Motorola ACE3600 RTU Owner's Manual

Owner’s Manual

MOTOROLA , MOTO, MOTOROLA SOLUTIONS and the

ACE3600 RTU

6802979C35-L

Stylized M Logo are trademarks or registered trademarks of
Motorola Trademark Holdings, LLC and are used under l i cense.
All other product or service names are the property of their
respective owners.

Copyright © 2014 All rights reserved

Motorola Solutions, Inc.

COMPUTER SOFTW ARE COPYRIGHTS

The Motorola products described in t hi s instruction manual may include copyrighted Motorola com puter programs stored in
semi conductor memories or other media. Laws in t he Uni t ed States and other countries pres erve f or Motorol a certain
exclusive rights for copyrighted computer programs including t he exclusive right to copy or reproduce in any form t he
copyrighted computer program . Accordingly, any copyrighted Motorola computer programs contai ned i n the Motorola
products described in this manual may not be copied or reproduced i n any manner without the express written permissi on of
Motorola Solutions, Inc. Furthermore, the purchas e of Mot orola products shall not be deemed t o grant ei ther directly or by
implication, es toppel, or otherwise, any license under the copyrights, patents or patent applications of Motorola, except for
the normal non-exclusive, royalty free license to use that arises by operat i on of l aw in the sale of a product.

The ACE3600 RTU/ACE IP Gateway sof tware includes additional third party software components governed by specific
licenses and under different c opyri ght s. For details on how to view these legal notic es and copyright notices, refer to
Viewing the Legal Notices in the Operation chapter.

EUROPEAN UNION DIRECTIVE 2002/95/EC CONFORMANCE STATEMENT

Hereby, Motorola declares that these produc ts comply with RoHS European Directi ve no. 2002/95/EC (Restriction of t he us e
of Hazardous Substances) and WEEE Directive no. 2002/96/EC (Strategy of Waste management), with the exception of
models listed in A ppendi x B.

1301 E. Algonquin Road,
Schaumburg, IL 60196 U.S.A.

CONTENTS

GLOSSARY .............................................................................................................................................................. VI

DESCRIPTION........................................................................................................................................................ 1-1

PRODUCT OVERVIEW.............................................................................................................................................. 1-1

GENERAL DESCRIPTION .......................................................................................................................................... 1-1

ACE3600 RTU CONSTRUCTION ............................................................................................................................. 1-3

RTU COMPONENTS ................................................................................................................................................ 1-7

MODEL OPTIONS AND ACCESSORIES ...................................................................................................................... 1-9

PRODUCT SAFETY AND RF EXPOSURE .................................................................................................................. 1-10

INSTALLATION ..................................................................................................................................................... 2-1

GENERAL ................................................................................................................................................................ 2-1

MOUNTING THE ACE3600 FRAME ON A WALL ...................................................................................................... 2-2

INSTALLING THE ACE3600 IN A 19" RACK ............................................................................................................. 2-4

INSTALLING THE ACE3600 IN A 19" RACK (FOR RTUS ORDERED BEFORE OCTOBER 2010) .................................. 2-6

MOUNTING THE ACE3600 8 I/O FRAME ON A WALL .............................................................................................. 2-9

MOUNTING THE ACE3600 8 I/O FRAME ON A WALL (FOR RTUS ORDERED BEFORE OCTOBER 2010) ................. 2-11

MOUNTING THE ACE3600 NEMA 4 HOUS ING ON A WALL .................................................................................. 2-12

CONNECTING POWER AND GROUND ..................................................................................................................... 2-14

CONNECTING I/O MODULES TO GROUND ............................................................................................................. 2-20

CONNECTING AN RTU TO GROUND ...................................................................................................................... 2-21

CONNECTING THE RADIO ...................................................................................................................................... 2-22

OPENING/CLOSING THE HOUSING DOOR ............................................................................................................... 2-22

INSTALLING ACCESSORY BOX INTERFACES .......................................................................................................... 2-23

19" FRAME METAL BACK INSTALLATION COMBINATIONS .................................................................................... 2-24

POWER SUPPLY MODULE AND BACKUP BATTERY ................................................................................. 3-1

GENERAL DESCRIPTION/MODULE OVERVIEW ........................................................................................................ 3-1

REDUNDANT POWER SUPPLY.................................................................................................................................. 3-8

BATTERY CHARGER ............................................................................................................................................... 3-8

CONNECTING THE POWER SUPPLY TO A POWER SOURCE........................................................................................ 3-9

POWER SUPPLY DETAILED SPECIFICATIONS .......................................................................................................... 3-11

BACKUP BATTERY ................................................................................................................................................ 3-14

CPU MODULE ........................................................................................................................................................ 4-1

GENERAL DESCRIPTION .......................................................................................................................................... 4-1

FRONT PANEL ......................................................................................................................................................... 4-2

CPU WITH SECURITY .............................................................................................................................................. 4-5

EDUNDANT CPU .................................................................................................................................................. 4-5

R

CPU FIRMWARE AND OPERATION MODES .............................................................................................................. 4-5

CPU STATUS AND DIAGNOSTICS ............................................................................................................................ 4-7

CONNECTING PLUG-IN PORTS TO THE CPU MODULE ............................................................................................. 4-7

CONNECTING SRAM EXPANSION MEMORY TO THE CPU MODULE ........................................................................ 4-9

PUSHBUTTON FUNCTIONALITY ............................................................................................................................. 4-10

CPU LEDS BEHAVIOR ......................................................................................................................................... 4-12

CPU 3610*/CPU 3640 MODULE SPECIFICATIONS ................................................................................................ 4-15

CPU 3680 MODULE SPECIFICATIONS ................................................................................................................... 4-16

i

Contents

I/O MODULES ........................................................................................................................................................ 5-1

GENERAL DESCRIPTION .......................................................................................................................................... 5-1

INSERTING/REMOVING AN I/O MODULE FROM THE RACK ...................................................................................... 5-9

24V DC FLOATING PLUG-IN POWER SUPPLY ....................................................................................................... 5-10

24V DC FLOATING PLUG-IN POWER SUPPLY MODULE DETAILED SPECIFICATIONS .............................................. 5-12

DIGITAL INPUT MODU LE .................................................................................................................................. 6-1

GENERAL DESCRIPTION .......................................................................................................................................... 6-1

DI MODULE CONFIGURATION ................................................................................................................................. 6-3

MODULE STATUS AND DIAGNOSTICS ...................................................................................................................... 6-5

I/O CIRCUIT DIAGRAM ............................................................................................................................................ 6-6

MODULE BLOCK DIAGRAM .................................................................................................................................... 6-7

CONNECTION CHARTS ............................................................................................................................................ 6-9

I/O CONNECTION DIAGRAM .................................................................................................................................. 6-10

DI MODULE SPECIFICATIONS ................................................................................................................................ 6-11

DIGITAL INPUT 120/2 30V MODULE ................................................................................................................. 7-1

GENERAL DESCRIPTION .......................................................................................................................................... 7-1

DI MODULE CONFIGURATION ................................................................................................................................. 7-2

MODULE STATUS AND DIAGNOSTICS ...................................................................................................................... 7-3

I/O CIRCUIT DIAGRAM ............................................................................................................................................ 7-4

MODULE BLOCK DIAGRAM .................................................................................................................................... 7-5

CONNECTION CHARTS ............................................................................................................................................ 7-6

I/O CONNECTION DIAGRAM .................................................................................................................................... 7-7

HIGH VOLTAGE DI MODULE SPECIFICATIONS ........................................................................................................ 7-8

DIGITAL OUTPUT/DIGITAL INPUT FET MODULE ..................................................................................... 8-1

GENERAL DESCRIPTION .......................................................................................................................................... 8-1

MODULE CONFIGURATION ...................................................................................................................................... 8-2

MODULE STATUS AND DIAGNOSTICS ...................................................................................................................... 8-4

I/O CIRCUIT DIAGRAM ............................................................................................................................................ 8-5

MODULE BLOCK DIAGRAM .................................................................................................................................... 8-6

CONNECTION CHARTS ............................................................................................................................................ 8-8

I/O CONNECTION DIAGRAM .................................................................................................................................... 8-9

DO/DI FET MODULE SPECIFICATIONS ................................................................................................................. 8-10

DIGITAL OUTPUT RELAY MODULE ............................................................................................................... 9-1

GENERAL DESCRIPTION .......................................................................................................................................... 9-1

MODULE CONFIGURATION ...................................................................................................................................... 9-3

MODULE STATUS AND DIAGNOSTICS ...................................................................................................................... 9-5

I/O CIRCUIT DIAGRAM ............................................................................................................................................ 9-6

MODULE BLOCK DIAGRAM .................................................................................................................................... 9-8

CONNECTION CHARTS .......................................................................................................................................... 9-10

DO RELAY MODULE SPECIFICATIONS .................................................................................................................. 9-11

DIGITAL OUTPUT RELAY 120/230V MODULE ............................................................................................ 10-1

GENERAL DESCRIPTION ........................................................................................................................................ 10-1

MODULE CONFIGURATION .................................................................................................................................... 10-4

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 10-6

MODULE BLOCK DIAGRAM .................................................................................................................................. 10-7

I/O CIRCUIT DIAGRAM .......................................................................................................................................... 10-8

CONNECTION CHARTS .......................................................................................................................................... 10-9

DO RELAY 120/230V MODULE SPECIFICATIONS ................................................................................................ 10-10

ii

Contents

DIGITAL OUTPUT SBO RELAY MODULE .................................................................................................... 11-1

GENERAL DESCRIPTION ........................................................................................................................................ 11-1

MODULE CONFIGURATION .................................................................................................................................... 11-4

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 11-6

I/O CIRCUIT DIAGRAM .......................................................................................................................................... 11-7

MODULE BLOCK DIAGRAM .................................................................................................................................. 11-9

CONNECTION CHARTS .......................................................................................................................................... 11-1

DO SBO RELAY MODULE SPECIFICATIONS ........................................................................................................ 11-12

ANALOG INPUT MODULE ............................................................................................................................... 12-1

GENERAL DESCRIPTION ........................................................................................................................................ 12-1

AI MODULE CONFIGURATION ............................................................................................................................... 12-3

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 12-4

I/O CIRCUIT DIAGRAM .......................................................................................................................................... 12-7

MODULE BLOCK DIAGRAM .................................................................................................................................. 12-8

CONNECTION CHARTS ........................................................................................................................................ 12-10

I/O CONNECTION DIAGRAM ................................................................................................................................ 12-11

AI MODULE SPECIFICATIONS .............................................................................................................................. 12-12

ANALOG OUTPUT MODULE ........................................................................................................................... 13-1

GENERAL DESCRIPTION ........................................................................................................................................ 13-1

AO MODULE CONFIGURATION ............................................................................................................................. 13-3

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 13-6

I/O CIRCUIT DIAGRAM .......................................................................................................................................... 13-7

