALLED (WELDED) ON SOME HOUSING BRANDS

Mounting the NEMA 4 Housing

Page 97

Communications

The ACE3600 (as well as MOSCAD family RTUs) facilitates the establishment of a highly sophisticated hybrid data communication network for SCADA that utilizes a variety of radio and/or line communication links. Radio links may include conventional (VHF, UHF, 800 & 900 MHz), analog trunked, digital trunked, and both analog and digital microwave radio technologies. Line links may include point-to-point, multi-drop, Public Service Telephone Network (PSTN) voice/data via dial-up modems, cellular packet data modems and Local Area Networks (LAN).

Multiple data bit rates are available to accommodate the particular need of these links. Lower data speeds are used when the bandwidth of the link is reduced either by their design or by laws in the user’s country, or when data speed is sacrificed to achieve greater communication range. The higher data speeds typically usable, combined with the optimized-for-radio MDLC data protocol, ensure high network throughput even if the network is spread over a large geographical area.

The ACE3600 system network consists of RTUs communicating with one or more computerized control centers and/or with other RTUs. Each control center is connected to the communication network.

The system can be relatively simple, comprising several RTUs and one control center. It can be modularly expanded to a more hierarchical system, where several sub-systems (comprising intelligent RTUs and/or sub-centrals controlling their peripheral RTUs) communicate with a central computer.

The communication network is flexible, enabling each RTU to communicate with hierarchies above it (RTU-to-central), parallel to it (RTU-to-RTU), under it (another RTU), and also relaying messages through it (when the RTU serves as a communication node).

While the communication protocol allows for a complex hierarchical system structure, it does not make it complicated. This is because most of the communication interactions are transparent to the user, except in those cases where the communication is to be defined by the user program ladder application. In such cases, you should perform simple programming operations to configure the required application.

Each RTU may be configured to serve as a far-end terminal or as a regional center. The RTU may function as a regional center either by definition or only after loss of communication with the central. It also can act as a communication node (an interconnection point between two or more different links) while performing its other tasks.

The RTU network uses the MDLC protocol, which incorporates all seven layers of the OSI model adapted for SCADA. It supports multiple logical channels per physical port, enabling simultaneous central-to-RTU and RTU-to-RTU sessions. It also enables each

Page 98

Communications

RTU to simultaneously run several kinds of communication applications, such as reporting alarms by contention, on-line monitoring, performing diagnostics checks, etc. The MDLC protocol is discussed below.

MDLC Protocol

The MDLC protocol is a Motorola SCADA protocol that is based on the Open System Interconnection (OSI) model recommended by the International Organization for Standardization. MDLC utilizes all seven layers of the OSI model. This protocol is designed for optimum operation in SCADA systems which operate with diverse communication media such as two-way radio, line, LAN, etc. Each RTU, FEP, or ToolBox has all seven layers of the MDLC protocol available to them. The functions of the seven layers are summarized below.

Layer Function Layer 1:

Physical

Layer 2: Link

Layer 3. Network

Layer 4. Transport

Layer 5. Session

Layer 6. Presentation

This layer caters to communications over conventional radio, trunked radio, data radio, serial data channels, modems, Ethernet or telephone lines. The layer is also responsible for channel access and collision control on shared media.

This layer ensures proper communications over a physical link. The layer arranges the data in variable-length frames and attaches addresses, frame sequence numbers, and Cyclic Redundancy Code (CRC) to the frames.

This layer is responsible for the establishment of end-to-end communication paths in a network. This is necessary since communications may take place on more than one link and a message may travel through several nodes before reaching the final destination.

This layer ensures end-to-end integrity of the information flow between two nodes in the network. This is achieved by remote-end acknowledgement that data has been received completely and passed in the correct order to the next layer.

This layer allows the definition of any number of entities capable of conducting simultaneous sessions with an equivalent entity in some remote unit. This enables transparent communications among multiprocessing machines without interference in their applications.

This layer structures the information to/from various applications. This layer may also perform format conversion, data authentication, etc. if implemented.

Layer 7. Application

This layer interfaces to the various applications such as data transfer, configuration downloading, application software monitoring, remote diagnostics, etc.

The MDLC protocol is intended for operation in point-to-multipoint links, such as twoway radio or multidrop wireline, as well as in point-to-point communication networks. The protocol facilitates communications among all sites in the system, including extensive diagnostic messaging. MDLC is transparent and liberates the system engineer

Page 99

Communications

from the technical constraints and complexities of network operations thus allowing the intended application to be the item of focus.

MDLC uses a semi-synchronous data format on two-way radio and an asynchronous format on wirelines. It is not correct to refer to message size in byte notation because of the 16-bit architecture; the data may not be sent in asynchronous format—no start and stop bits—but it is not true synchronous either because there is no single networkprovided clock signal. Instead, each CPU has a clock that is entirely adequate to provide the synchronize signal for data transfer. It is therefore better to refer to MDLC in terms of data words where each word may be variable in length, consist of both header and body components, and contain up to 80 16-bit variables within the body. A physical message may consist of a single word or may consist of a concatenated series of words (packets), each word addressed to one or more destination sites with some or all words requiring subsequent store-&-forward operation by the recipient site(s). The concatenated data words may be any combination of the supported functions, i.e. data upload to the SCADA Manager, error logger data to the STS/ToolBox, etc.

Page 100

Communications

The lower three layers of the MDLC protocol stack are commonly known as Network Services. These layers only are used when communicating with intermediary sites which make it possible to pass any data through the system and not require the total system to know the details of the data. Each layer adds (removes) data to what was received and thereby communicates with equivalent layers in the destination (source) site—see figure above.

RTU-to-RTU communications suppress the Presentation, Session, and Transport layers; all layers are present for SCADA Manager-to-RTU communication and for communications with the STS.

Motorola V186 - Cell Phone - GSM, ACE3600 System Planner Manual

Specifications and Main Features

Frequently Asked Questions

User Manual