MODULE BLOCK DIAGRAM .................................................................................................................................. 13-8

CONNECTION CHARTS .......................................................................................................................................... 13-9

I/I CONNECTION DIAGRAM ................................................................................................................................. 13-10

AO MODULE SPECIFICATIONS ............................................................................................................................ 13-11

MIXED I/O MODULE .......................................................................................................................................... 14-1

GENERAL DESCRIPTION ........................................................................................................................................ 14-1

MIXED I/O MODULE CONFIGURATION .................................................................................................................. 14-3

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 14-4

MODULE BLOCK DIAGRAM .................................................................................................................................. 14-5

CONNECTION CHARTS .......................................................................................................................................... 14-6

MIXED I/O MODULE SPECIFICATIONS ................................................................................................................... 14-7

MIXED ANALOG MODULE .............................................................................................................................. 15-1

GENERAL DESCRIPTION ........................................................................................................................................ 15-1

MIXED ANALOG MODULE CONFIGURATION ......................................................................................................... 15-2

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 15-3

MODULE BLOCK DIAGRAM .................................................................................................................................. 15-4

CONNECTION CHARTS .......................................................................................................................................... 15-5

MIXED ANALOG MODULE SPECIFICATIONS .......................................................................................................... 15-6

I/O EXPANSION ................................................................................................................................................... 16-1

GENERAL DESCRIPTION ........................................................................................................................................ 16-1

I/O EXPANSION FRAME ........................................................................................................................................ 16-4

I/O EXPANSION POWER ........................................................................................................................................ 16-4

STATUS AND DIAGNOSTICS ................................................................................................................................... 16-5

iii

Contents

EXPANSION MODULE ....................................................................................................................................... 17-1

GENERAL DESCRIPTION ........................................................................................................................................ 17-1

FRONT PANEL ....................................................................................................................................................... 17-2

MODULE FIRMWARE AND OPERATION MODES ..................................................................................................... 17-3

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 17-6

CONNECTING THE EXPANSION MODULE ............................................................................................................... 17-7

SETTING THE FRAME NUMBER ............................................................................................................................. 17-8

PUSHBUTTON FUNCTIONALITY ........................................................................................................................... 17-10

LEDS BEHAVIOR ................................................................................................................................................ 17-11

EXPANSION MODULE SPECIFICATIONS ................................................................................................................ 17-16

EXPANSION LAN SWITCH ............................................................................................................................... 18-1

GENERAL DESCRIPTION ........................................................................................................................................ 18-1

FRONT PANEL ....................................................................................................................................................... 18-2

INSERTING/REMOVING AN EXPANSION LAN SWITCH FROM THE FRAME .............................................................. 18-3

SWITCH STATUS AND DIAGNOSTICS ...................................................................................................................... 18-3

CONNECTING THE EXPANSION LAN SWITCH TO THE MAIN CPU .......................................................................... 18-3

CONNECTING THE EXPANSION LAN SWITCH TO I/O EXPANSION FRAMES ............................................................ 18-3

EXPANSION LAN SWITCH LEDS BEHAVIOR ......................................................................................................... 18-5

EXPANSION LAN SWITCH SPECIFICATIONS ........................................................................................................... 18-6

EXPANSION POWER SUPPLY MODULE ...................................................................................................... 19-1

GENERAL DESCRIPTION/MODULE OVERVIEW ...................................................................................................... 19-1

MODULE STATUS AND DIAGNOSTICS .................................................................................................................... 19-4

CONNECTING THE EXPANSION POWER SUPPLY TO THE MAIN FRAME POWER SUPPLY ......................................... 19-4

CONNECTING THE EXPANSION POWER SUPPLY TO GROUND ................................................................................. 19-4

EXPANSION POWER SUPPLY FUSES ....................................................................................................................... 19-5

EXPANSION POWER SUPPLY MODULE DETAILED SPECIFICATIONS........................................................................ 19-6

ACE IP GATEWAY MODULE ........................................................................................................................... 20-1

GENERAL DESCRIPTION ........................................................................................................................................ 20-1

FRONT PANEL ....................................................................................................................................................... 20-3

ACE IP GATEWAY FIRMWARE AND OPERATION MODES ...................................................................................... 20-5

ACE IP GATEWAY STATUS AND DIAGNOSTICS ..................................................................................................... 20-7

PUSHBUTTON FUNCTIONALITY ............................................................................................................................. 20-8

ACE IP GATEWAY LEDS BEHAVIOR .................................................................................................................. 20-10

ACE IP GATEWAY MODULE SPECIFICATIONS .................................................................................................... 20-12

RADIO TYPES AND INSTALLATION KITS ................................................................................................... 21-1

ACE3600 RADIO TYPES ....................................................................................................................................... 21-1

RADIO INSTALLATION KITS ................................................................................................................................... 21-4

MOUNTING THE ACE3600 RADIOS ON A WALL .................................................................................................. 21-83

RS485 CONNECTION BOX ................................................................................................................................ 22-1

GENERAL DESCRIPTION ........................................................................................................................................ 22-1

INSTALLATION ...................................................................................................................................................... 22-2

AUDIO CONTROL AND TONE (ACT) MODULE .......................................................................................... 23-1

INTRODUCTION ..................................................................................................................................................... 23-1

FRONT PANEL DESCRIPTION ................................................................................................................................. 23-1

ACT MODULE FEATURES ..................................................................................................................................... 23-2

AUDIO HANDLING CAPABILITIES .......................................................................................................................... 23-4

NTERFACE TO THE RTU ....................................................................................................................................... 23-4

I

INSTALLATION AND WIRING ................................................................................................................................. 23-6

iv

Contents

PORT CONFIGURATION ................................................................................................................................. 23-8

RTU

CONTROLLING THE MODULE ................................................................................................................................ 23-9

ACT MODULE SPECIFICATIONS .......................................................................................................................... 23-12

CONFIGURATION .............................................................................................................................................. 24-1

GENERAL .............................................................................................................................................................. 24-1

OPTIMIZATION .................................................................................................................................................. 25-1

GENERAL .............................................................................................................................................................. 25-1

OPERATION ......................................................................................................................................................... 26-1

GENERAL .............................................................................................................................................................. 26-1

IEWING THE LEGAL NOTICES .............................................................................................................................. 26-1

V

MAINTENANCE ................................................................................................................................................... 27-1

GENERAL .............................................................................................................................................................. 27-1

TROUBLESHOOTING ........................................................................................................................................ 28-1

BREAK-FIX PROCEDURES .............................................................................................................................. 29-1

GENERAL .............................................................................................................................................................. 29-1

REPLACING A CPU/GATEWAY MODULE ............................................................................................................... 29-1

REPLACING A POWER SUPPLY MODULE ................................................................................................................ 29-2

REPLACING AN I/O MODULE OR EXPANSION LAN SWITCH .................................................................................. 29-3

INSERTING A NEW I/O MODULE INTO AN EMPTY SLOT ......................................................................................... 29-4

REPLACING A PLUG-IN PORT ON THE CPU MODULE ............................................................................................. 29-4

REPLACING A PLUG-IN SRAM MEMORY CARD IN THE CPU MODULE.................................................................. 29-4

REPLACING THE MOTHERBOARD .......................................................................................................................... 29-5

REPLACING THE FUSES ON THE POWER SUPPLY MODULE FOR AUX1/AUX2 OR I/O EXPANSION ........................ 29-6

REPLACING THE BACKUP BATTERY ON THE RTU ................................................................................................. 29-6

INTERCONNECTION DIAGRAMS ............................................................................................................................. 29-6

APPENDIX A: GENERAL SPECIFICATIONS ................................................................................................. A-1

SPECIFICATIONS ......................................................................................................................................................A-1

APPENDIX B: ENVIRONMENTAL PROTECTION ......................................................................................... B-1

DISPOSAL OF COMPONENTS .................................................................................................................................... B-1

APPENDIX C: ACCESSORIES, ADAPTORS AND CABLES ......................................................................... C-1

GENERAL ................................................................................................................................................................ C-1

APPENDIX D: ACE3600 MAXIMUM POWER RATINGS .............................................................................. D-1

POWER RATING TABLES ........................................................................................................................................ D-1

APPENDIX E: CPU AND POWER SUPPLY REDUNDANCY ......................................................................... E-1

GENERAL ................................................................................................................................................................ E-1

REDUNDANT CPU AND POWER SUPPLY FRAME ..................................................................................................... E-1

REDUNDANCY DEFINITIONS .................................................................................................................................... E-1

REDUNDANT CPU .................................................................................................................................................. E-2

REDUNDANT POWER SUPPLY.................................................................................................................................. E-3

REDUNDANT CPU AND POWER SUPPLY RTU CONFIGURATION ............................................................................. E-3

v

GLOSSARY

ACE Advanced Control Equipment
AI Analog Input
AO Analog Output
AWG American Wire Gauge
DCD Data Carrier Detect
DFM Direct Frequency Modulation
DI Digital (Discrete) Input
DNP Distributed Network Protocol
DO Digital (Discrete) Output
DPSK Differential Phase Shift Keying
EMI Expansion Microcode Interface
EPP Environmentally Preferred Product
ESD Electrostatic Discharge
EU European Union
FCC Federal Communication Commission
FEP Front End Processor (MCP-M, MCP-T, or FIU)
FET Field Effect Transistor
FPGA Field Programmable Gate Array
FSK Phase Shift Keying
FIU Field Interface Unit
GND Ground
GPRS General Packet Radio Service
GPS Global Positioning Satellite
GSM Global System for Mobile Communications
GW ACE IP Gateway
HV High Voltage
HW Hardware
IEC International Electrotechnical Commission
IO (I/O) Inputs Outputs
IP Internet Protocol

vi

Glossary

IPGW IP Gateway
LAN Local Area Network
LED Light Emitting Diode
MCC Master Control Center
MCP-M Motorola Communication Processor – MODBUS
MDLC Motorola Data Link Communication
MODBUS MODICON BUS Protocol
MOSCAD Motorola SCADA
MOSCAD-L Motorola SCADA-Light
NEMA National Electrical Manufacturers Association (issues enclosure standards)
NTP Network Time Protocol
OPC Open Connectivity
OVF Overflow
PC Personal Computer
PLC Programmable Logic Controller
PPC Power PC
PPH Pulse per Hour
PPM Parts Per Million
PPP Point-to-Point Protocol
PPS Pulse per Second
PSTN Public Switched Telephone Network
RAM Random Access Memory
RF Radio Frequency
ROM Read Only Memory
RST Reset
RTS Request to Send
RTU Remote Terminal Unit (can be MOSCAD or MOSCAD-L)
RX Receive
SCADA Supervisory Control and Data Acquisition
SBO Select Before Operate
SDRAM Synchronous Dynamic Random Access Memory
SNMP Simple Network Management Protocol
SNTP Simple Network Time Protocol
SPDT Single Pole Double Trigger

vii

SPST Single Pole Single Trigger
STS System Tools Suite
SW Software
TB Terminal Block
TCP Transmission Control Protocol
TDPSK Trunked Differential Phase Shift Keying
TX Transmit
UDF Underflow
UDP User Datagram Protocol
UHF Ultra High Frequency
USB Universal Serial Bus
VHF Very High Frequency
WAN Wide Area Network
WB Wire Break

Glossary

viii

DESCRIPTION

Product Overview

The ACE3600 is a programmable Remote Terminal Unit (RTU). Almost any automation task
can be implemented with a suitable choice of ACE3600 components. Typically the RTU
monitors and controls local equipment and communicates with a control center and with other
RTUs in the system. The ACE3600 is the newest Motorola SCADA (MOSCAD) RTU, a
member of MOSCAD family of RTUs and Control Center Front End Processors.

The ACE3600 System Tools Suite (STS) can be run on a local or remote PC to perform all the
setup, programming and monitoring operations such as RTU configuration,
system/application, download, monitoring, etc.

Features of the ACE3600

The ACE3600 combines all the advantages of the legacy MOSCAD and MOSCAD-L RTUs
with those of modern hardware and software technologies.

Among these are:

• A modern CPU platform with powerful microprocessor

• Real-time operating system based on Wind Rivers VxWorks OS

• Enhanced communication and networking capabilities

• Rugged modular design

• Extended operating temperature range

• Improved power supply/charger

• Modules with a high component density

• System building tools

• Interoperability with legacy MOSCAD family RTUs

General Description

The ACE3600 RTU is a modular unit, comprised of removable modules installed in a multi­slot frame. These modules include

• Power supply

• CPU

• I/O modules

1-1

Description

POWER
CPU MODULE

MOUNTING

I/O MODULES

The basic (default) model includes one power supply and one CPU module. The number of
I/O modules is selected as an option of the base model.

Figure 1-1 provides a general view of the ACE3600 RTU with five I/O modules.

SUPPLY
MODULE

Figure 1-1 ACE3600 RTU – General View

I/O Module Options

The following types of I/O modules are available:

• Digital Inputs (DI), including High Voltage

PLATE

• Digital Outputs (DO), including High Voltage

• Analog Inputs (AI)

• Analog Outputs (AO)

• Mixed I/O

• Mixed Analog

Communication Interfaces

The ACE3600 CPU includes the following serial ports:

• Configurable RS232 or RS485 serial port

• Configurable RS232 with GPS receiver support (for time sync)

• Ethernet 10/100 Mb/s (ACE3600 CPU 3640, CPU 3680 models)

1-2

• Two USB full speed host ports (12 Mbs) for MotoTrbo radios only (ACE3600 CPU 3680

and ACE IP Gateway only)

• One USB device port (ACE3600 CPU 3680 and ACE IP Gateway only)
Two additional plug-in ports can be added to the CPU. The following types of communication

modules are available for the plug-in ports:

• RS232

• RS485

• General radio interface (Conventional or Trunking, DPSK 1200, FSK 2400, DFM 4800)

• Ethernet 10 Mb/s

• Ethernet 10/100 Mb/s (on plug-in Port 1 only)

ACE3600 RTU Construction

The ACE3600 is available in various structures:

Description

• 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 connect 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. For
more information, see the Installation chapter below

The ACE3600 frame can include wide or narrow plastic slot units:

• Wide slot unit - can hold a power supply and a CPU or up to three I/O modules

• Narrow slot unit - can hold up to two I/O modules

1-3

RTU Options

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

Housing/Mounting Type Capacity/Options Illustration

Description

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

Can be installed on a wall.

2 I/O slot frame
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.

Power supply and CPU
Can be ordered with metal

chassis or housing options.
Can be ordered with 19"

frame metal back.
Power supply and CPU,

up to 2 I/Os
Can be ordered with small

metal chassis.

Power supply and CPU,
up to 3 I/Os

Can be ordered with metal
chassis or housing.

Can be ordered with 19"
frame metal back.

Power supply and CPU,
up to 5 I/Os

Can be ordered with large
metal chassis or housing.

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

Can be ordered with 19"
frame metal back.

Power supply and CPU,
up to 7 I/Os

Can be ordered with large
metal chassis or housing.

1-4

Housing/Mounting Type Capacity/Options Illustration

Description

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

19” rack/enclosure.

I/O expansion frame
2 I/O slot, 3 I/O slot, 5 I/O slot,

7 I/O slot, or 8 I/O slot

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
1 radio; up to 4 accessory
boxes.

For all possible
combinations, see 19” Metal
Back Installation
Combinations in the
Installation chapter below.

I/O expansion power supply,
I/O expansion module, up to
8 I/Os.
Can be connected to the main
RTU frame.

Can be ordered with large
metal chassis or housing.

Redundant CPU and power
supply frame

Can be installed on a wall, in
housing, 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.

Medium metal chassis
Enables installation of radio,

backup battery and other
accessories.

Can be installed on a wall or in
housing.

2 power supplies and 2
CPUs, 4 I/Os.

Can be ordered with large
metal chassis, housing or 19”
frame metal back.

Power supply and CPU,
up to 2 I/Os,
1 mobile/portable radio,

6.5Ah Lead-Acid backup
battery, (or 10 Ah battery
with portable radio only,)
1 accessory box can be
installed in place of the radio.

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

6.5 Ah Lead-Acid backup
battery

1-5

Housing/Mounting Type Capacity/Options Illustration

Description

Large painted metal chassis
Enables installation of radio,

backup battery and other
accessories.

Can be installed on a wall or in
housing.

19" frame metal back
Enables installation of radio,

backup battery and other
accessories.

Can be installed in 19” rack or
on a wall.

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

6.5 or 10 Ah Lead-Acid
backup battery

Power supply and CPU,
0, 3, 5, or 8 I/Os, 1 radio, 6.5
or 10 Ah Lead-Acid backup
battery, and up to 4 accessory
boxes. (Not all combinations
are valid together.)

Can be ordered with ACE IP
Gateway, power supply,
radio, 6.5 or 10 Ah Lead­Acid backup battery and up
to 2 accessory boxes.

For all possible
combinations, see 19" Metal
Back Installation
Combinations in the

Installation chapter below.
Small NEMA 4X/IP66 housing
Enables installation of radio,

backup battery and other
accessories.

Can be installed on a wall.

Large metal NEMA 4X/IP66
housing

Enables installation of radio,
backup battery and other
accessories.

Can be installed on a wall.

Power supply and CPU,

up to 3 I/Os,

1 mobile/portable radio,

1 accessory box,

6.5 Ah Lead-Acid backup

battery

Power supply and CPU,

up to 7 I/Os,

1 accessory box,

up to 2 mobile/portable

radios,

6.5 or 10 Ah Lead-Acid

backup battery

For installation instructions of each housing/mounting type, see the Installation chapter.
For information on I/O expansion, see the I/O Expansion chapter.
For the dimensions and weight of each combination, see Appendix A: General Specifications.

1-6

For a detailed list of all ACE3600 options, see the ACE3600 price pages and ordering
information.

For a detailed description of the individual modules, see the appropriate chapter below.

RTU Components

The ACE3600 RTU can include the following components.

Component Function Notes

Description

Power supply module Converts the main AC or DC

power source to the voltages

required by the modules,

See Power Supply Module
and Backup Battery

chapter.
radio/modems and
accessories.
Charges the backup battery
and switches to the battery
voltage when the main power
fails (in models with
charger.)

CPU module Stores and runs the user

See CPU Module chapter.
application program, stores
data collected by the I/O
modules and communicates
with the control center, RTUs
and other devices via the
communication ports.

CPU plug-in port Enables adding various

See CPU Module chapter.
communication ports to the
CPU modules.

CPU plug-in SRAM Provides static RAM. See CPU Module chapter.
I/O module Matches between the

Terminal blocks (TB) Connects the signals to the

Plug-in 24V DC power supply Enables adding 24 V floating

See I/O Modules chapter.
ACE3600 and signals of
various types/levels.
Interfaces between the
ACE3600 and the process
signals.

See I/O Modules chapter.
I/O modules.

See I/O Modules chapter.
power supplies to I/O
modules for contact
“wetting” and sensor
operation.

1-7

Component Function Notes

Description

I/O expansion module Connects the I/O modules on

an I/O expansion frame to the
CPU module on the RTU’s
main frame (frame 0),
directly or via an expansion
LAN switch).

I/O expansion power supply Connects 12V power and

12V DO from the power
supply on the RTU’s main
frame to an I/O expansion
frame, or from one I/O
expansion frame to another.

I/O expansion LAN switch One switch enables

connection of up to seven
expansion frames to the main
frame CPU.

Two switches allow
connection of up to thirteen
expansion frames to the main
frame CPU.

ACE IP Gateway module Serves as a front end unit

between
ACE3600/MOSCAD RTUs
and control center SCADA
clients using TCP/IP
protocol.

See Expansion Module

chapter.

See Expansion Power

Supply Module chapter.

See Expansion LAN Switch

chapter.

See ACE IP Gateway

Module chapter.

TB holder kit Holds Module TBs. See I/O Modules chapter.
Cable with TB holder A cable to connect signals to

See I/O Modules chapter.
the I/O modules.

Backup battery Enables backup RTU

operation when main power
fails.

Radio installation kit Mechanical support and

cables that enable installation

See Power Supply Module

and Backup Battery

chapter.

See Radio Types and

Installation Kits chapter.
of radio.

RS485 Connection Box Enables connection of up to 6

devices to the RS485 port on

See the RS485 Connection

Box chapter.
the CPU (2W multi-drop).

1-8

Component Function Notes

Description

RTU to PC RS232 cable Enables connection of the

RTU to a PC via the RS232
port.

RTU to PC Ethernet cable Enables connection of the

RTU to a PC via the Ethernet
port.

Ethernet cable Enables the following

connections:

1. CPU to LAN switch

2. LAN switch to expansion
frame

For use of the ACE3600

Software Tools Suite (STS)

to perform operations such

as RTU configuration,

system/application,

download, monitoring, etc.

See the ACE3600 STS User

Guide.

For use of the ACE3600

Software Tools Suite (STS)

to perform operations such

as RTU configuration,

system/application,

download, monitoring, etc.

See the ACE3600 STS User

Guide.

See Expansion Module

chapter.

3. LAN switch to LAN
switch

Ethernet cross cable Enables the following

connections:

1. A single I/O expansion
frame directly to the RTU
main frame.

2. PC (STS) directly to one of
the CPU Ethernet ports.

Model Options and Accessories

F7500 - ACE3600 System Tools Suite Software
F7600 - ACE3600 ‘C’ Toolkit Software
The full list of ACE3600 options and accessories are listed in the ACE3600 System Planner.

See Expansion Module

chapter.

1-9

Product Safety and RF Exposure

Before using an ACE3600 RTU model with a radio installed, read the operating instructions
and RF exposure booklet for the specific radio contained in the product.

Description

1-10

INSTALLATION

General

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 eight
I/O frame can be installed on a 19" rack.

Modules can be added to the slots in a frame before or after mounting the RTU on a
wall/enclosure.

Installation of the ACE3600 should b e 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.

This unit is intended for installation in a Restricted Access Location for
service personnel only.

Connection of this equipment to an IT earthing system is permitted for the
IT power system of Norway only.

INSTALLATION CODES
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 2-pole Listed branch circuit overcurrent protective

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

External wiring which connects an I/O module to instruments/devices may

2-1

not exceed 42.67m (140 feet).

295 mm

330 mm

335 mm

355 mm

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 o n vibra tion-damping materials
(for example, rubber-metal anti-vibration mountings).

METAL PARTS OF THE POWER SUPPLY MAY BE VERY HOT.

After removing the power supply modu le, allow the metal parts to cool
down before servicing the unit.

A TORX screwdriver is required for ins tallation.

Mounting the ACE3600 Frame on a Wall

Installation

205 mm

264 mm

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

Four holes are provided, one in each corner of the RTU frame, for wall mounting the RTU.
Figure 2-1, Figure 2-2, and Figure 2-3 show the dimensions of the various frames/metal chassis
and the distances between the holes. 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.

448 mm
410 mm

365 mm
340 mm

443 mm

468 mm

Small Metal Chassis Medium Metal Chassis Large Metal Chassis

Figure 2-1 Small//Medium/Large Metal Chassis Installation Dimensions and Screw Holes

for Installation

2-2

117 mm

209 mm

124 mm

82 mm

244 mm

234 mm

199.6 mm

124 mm

244 mm

278.5 mm

314 mm

244 mm

124 mm

391 mm

356.9 mm

244 mm

124 mm

124 mm

Installation

195 mm

161 mm

0 I/O Frame 2 I/O Frame 3 I/O Frame

Figure 2-2 No I/O, 2 I/O, and 3 I/O Frame Installation Dimensions and Screw Holes for

Installation

5 I/O Frame 7 I/O Large (or Redundant) Frame

Figure 2-3 5 I/O and 7 I/O Frame Installation Dimensions and Screw Holes for

Installation

Note: The default redundant CPU and power supply frame is the same size as the 7 I/O frame.
The following screw mount installation procedure should be used to install all ACE3600

frames (with or without a metal chassis) on a wall, except the 8 I/O (19") frame. For the 8 I/O
frame, see Installing the ACE3600 in a 19" Rack and Mounting the ACE3600 8 I/O Frame on a
Wall below.

Procedure 2-1 How to Mount the RTU Frame on a Wall

1) Drill four holes in the wall at the horizontal and vertical distances shown in Figure 2-1,

Figure 2-2, and Figure 2-3.

2) Insert M4 screws (not supplied) with head size DIN 7981C/ST4, 2x38mm into the holes.

3) Remove the modules from the frame.

4) Lift the RTU frame and hang over the four screws.

5) Remove the outermost modules in order to access the screws.

2-3

6) Tighten all four screws with a screwdriver to secure the frame firmly against the wall.

7) Replace the removed modules in their slots.

Installing the ACE3600 in a 19" Rack

The following screw mount installation procedure should be used to install the ACE3600 8 I/O
(19") frame / 19" frame metal back in a 19" rack unit. The redundant CPU and power supply
frame on a 19" frame metal back can also be installed in a 19" rack unit.

Note: The brackets for 19" rack installation are not provided with the RTU and should be
ordered separately.

Procedure 2-2 How to Mount the RTU in a 19" Rack Unit

1) Using three M4 screws supplied with kit FHN7420A, attach the metal bracket (p/n

07013005001 from kit FHN7420A) to the side of the 19" frame metal back, according to
the desired depth of the unit on the rack. Repeat with the second bracket on the other side
of the 19" frame metal back. See Figure 2-4.

Installation

Figure 2-4 Attaching Brackets to 19" Frame - Exploded View

2) Screw one M5 screw (not supplied) into the upright of the 19" rack unit, to correspond to

the top keyhole on the metal bracket. Repeat on the opposite upright. See Figure 2-5.

2-4

19” Rack Unit

Metal Uprights

Installation

Figure 2-5 Screws for Hanging 19" Frame in Rack Unit - Exploded View

3) Align the keyholes on the brackets with the two screws on the rack metal uprights, and

hang the frame on the rack metal uprights. See Figure 2-6. Tighten the two screws to the
uprights.

4) To reinforce the installation, add three more M5 screws (not supplied), through the

remaining three holes on the metal bracket, into the upright of the 19" rack unit. Repeat on
the opposite upright. See Figure 2-6.

2-5

Installation

Metal Uprights

Screws for

Hanging

Screws for

Reinforcement

Figure 2-6 Installation of ACE3600 RTU 19" Frame in Rack Unit - Exploded View

Installing the ACE3600 in a 19" Rack (for RTUs Ordered before
October 2010)

The following screw mount installation procedure should be used to install the ACE3600 8 I/O
(19") frame in a 19" rack, for RTUs ordered before October 2010.

Note: The brackets for 19" rack installation are not provided with the RTU and should be
ordered separately.

Procedure 2-3 How to Mount the RTU in a 19" Rack Unit

1) Press the small metal bracket into the slot of the larger bracket. See Figure 2-7.

2) Secure the two brackets together with two M5 screws (supplied), according to the desired

depth of the unit on the rack. See Figure 2-7.

3) Repeat steps 1-2 for the other pair of brackets.

2-6

Installation

Bracket Groove

Small Bracket

Large Bracket

Metal Upright

4) Using the supplied two screws, attach the combined brackets to the metal upright of a 19"

rack unit. See Figure 2-7. Repeat on other side.

Figure 2-7 Installation of Brackets for 19" Rack Units

2-7

Installation

5) Hang the 19'' metal chassis on the brackets, so that the two teeth on the back of the metal

chassis hook onto the groove of the larger bracket. See Figure 2-8.

Figure 2-8 Installation of ACE3600 RTU 19" Rack- Exploded View

6) From the standard rack unit, remove the two modules from the leftmost slots and the two

modules from the rightmost slots. For the 19" accessories metal chassis, no accessories
need to be removed. (See Figure 2-9.)

7) Using two supplied M5 (X6) screws and a 16 cm (6.3") long screwdriver, from inside the

slot secure the 19" frame metal back to the small bracket. Repeat on the second side. See
Figure 2-8.

8) Replace any removed modules to their slots.

2-8

Installation

Mobile Radio

Portable Radio

Accessory Boxes

Battery

465.9 mm

235 mm

146.1 mm*

88.9 mm*

*Additional screws for extra fortification

Figure 2-9 Installation of ACE3600 RTU 19" Rack Accessories - General View

Mounting the ACE3600 8 I/O Frame on a Wall

The following screw mount installation procedure should be used to install the ACE3600 8 I/O
(19") frame on the wall. The redundant CPU and power supply frame on a 19" frame metal
back can also be installed in a 19" rack unit.

Figure 2-10 8 I/O Frame (19") Metal Back Installation Dimensions

2-9

Installation

Note: For the 8 I/O slots option and the 19" frame metal back option, the brackets for wall
mount installation are included and need not be ordered separately.

Procedure 2-4 How to Mount the RTU 19" Frame Metal Back on a Wall

1) Remove the CPU, Power Supply and I/O modules from the RTU frame.

2) Drill four holes into the wall at the horizontal and vertical distances shown in Figure 2-10.

(If you choose to further secure the 19" frame, drill four additional four holes, at the
distances shown in Figure 2-10.)

3) Using two M5 screws (not supplied), secure the rectangular wall mounting bracket

(07013022001 from kit FHN7419A) to the wall, as shown in Figure 2-11. Repeat for the
second bracket.

Figure 2-11 19" Frame Metal Back Bracket Installation

4) Fit the metal frame in between the two brackets, lining up the holes on the sides. (See

Figure 2-12.)

5) Using three supplied M4 screws, secure the left bracket to the left side of the frame. (See

Figure 2-12.) Using three more screws, secure the right bracket to the right side of the
frame.

6) If you choose to further secure the 19" frame, screw two additional M5 screws (not

supplied) into the two middle holes on the left bracket, as shown in Figure 2-12. Repeat
for the right bracket.

2-10

Installation

453 mm

450 mm

128 mm

93 mm

Figure 2-12 19" Frame Metal Back Installation

Mounting the ACE3600 8 I/O Frame on a Wall (for RTUs Ordered
before October 2010)

Figure 2-13 RTU Frame Metal Back Installation Dimensions

Procedure 2-5 How to Mount the RTU 19" Frame Metal Back on a Wall

The following installation procedure should be used to install the 8 I/O (19") frame on a wall,
using the special wall mount brackets provided with the RTU.

1) Remove the CPU, Power Supply and I/O modules from the RTU frame.

2) Drill four holes into the wall at the horizontal and vertical distances shown in Figure 2-13.

3) Using two supplied screws, secure the rectangular wall mounting bracket to the wall.

Repeat for the second bracket.

2-11

Installation

4) Hang the metal chassis on brackets so that the two teeth of the metal chassis hook onto the

groove of the brackets. (See Figure 2-14.)

5) Using two M4 screws (not supplied) with head size DIN 7981C/ST4, 2x38mm screws,

secure the top and bottom of the frame to the left bracket. Repeat for the right bracket.

Figure 2-14 RTU Metal Chassis Installation

Mounting the ACE3600 NEMA 4 Housing on a Wall

The following screw mount installation procedure should be used to install ACE3600 frames in
NEMA 4 housing on a wall.

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 Figure 2-15 through Figure 2-17). Figure 2-15 and Figure 2-16 show the
distances between the bracket holes.

2-12

Installation

Horizontal Bracket Installation Vertical Bracket Installation

Figure 2-15 Large NEMA 4 Housing - Installation Dimensions

Figure 2-16 Small NEMA 4 Housing - Installation Dimensions

Procedure 2-6 How to Mount the RTU NEMA 4 Housing

1) Drill four holes in the wall at the horizontal and vertical distances shown in Figure 2-15

(for the large housing) and in Figure 2-16 (for the small housing.)

2) Using the brackets and the screws supplied in the plastic bag, fasten the mounting brackets,

either horizontally or vertically, onto the four back corners of the housing. See Figure 2-

17.

3) Mount the RTU onto the wall and secure with M4 screws (not supplied) with head size

DIN 7981C/ST4, 2x38mm through the bracket hole. See Figure 2-17.

2-13

Installation

Figure 2-17 Mounting the NEMA 4 Housing

Connecting Power and Ground

All internal electrical connections except for the main power, ground and battery are performed
in the factory and supplied with the RTU. The electrical interconnection diagrams are
provided in the Break-Fix Procedures chapter.

The procedures for the main power, ground and battery connections are provided below.

The power and ground connections should b e performed only by qualified
and authorized service personnel. All power and ground connections
must be in accordance with local standards and laws.

Per UL 60950 / EN 60950, for all I/O modules connections, the maximum
voltage should not exceed 60V DC or 30 V AC unless i t is specifically
written otherwise.

To maintain Overvoltage (Installation) Category II, install a suitable surge
suppressor device in the branch cir cuit to limit expected transients to
Overvoltage Category II values. The limits are based on IEC60664 and are
also located in Table 2H of UL60950 (for mains = 150V, the transient rating
is 1500V; for 150V < mains = 300V, the transient rating is 2500V; and for
300V < mains = 600V, the transient rating is 4000V).

2-14

Make sure that the ground wire on the user cable is long enough to reach the

Clamp - Anchor Point

Clamp - Anchor Point

grounding strip.

Connecting AC/DC Main Power

The power connection to all the ACE3600 power supply types is via the power junction box
located on the frame beneath the power supply slot.

Safety standards require that the power cable be attached to the unit at two anchor
points:

• Anchor point 1 for all units is inside the power junction box. (See Figure 2-18

below.)

Installation

• Anchor point 2 for the basic model (No I/O Slots Frame) is located on the right of

the power junction box. (See Figure 2-18 below.)
Anchor point 2 for all units with housing (other than No I/O Slots) is in the
housing power cable gland. (See Figure 2-22 below.)
Anchor point 2 for all other units without housing (other than No I/O Slots) is
near the unit’s ground strip. (See Figure 2-19 below.)

Figure 2-18 RTU on No I/O Frame – Cable Anchor Points 1 and 2

2-15

Installation

Anchor Point 2 Clamp

Figure 2-19 RTU on Metal Chassis – Cable Anchor Point 2

Procedure 2-7 How to Connect the RTU to Main Power Source (Units with Frames and Metal
Chassis)

1) Using a screwdriver, open the power junction box cover (save the screws) and unscrew the

power terminals screws inside the power junction box.

2) Thread the user's main power cable through the two supplied clamps.

3) Attach the wires of the user cable, according to the labels (~/0 for AC and +/- for DC. ) For

the No I/O Frame, connect the ground cable to the lower wire terminals (third pair). See
Figure 2-20 and Figure 2-21.

Cable to Power Supply

Power Supply
Cable Inlet

User Power Cable

0

Wire

~

Terminals

0 ~

Anchor Point 1

Ground Cables

Figure 2-20 RTU Power and Ground Connecti o n s - No I/O Frame Installation

Junction Box

2-16

Installation

Cable to Power Supply

Power Supply
Cable Inlet

User Power Cable

0

Wire
Terminals

0 ~

~

Anchor Point 1

Junction BoxGround Cables

Figure 2-21 RTU Power and Ground Connections – All Other Installation s

4) Pass the power cable to the right of the wire terminals inside the junction box, over the

horizontal ridge.

5) Close the first clamp around the user cable and screw it onto the junction box, into the hole

next to wire terminals (anchor point #1).

6) Close the second clamp and screw it onto the anchor point near the grounding strip (or on

the bottom of the plastic to the right of the junction box in case of the No I/O Slots frame.)

7) Replace the junction box cover over the junction box.

8) Secure the junction box cover with two saved screws.

9) For all installations except the No I/O frame, loosen the two screws on the grounding strip

at the bottom of the metal chassis/housing and connect the ground cable to the protective
ground. Tighten the screws firmly.

10) Open the door of the power supply module and press in the cable holder downwards.

11) Plug the connector of the power supply cable (FKN8381A/3089004V64 for DC,

FKN8382A/3089004V65 for AC) into the cable inlet on the power supply module (on the
bottom of the front panel.) and rotate the cable holder upwards to secure.

2-17

Installation

Procedure 2-8 How to Connect the RTU to Main Power Source (Units with Housing)

1) Using a screwdriver, open the power junction box cover (save the screws) and unscrew the

power terminals screws inside the power junction box.

2) Insert the rubber grommet (supplied) into the threaded plastic cable gland, and place it into

the hole on the bottom of the housing (from the outside.) (See Figure 2-22.)

3) Place the nut into the same hole from inside the housing and screw the nut onto the cable

gland. (See Figure 2-22.)

4) Thread the user's main power cable (110/220VAC or 24-48VDC) through the cable gland

cover from below, through the cable gland, and into the housing. (See Figure 2-22.)

RTU Housing

Cable
Gland

Cable
Gland

Nut

Cover

Grommet

Power
Cable

Figure 2-22 RTU in NEMA 4 Housing – Cable Gland Anchor Point 2

5) Attach the wires of the user cable, according to labels (~/0 for AC and +/- for DC.) See

Figure 2-20 and Figure 2-21. For the No I/O frame, connect the ground cable to the lower
wire terminals (th ird pair).

6) Tighten the screws of the wire terminals and screw the wire terminals onto the junction

box.

7) Pass the power cable into the right side of the junction box, over the horizontal ridge.

8) Place the user cable into the clamp, close the clamp and screw it onto the junction box, into

the hole next to wire terminals (anchor point #1).

9) Replace the junction box cover over the junction box.

2-18

10) Secure the junction box cover with the two saved screws.

11) For all installations except the No I/O frame, loosen two screws on the grounding strip at

the bottom of the metal chassis/housing and connect the ground cable to the protective
ground. Tighten the screws firmly.

12) Screw the top of the cable gland tightly to the cable gland to secure the cable (anchor point

#2).

13) Open the door of the power supply module and release the cable holder (press downward).

14) Plug the connector of the power supply cable (FKN8381A/3089004V64 for DC,

FKN8382A/3089004V65 for AC) into the cable inlet on the power supply module (on the
bottom of the front panel.) and close the cable holder.

Connecting the Expansion Power Supply to the Main Frame Power Supply

When an I/O Expansion frame with an I/O Expansion power supply is added to the RTU,
connect the power as follows:

Procedure 2-9 How to Connect the Expansion Power Supply to the Main Frame Power Supply

1) Using a DC power cable (FKN8559A/#3002360C26), connect the Rack Exp connector

from the power supply on the main frame to the Power In connector on the Expansion
power supply.

Installation

2) If the RTU includes more than one Expansion frame, use a DC power cable

(FKN8559A/#3002360C26), to connect the Expansion Power Out connector on the
preceding Expansion power supply to the Power In connector on the next Expansion power
supply.

Before connecting I/O Expansion frames to the main frame, make sure that the power
supplies in question meet the power requirements of the RTU. For information, see
the ACE3600 System Planner.

Connecting the Backup Battery

The backup battery of ACE3600 is shipped from factory disconnected. Use this
procedure to connect the battery cable to the power supply charger.

Before using the Lead Acid backup battery, it is strongly recommended to read the
information on the battery provided in the Power Supply Module and Backup Battery
chapter.

2-19

Installation

Lead acid batteries will self-discharge if they are stored without charging. Self­discharge below the manufacturer's recommended voltage will result in internal
permanent damage to the battery rendering it inoperable. When this occurs, if
connected to a power supply/charger, the battery may produce excessive internal heat
and therefore deform and/or leak.

A battery contains d iluted sulfuric acid, a toxic and corrosive substance.
Avoid any bodily contact with the le aking liquid when handling leaking
batteries and affected parts. If the battery leaks and the liquid inside touch
the skin or clothing, immediately wash it off with plenty of clean water. If
the liquid splashes into eyes, immediately flush the eyes with plenty of
clean water and consult a doctor. Sulfuric acid in the eyes may cause loss
of eyesight and acid on the skin will cause burns.

Procedure 2-10 How to Connect the Backup Battery

1) Check the battery visually. If the battery looks deformed and / or you notice corrosion on

the battery terminals and / or the battery leaks, DO NOT use the battery and replace it with
a new battery.

2) Check the battery terminal voltage level before connecting it. If the battery voltage is less

than 12.5V DC, DO NOT use the battery and replace it with a charged battery that
measures at least 12.5V DC.

3) If the battery passes a visual inspection and the terminal voltage is correct, plug the battery

cable (FKN8376A/#3089927V10) into the Battery In/Out connector on the power supply
module.

4) Fully charge the battery prior to initial use (~10 hours).

Connecting I/O Modules to Ground

Before operating the I/Os in the ACE3600, the I/O modules must be connected to ground.

Procedure 2-11 How to Connect an I/O Module to Ground

1) Identify the PGND pin(s) on the I/O module using the Module Block Diagram or

Connection Charts in the relevant chapter for the I/O module type. See the symbol
next to the Protective Ground in the Module Block Diagrams.

2) If user-supplied cables are used, connect the ground wire(s) to the PGND pin(s) on the I/O

module and to the grounding strip at the bottom of the RTU. (See grounding strip in
Figure 2-19 above.)

3) If the wired cable braid is used, identify the ground wire(s) based on the wire color (see the

I/O Modules chapter) or the pin number printed on the wire label.
Connect the ground wire(s) from the cable braid to the PGND pin(s) on the I/O module and
to the grounding strip at the bottom of the RTU. (See grounding strip in Figure 2-19
above.)

2-20

4) Repeat steps 1-3 for the PGND wires on all I/O modules.

I/O Frame #3

Main Frame

Protective Ground

I/O Frame#1

I/O Frame #2

Ground Wire

Expansion
Power Cable

LAN Cable

Connecting an RTU to Ground

When an RTU is installed, individual ground wires (from the power cable and from the PGND
pin on the I/O module cables) are connected to the grounding strip on the chassis. The
grounding strip must then be connected to the grounding point of the cabinet or 19" rack.

In an RTU with I/O expansion, the grounding strip of each frame must be connected to the
grounding point of the cabinet or 19" rack. Figure 2-23 below depicts the ground connections
of an RTU with a single expansion frame and Figure 2-24 depicts the ground connections of an
RTU with multiple expansion frames.

Main Frame

DC
Cable

Installation

Grounding
Wire

I/O Frame

Crossed
LAN Cable

Protective Ground

Figure 2-23 Ground Connections of an RTU with a Single Expansion Frame

Figure 2-24 Ground Connections of an RTU with Multiple Expansion Frames

2-21

Connecting the Radio

A radio which is shipped in the ACE3600 is fully connected. To add a radio to the ACE3600,
use the appropriate radio installation kit. For information on radio types, radio installation kits
and connections, see the Radio Types and Installation Kits chapter.

Opening/Closing the Housing Door

The door to the small ACE3600 NEMA 4 housing is equipped with a latch or with an optional
padlock accessory. See Figure 2-25. The door to the large ACE3600 NEMA 4 housing is
equipped with two door latches or with an optional padlock accessory plus a latch. See Figure
2-26.

Procedure 2-12 How to Open and Close the Housing Door

1) To open a small RTU housing equipped with a door latch, turn the latch clockwise. The

door will open.
To open a small RTU housing equipped with the padlock accessory, remove the user­supplied padlock (if one exists) and turn the padlock accessory clockwise. The door will
open.
To open a large RTU housing equipped with two door latches, turn both latches clockwise.
The door will open.
To open a large RTU housing equipped with the padlock accessory and a latch, remove the
user-supplied padlock (if one exists) and turn the padlock accessory and latch clockwise.
The door will open.

Installation

2) To close a small RTU housing equipped with a door latch, turn the latch counterclockwise

and push the door closed until the latch clicks.
To close a small RTU housing equipped with the padlock accessory, turn the padlock
accessory counterclockwise and push the door closed until the latch clicks. Add the user­supplied padlock (if one exists) to lock the door.
To close a large RTU housing equipped with two door latches, turn both latches
counterclockwise and push the door closed until the latch clicks.
To close a large RTU housing equipped with the padlock accessory and a latch, turn the
padlock accessory and latch counterclockwise and push the door closed until the latch
clicks. Add the user-supplied padlock (if one exists) to the padlock accessory to lock the
door.

Figure 2-25 Small ACE3600 NEMA 4 Housin g /Housing with Padlock

2-22

Installation

Figure 2-26 Large ACE3600 NEMA 4 Housing/Housing with Padlock

Installing Accessory Box Interfaces

Cards such as RS485 interface card can be attached to the ACE36 00 RTU using a plastic
accessory box. The accessory box can be attached to the 19" accessories metal chassis,
small/large metal chassis, or small/large NEMA housing.

Procedure 2-13 How to Install the Accessory Box Interface on the Metal Chassis

1) To connect the accessory box interface to the metal chassis, place the box on the metal

plate and click the two pegs on the back of the accessory box into the desired holes on the
metal chassis. See Figure 2-27.
Note: This figure is for illustration purposes only. It is not relevant to install all the
accessories below on the same metal chassis.

2-23

Accessory Boxes

Installation

Portable Radio

Mobile Radio

Battery

Figure 2-27 Accessories Installed on a Metal Chassis

2) To remove the accessory box interface from the metal chassis, insert a screwdriver into the

notch located in the snap securing the unit to the chassis. Slightly bend the snap outwards
to release it from the slot, and carefully pull out the unit.

19" Frame Metal Back Installation Combinations

The 19" frame metal back can be ordered with a variety of frames, modules, and accessories
(e.g. battery, radio, accessory box.) In certain cases, choosing a certain accessory reduces the
other options. For example, the portable radio is installed on the 19" frame metal back with the
No I/O Frame in place of one accessory box. Likewise a battery is installed on the 19" frame
metal back with the No I/O Frame in place of one accessory box.

For diagrams of the various combinations, see Figure 2-28 below.

2-24

Installation

2-25

Installation

Figure 2-28 19" Frame Metal Back Installation Combinations

2-26

POWER SUPPLY MODULE AND BACK UP BATTERY

General Description/Module Overview

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 by default with the ACE3600 RTU

• 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 (not including the DC power supply low­tier):

• On/Off button on the front panel

• Controlled auxiliary voltage outputs

• Heat convection cooling (no need for fans)

• Short protection outputs

• Over heating protection

• Status LEDs in the front panel

• Power supply located on the leftmost slot of the frame, to the left of the CPU.

In a frame with both redundant CPUs and redundant power supplies, the third slot from the
left (between the primary CPU and the secondary CPU) is used by the redundant power
supply.

• Input current protection fuse

• Controlled power line enables centralized disabling of Electrically Energized 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.

3-1

Power Supply Module and Backup Battery

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

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

• Over-discharge protection

• Battery test and diagnostics, including battery controlled discharge

• Battery charging current control

Characteristics of the DC power supply low-tier:

• Two auxiliary voltage outputs

• Short circuit protection outputs

• PS located on the leftmost slot of the frame

• Overvoltage protection for CPU and I/Os

• Reverse voltage protection

Figure 3-1 below depicts a general view of the power supply.

3-2

Power Supply Module and Backup Battery

D

O

BA

T

T

AU

X

1

P

W

R

AUX

2

This converter
exists only in AC
or 18-72V DC PS

A

U

X

1A

A

UX

1B

A

UX

2A

A

U

X

2

B

1

2V

_DO

B

a

t

t

er

y

R

a

ck

Ex

p

T

em

p

P

ow

er

In

1

8

-

7

2

V

D

C

A

U

X

1A

O

N

O

F

F

Power Supply DC Power Supply Low-Tier

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

METAL PARTS OF THE POWER SUPPLY MAY BE VERY HOT.
After rem o ving th e power supply module, allow the metal parts to cool
down before servicing the unit.

Figure 3-1 ACE3600 Power Supply – General View

3-3

Power Supply Module and Backup Battery

AUX

AUX

DO

Auxiliary Output 1A
Auxiliary Output 1B

Auxiliary Output 2A
Auxiliary Output 2B

12V DO Control
12V Out to I/O E x pansion
B atter y I n / Out

T emperatur e S ens or

AC/DC Main P ower Input

BAT

On/Off B utton

I ndi cati on L E D s

D C Mai n P ower I n pu t

Figure 3-2 below depicts a detailed view of the power supply front panel.

Power Supply DC Power Supply Low-Tier

ON/OFF Button

The front panel of the power supply module includes an ON/OFF button for the module.
When the power supply module is in the OFF state, all the power outputs except Battery
In/Out are disabled. Press the button for at least two seconds to change states.

In power supply modules equipped with a battery charger, if the power supply module
is in the OFF state, and the RTU main power is connected, the Battery In/Out is not
disabled to ensure battery charging.

If the RTU main power (AC/DC) is disconnected and the power supply module is shut

off, there is still some current draw from the battery. Therefore, if the power supply is
to be off for a long period (more than several hours), the battery should be
disconnected from the power supply in order to maintain battery capacity. To do so,
disconnect the battery cable from the Battery In/Out connector on the front panel of
the power supply module.

If main power is cut to the RTU, the power supply module remembers its previous
state (ON or OFF) and reverts to it when main power is restored.

Figure 3-2 ACE3600 Power Supply – Front Panel

3-4

Input/Output Connectors

Auxiliary Output

13.8V DC (±5%) @ 20°C

This output is used for powering radios,

Auxiliary Output 1B

Same as Auxiliary Output

Same as Auxiliary Output 1A

Auxiliary Output

DC Power Output

This output is used for powering radios,

Caution: If both 2A and 2B are ON, they must have the same output level. If cables are

The front panel of the power supply module (not including DC power supply low-tier)
includes the following connectors.

Connector Name Description Notes

Power Supply Module and Backup Battery

1A

User controlled power
output.
Short protected.

modems, etc.
The output can be switched ON/OFF
either by the user application program
or using the STS hardware test.
(Default = ON)
For more information, see the
Performing Hardware Tests section or
Application Programmer section of
ACE3600 STS User Guide.

1A

Caution: Auxiliary Output 1A and 1B are ON by default with 13.8V DC. Do NOT plug in a
radio which requires less voltage or the radio may be damaged.

2A

Selectable/programmable

3.3 to 9V DC or

13.8V DC (±5%) @ 20°C.
User controlled power
output.
Short protected.

modems, etc.
The output voltage can be set by the
user using the STS site configuration.
The output can be switched ON/OFF
either using the STS hardware test or by
the user application program. (Default =
OFF)
If both 2A and 2B are ON, they must
have the same output level. The voltage
levels of AUX2A and AUX2B are the
same.

Auxiliary Output 2B Same as Auxiliary Output

2A

Note: Auxiliary Output 2B can be ON
independently of 2A.
The voltage levels of AUX2A and
AUX2B are the same.

connected to Auxiliary Output 2A and 2B, they must use the same voltage.

3-5

Power Supply Module and Backup Battery

Connector Name Description Notes

12V DO Control Control input that enables

centralized disabling of
Electrically Energized (EE)
relay outputs in selectable
DO modules.

This input controls a dedicated 12V
power line that is available to all the
slots in the frame. In each relay DO
module, the user can mechanically
select to power the relay coils from this
dedicated 12V power line.

Input open = Relays are
disabled. (ML relays do not
change state)
Input shorted = Relays are

For details on setting this control, see
the Module Configuration section of the
DO Relay Module chapter.

enabled.

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.

If the main power supply does not
control all other power supplies in the
RTU, it is recommended to have a
single on/off to control DO relays
simultaneously.

3-6

Power Supply Module and Backup Battery

Battery In/Out

Battery charger output when

The charging voltage level is controlled
Temperature Sensor

Sensor for battery

(In modules with power supply and

AC/DC Main Power

Cable inlet for main power

The cable is part of the RTU frame

Connector Name Description Notes

12V Out In systems with I/O

expansion, provides 12V
output to expansion power
supplies on expansion

Pin 1- PGND
Pin 2- 12V DO
Pin 3- GND
Pin 4- MAIN (12V)

frames.

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 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, it is recommended to have a
single on/off switch to control all power
supplies simultaneously.

(only in power
supply with charger)

Input

the main power exists.
Backup power input from

battery when the main power
fails.

temperature to control
charging level.

cable (AC or DC)

by the battery charger and is a function
of the temperature.

charger only)
For more information, see the Backup
Battery section below.

(connected to the power junction box.)
Note: When the cable male connected is

place in this input, it locks the power
supply module in its slot. To remove
the power supply module, first unplug
the power input cable.

3-7

Power Supply Module and Backup Battery

Auxiliary Output

Vin=Vout

This output is used for powering radios,

10.8-16V DC Main

Cable inlet for main power

The cable is part of the RTU frame

The front panel of the DC power supply low-tier includes the following connectors.

Connector Name Description Notes

LEDs

1A
Auxiliary Output 1B Vin=Vout

Power Input

Shorted to Power IN.

Shorted to Power IN.

cable (DC)

modems, etc.
This output is used for powering radios,

modems, etc.

(connected to the power junction box.
Note: When the cable male connected is

place in this input, it locks the power
supply module in its slot. To remove
the power supply module, first unplug
the power input cable.

The front panel of the power supply module (not including the DC power supply low-tier)
includes five indication LEDs.

LED Name Description Status

PWR Power LED Indicates the existence of AC or DC main power in

the Main Power input.

AUX1 Auxiliary Output 1

AUX2 Auxiliary Output 2

LED

LED

When the power supply module is in the ON state ­LED ON - Green.

When the power supply module is in the OFF state,
but there is AC or DC input or battery -
LED ON - Red.

When the power supply module is in the ON state
and the unit is powered from the battery -
LED is ON - Orange.

When there is no AC or DC input or battery
connected - LED OFF.

AUX1A is ON - Green
AUX1B is ON - Red
AUX1A and AUX1B are ON – Orange

AUX2A is ON - Green
AUX2B is ON - Red
AUX2A and AUX2B are ON – Orange

3-8

LED Name Description Status

Power Supply Module and Backup Battery

DO Digital Output Control

LED

Power to relays is enabled (12V DO Control plug is
connected) – LED ON – Green

Fault state (12V DO Control plug is disconnected
but power to relays is enabled) – LED ON – Red

Power to relays is disabled (12V DO Control plug is
disconnected) – LED OFF

BATT Battery LED No battery/thermistor - LED OFF

Battery is fully charged (charging current <20mA) ­LED ON - Green

Battery is being charged (charging current >20mA
and <600mA)- LED ON – Green/Orange Blinking

Battery is being charged (charging current >600mA)­LED ON – Orange

Battery is discharging (battery voltage is higher than
voltage of power supply) - LED ON – Red

Power supply is limiting the battery charging current
when main power is applied - LED ON – Red

Battery charging current is stabilizing - LED ON –
Orange Blinking

Redundant Power Supply

Redundant power supplies are used to ensure a continuous supply of the required RTU
voltages, in the event that one power supply fails. For details on the redundant power supply,
see Appendix E: CPU and Power Supply Redundancy below.

Battery Charger

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 a 12 VDC smart 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.

When battery capacity test is being performed - LED
ON - Green Blinking.

Battery tests are performed using the STS Hardware
Test function or the user application program.

3-9

The 12V DC power supply and 12V DC power supply low-tier do not include a battery option.

Charging the Battery

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 temperature-compensated
float-voltage of the ACE3600 battery.

Diagnostics

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. For more
information, see the Hardware Test section or the Creating a User Application section of the
ACE3600 STS User Guide.

Power Supply Module and Backup Battery

It is recommended to run a battery capacity test once per month (for more exact
results perform at +10˚ to +30˚C), and a charge level test once per day. The capacity
test lowers the main DC to a safety net level (~12V) so that the battery will be
activated. The battery is heavily loaded for ~45 seconds, the power supply LED
blinks green, and the battery capacity is measured. If the capacity is below the
manufacturer recommended level, the battery should be replaced with a new one.
(See Replacing the Backup Battery below.) Note that the capacity test is only
available for the battery types supplied by Motorola.

The results of the battery capacity test can be:

• Battery OK

• Battery needs to be replaced

• Test blocked - bad environment

The battery capacity test will be blocked under the following conditions:

1. If the battery is discharging (battery is main power source of RTU),

2. If the battery or thermistor is disconnected,

3. If the battery temperature is outside the specified range,

4. If the battery type is not properly configured,

5. If the battery is not fully loaded.
For test accuracy, all heavy current consumers should be turned off. In the Hardware Test, the

user should freeze the power supply before performing the battery capacity test.

3-10

Power Supply Module and Backup Battery

Connecting the Power Supply to a Power Source

The power supply can be connected to an AC or DC power source. The DC power supply
low-tier can be connected to a DC power source only.

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

For instructions on connecting the power supply to a power source, see the Power and Ground
Connections section of the Installation chapter above.

All power and ground connections must be in accordance with local standards and
laws.

3-11

Power Supply Module and Backup Battery

Weight

Approx. 0.43Kg (0.95 Lb)

Weight

Approx. 0.43Kg (0.95 Lb)

Power Supply Module Specifications

The following charts detail the specifications of the various power supply modules. For
specifications of the power supply module used with I/O expansion frames, see the Expansion
Power Supply Module chapter below.

12V DC Power Supply Module (Default)

Input Voltage DC 10.8-16 V

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

Outputs Motherboard connector (to CPU and I/O modules): equal to input voltage, max.

4 A
AUX1A/AUX1B: equal to input voltage, max. 8 A, on/off controlled by user
program
AUX2A/AUX2B (configurable): equal to input voltage (default), max. 8A,
or 3.3, 5, 7.5, 9 V DC ±10%, max. 2.5A, on/off (default) controlled by user
program

Note: max. 8 A total current consumption from all outputs

No Load Power

Max. 50 mA

Consumption
Diagnostic LEDs Status LED for: input voltage, AUX1 and AUX2 outputs, 12V control for DO

modules
Input Protection Internal line fuse, replaceable
Output Protection AUX2A/B short circuit, automatic recovery on 3.3, 5, 7.5, 9 V
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)

12V DC Low-Tier Power Supply Module

Input voltage 10.8-16 V DC
Outputs Motherboard connector (to CPU and I/O modules): The same as input voltage /

max. 4 A

AUX1A/AUX1B: equal to input voltage max. 8A

Note: max. 8 A total current consumption from all outputs
Input Protection Internal line fuse, replaceable
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)

Specifications subject to change without notice.

3-12

Power Supply Module and Backup Battery

Weight

Approx. 1Kg (2.2 Lb)

18-72V DC Power Supply Modules

Input Voltage 18-72 V DC
Total Power 18-72 V DC Max. 60 W continuous; max. 105 W peak @ 25% duty cycle
Outputs Motherboard connector (to CPU and I/O modules): 13.2 V DC ±20%, max. 4 A

AUX1A/AUX1B: 13.2 V DC ±20%, max. 8 A, on/off controlled by user

program

AUX2A/AUX2B (configurable): equal to AUX1A/AUX1B voltage, max. 8 A,

or 3.3, 5, 7.5, 9 V DC ±10%, max. 2.5A, on/off (default) controlled by user

program

Note: max. 8 A total current consumption from all outputs
Battery Charger 12 V Lead Acid battery charger (in PS model with charger)

Automatic charging of 6.5 or 10 Ah backup battery, battery temperature sensing,

overcharging protection, battery capacity test and diagnostics, automatic battery

switch-over
Diagnostic LEDs Status LED for: input voltage, AUX1 and AUX2 outputs, 12 V Control DO for

DO modules, and battery
No Load Power

Max. 250 mA
Consumption

Efficiency 80% typical, 76% with full load
Inrush Current 10 A maximum, for 2 mSec. Max, cold start at 25°C
Protection Internal line input fuse (replaceable), short circuit automatic recover
Output Protection AUX2A/B short circuit, automatic recovery on 3.3, 5, 7.5, 9 V
Insulation Input to case: 500 V DC, input to output 500 V DC
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)

Specifications subject to change without notice.

3-13

Power Supply Module and Backup Battery

Weight

Approx. 1kg (2.2 lb)

AC Power Supply Module

Input voltage 100-240 V AC, 50/60 Hz

100-240 V AC, 50/60 Hz with 12V smart battery charger
Total Power Maximum 60 W continuous; maximum 105 W peak @ 25% duty cycle

Outputs Motherboard connector (to CPU and I/O modules): 13.2 V DC ±20%, max. 4 A

AUX1A/AUX1B: 13.2 V DC ±20%, max. 8 A, on/off controlled by user

program

AUX2A/AUX2B (configurable): equal to AUX1A/AUX1B voltage, max. 8 A,

or 3.3, 5, 7.5, 9 V DC ±10%, max. 2.5A, on/off (default) controlled by user

program

Note: max. 8 A total current consumption from all outputs
Battery Charger 12 V Lead Acid battery charger (in PS with charger)

Automatic charging of 6.5 or 10 Ah backup battery, battery temperature sensing,

overcharging protection, battery capacity test and diagnostics, automatic battery

switch-over
Diagnostic LEDs Status LED for: input voltage, AUX1 and AUX2 outputs, 12V Control for DO

modules, and battery
No Load Power

130 mA @ 220 V AC
Consumption

Efficiency 80% typical @230 V AC, 76% typical @115 V AC (full load)
Inrush Current 25 A maximum, for 2 mSec. Max, cold start at 25°C
Power Factor 0.98 typical at 230 V AC, 0.99 typical at 115 V AC

Protection Internal line fuse, replaceable
Output Protection AUX2A/B short circuit, automatic recovery on 3.3, 5, 7.5, 9 V
Insulation Input to case: 1500 V AC, input to output: 3000 V AC
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)

Specifications subject to change without notice.

3-14

Backup Battery

Overview

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.

Lead Acid batteries will self-discharge if they are stored without charging. Self­discharge below the manufacturer's recommended voltage will result in internal
permanent damage to the battery rendering it inoperable. When this occurs, if
connected to a power supply/charger, the battery may produce excessive internal heat
and therefore deform and/or leak.

Power Supply Module and Backup Battery

The batteries are shipped disconnected from the power supply/charger. To ensure that
there are no battery problems on your ACE3600 project, each Lead Acid battery
MUST be fully charged and checked before connecting it to the ACE3600 power
supply/charger. To verify that the battery is fit for use, measure the BATTERY OPEN
CIRCUIT voltage (when the battery is not connected to the power supply/charger)
with a digital voltmeter. If the battery voltage is less than 12.5 V DC, DO NOT use
the battery and replace it with a new ACE3600 battery that measures more than 12.5
V DC.

Before transporting the battery, read and follow all safety information located on the
battery case.

If the RTU main power (AC/DC) is disconnected and the power supply module is shut
off, disconnect the battery from the power supply to maintain battery capacity.

ACE3600 batteries are shipped from the factory tested, fully charged and with a label
stating the next time it should be recharged when stored at temperatures of 30ºC or
less.

3-15

Power Supply Module and Backup Battery

Motorola battery warranty is valid only when the battery is charged with the original
Motorola ACE3600 charging power supplies. Use of any other power supply/charger
will void the battery warranty.

Under various state or local laws, the batteries must be recycled or disposed of
properly and cannot be disposed of in landfills or incinerators. Environmental
protection regulations classify used Lead Acid batteries as hazardous waste, unless
certain exemptions apply. Consideration should be given to the methods of collecting,
labeling, handling and shipping used Lead Acid batteries. Please consult the
environmental protection authority for specific legal requirements and for recycling
options in your country/area.

Backup Battery Storage, Lifespan, Inspection and Replacement

The manufacturer’s recommendations for handling during each of the battery’s life stages are:

• Transportation:

Batteries must be handled with care to prevent falls, impact, short circuit or exposure
to high temperatures and fire.

• Battery Storage:

Storage of batteries in a warehouse requires a periodic recharge. The time between
these recharge cycles depends upon the storage temperature. The minimum open
circuit voltage allowed on the battery before recharging is 12.42 V, which represents
remaining capacity of approximately 30%. Therefore it is recommended to perform a
full charging cycle every few months depending upon the storage temperature of the
battery. Please refer to Table 3-1 to determine the suggested maximal period between
recharge cycles that suits the actual storage conditions. Improper storage may cause
deep discharge of the battery, which might cause degradation of the battery operating
life and lower the actual delivered capacity. Motorola performs a periodic full charge
cycle procedure on stored batteries and a final full charge operation prior to shipment.

• Lifespan:

The average temperature of the battery environment affects the lifespan of batteries
installed in the field. Please refer to the battery vendor information at the following
website:

(Sonnenschein A512/6.5S and A512/10S): http://www.sonnenschein.org/A500.htm

• Inspection and Replacement:

It is important to inspect the batteries periodically (recommended every 6-12 month)
and replace any battery that has corrosion on the leads or it is deformed or leaks. Such
a battery should be disposed according to the local environmental laws. To assure the
battery availability and proper operation, the battery should be replaced at the end of
its lifespan (approximately 30% capacity) even if it is still functional. Measure the
battery open circuit voltage using a digital voltmeter as described above. Please note

3-16

Power Supply Module and Backup Battery

that using a battery beyond its lifespan period may cause a battery heating, leakage
and/or deformation.

Table 3-1: Recommended Time between Periodic Battery Recharge vs. Storage Temperature

Average Storage

Temp (°C)

Recharge Interval

(Months)

25 12
45 4
60 1

Replacing the Backup Battery

A battery contains diluted sulfuric acid, a toxic and corrosive substance. Avoid any
bodily contact with the leaking liquid when handling leaking batteries and affected
parts. If the battery leaks and the liquid inside touch the skin or clothing, immediately
wash it off with plenty of clean water. If the liquid splashes into eyes, immediately
flush the eyes with plenty of clean water and consult a doctor. Sulfuric acid in the
eyes may cause loss of eyesight and acid on the skin will cause burns.

Procedure 3-1 How to Replace the Lead Acid Backup Battery

To replace the Lead-Acid backup battery, follow the procedure below.

1) Disconnect the battery cable from the Battery connector of the power supply (see

Figure 3-2) and from the battery.

2) Unscrew the battery holders (two screws in the small battery and four screws in the

large battery) with the attached battery temperature sensor. (See Figure 3-3 below.)

3-17

Figure 3-3 Backup Batteries – Exploded View

3) Remove the old battery from the RTU.

Power Supply Module and Backup Battery

4) Check the replacement battery visually. If the battery looks deformed, if you notice

corrosion on the battery terminals, or the battery leaks, DO NOT use the replacement
battery; get another replacement battery.

5) Check the replacement battery terminal voltage level before connecting it. If the

battery voltage is less than 12.42V DC, DO NOT use the battery and replace it.

6) If the replacement battery passed the visual inspection and the terminal voltage is

satisfactory, put the battery into place on the RTU and screw in the battery holders.

7) Connect the battery cable to the battery terminals in the correct polarity.

8) Connect the battery cable to the Battery In/Out connector on the front panel of the

power supply module.

9) Recharge the replacement battery for 10 hours to be fully charged.

3-18

P

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1

CPU MODULE

General Description

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. (Inserting the module in the wrong slot will not cause any damage to the CPU.)

For information on the location and arrangement of CPUs in the redundant CPU and power
supply frame, see Appendix E: CPU and Power Supply Redundancy below.)

∗

Figure 4-1 provides a general view of the ACE3600 CPU (Models 3610

, 3640, and 3680).

Model 3610 Model 3640 Model 3680

Figure 4-1 ACE3600 CPU – General View

∗

The CPU 3610 model has been discontinued.

4-1

CPU Module

The CPU panel includes status LEDs, user LEDs, communication port LEDs, two pushbuttons,
and communication ports. The panel is covered by the module door.

Figure 4-2 provides a detailed view of the CPU front panel.

PWR

ERR

CPU Status
LEDs

Port
LEDs

User
LEDs

RST

APPL

CONF

H1

LNK1

LNK2

P1

Tx

Tx

Rx

CM

S1

Tx

Rx

CM

S2

Tx

Rx

CM

E1

LNK

Rx

E2

LNK

Rx

P2

Tx

Rx

CM

D1

LNK

USR1

USR2

USR3

USR4

Pushbuttons

Host (Model 3680)USB 1,2 Type A
Plug-in 1*

Serial 1

Serial 2

Ethernet 1(Model 3640, 3680)
Device USB 1 Type B (Model 3680)
Plug-in 2*

Figure 4-2 ACE3600 CPU (Models 3610/3640/3680) – Front Panel

Front Panel

Communication Ports

The CPU module includes several communication ports:
On Board ports:

• USB Host 1/2 (HU1/HU2) - USB Type A host full speed ports for MDLC over IP

communication via the MotoTrbo digital mode radio system (up to two radios
attached to two USB host ports at one time).

MotoTrbo radios are supported.

• Serial 1 (SI1) – RS232/RS485 serial port (configurable)

• Serial 2 (SI2) – RS232 serial port

• Ethernet (Eth1) - 10/100BaseT Ethernet port (CPU 3640 or 3680 only)

*Optional

No USB devices or USB Hubs other than

• DU1 – USB device port, Type B connector (for connection to the STS PC)

4-2

CPU Module

Peer Ethernet Port Mode

Auto

100 Mbs

Full Duplex

100 Mbs

Half Duplex

10 Mbs

Full Duplex

10 Mbs

Half Duplex

Speed Match

ACE3600

Duplex Match

ACE3600

• Internal Ethernet port (Int 1) – Internal 100 Mb Ethernet port, (for communication

between dual redundant CPUs) (CPU 3680 only)

Plug-in port 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.

For the detailed specifications of each port, see CPU 3640 Module Specifications and CPU
3680 Module Specifications below. For information on the cables and connectors, see
Appendix C.

The ACE3600 Ethernet port performs an Auto-Negotiation procedure whenever a
peer device connection is detected at a 10/100 Mbps Ethernet port.. The Auto­Negotiation procedure guarantees that the speeds of ACE3600 and peer Ethernet ports
will match, whether or not the peer supports Auto-Negotiation. If the peer supports
Auto-Negotiation, the duplex of ACE3600 and the peer Ethernet ports also match.

Buzzer

It is recommended to configure the Ethernet port of the device connected to the
ACE3600 Ethernet port (e.g. switch, etc.) to Auto-Negotiation mode. This will
guarantee a full match of speed and duplex between the ACE3600 and the peer device
Ethernet ports. If the peer device Ethernet port does not support Auto-Negotiation,
set the duplex of the peer to half duplex to avoid the duplex mismatch problem.

with

with

The CPU module includes a 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.

4-3

Pushbuttons

The CPU includes two pushbuttons on the front panel, PB1 and PB2.
These pushbuttons are used for activating and testing the modules LED, restarting the unit,

erasing the user Flash memory and activating memory test. Table 4-2 describes the
pushbuttons functionality.

The pushbuttons can also be monitored by the user application program (when it is running)
for the application purposes.

LEDs

The CPU includes CPU status LEDs, port status LEDs, and user LEDs. Some of the LEDs are
single color (green) and some are bicolor LEDs (red, green or orange).

Status LEDS indicate the CPU status in startup (boot), run-time or when there is a failure. The
communication LEDs are used to indicate the communication port status. The user LEDs can
be used by the user application program. Note that during startup or failure, the
communication and user LEDs are used to indicate various situations. Table 4-4 details the
LEDs functionality.

CPU Module

CPU Memory

The ACE3600 CPU 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. See Backup Battery for SRAM and
RTC for more information.

The size of the CPU memory is determined by the model as shown in the table below.

Table 4-1 ACE3600 CPU Memory

Model 3640 Model 3680 Model 3610*(discontinued)
Flash memory

SDRAM
memory:

User Flash:
User SDRAM:
SRAM Plug-In

16 MB 32 MB 16 Mb
32 MB 128 MB 32 Mb

3 MB 19 MB 3 Mb

10 MB 100 MB 10 Mb

4 MB 4 MB 4 Mb

4-4

Real Time Cloc k (RTC)

The CPU includes 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. For more information,
see the Setting/Getting a Site’s Date and Time section or the Creating a User Application
section of the ACE3600 STS User Guide.

Backup Battery for SRAM and RTC

The CPU module includes a rechargeable lithium battery that provides backup power and data
retention for the SRAM and RTC.

The lithium battery is located on the CPU board and cannot be replaced.
Typically, the battery in the CPU 3680 will retain the SRAM data and RTC for 40 continuous

days, and the battery in the CPU 3640/3610 will retain the SRAM data and RTC for 60
continuous days, without power and no Lead-Acid backup battery. When the SRAM option is
not used, the Lithium battery will keep the Real Time Clock running for a longer period of
time.

CPU Module

CPU with Security

In an ACE3600 system with security, the CPU 3680 has a dedicated security hardware
repository. Backup power and data retention for this repository is also provided by the
rechargeable lithium battery.

For more information on the security repository, see the ACE3600 Advanced System Security
User Guide.

Redundant CPU

CPU redundancy (ACE3680 only) ensures continuous RTU operation if one CPU fails. For
details on the redundant CPU, see Appendix E: CPU and Power Supply Redundancy below.

CPU Firmware and Operation Modes

The CPU firmware is a real-time multitasking operating system, based on the Wind River
VxWorks OS. The CPU 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 manual.) If the
new firmware download stops or fails, the CPU will restart with the existing firmware.

4-5

Power-up and Restart

The CPU requires DC voltage provided by the power supply module via the motherboard
(when the PS switch is ON). The CPU will power-up and restart in the range of 10.8V to 16V
DC. During power-up, the processor performs fast memory tests, initiates the RTU and starts
the user program (if one was downloaded). The end of the power-up sequence is indicated by
the buzzer. The length of time from the beginning of CPU power-up until the user program
starts running is approximately 10-15 seconds.

It is possible to perform a comprehensive memory test during power-up by pressing push­button PB1 for few seconds while switching the power supply from OFF to ON. In this case
the power-up period is about 30-35 seconds long.

If the startup fails, the RTU will freeze (boot sequence stops), the PWR LED will blink and
the four indicator LEDs (see LEDs Location in Table 4-3) will blink seven times. The four
LEDs will then display the failure error in binary code, as described in Table 4-3.

Restart after Firmware Download

The RTU will restart after downloading system firmware. If the firmware is faulty or the
firmware download failed, the RTU, if protected by the Safe Firmware Download feature, will
restart and roll back to the previous firmware version. A failure message will appear in the
STS Downloader screen. For information on using the Safe Firmware Download feature, see
the Safe Firmware Download section of the ACE3600 STS Advanced Features manual.

CPU Module

Restart after Configuration Download

The RTU will restart after downloading a site configuration. For information on downloading
to the RTU, see the Operation chapter of the ACE3600 STS User Guide.

If the RTU fails to restart after the user-defined site configuration was downloaded, a unique
LED display (in the range of the PI1-TX and SI2-RX LEDs) and a series of buzzer tones will
follow. The RST LED will turn RED and the RTU will restart itself with the previous “good”
configuration. The following message will appear in the RTU Error Logger “Configuration
file was deleted due to failure in startup. Rolling back to the last configuration file”. Errors
can be retrieved from the RTU using the ACE3600 STS Error Logger utility.

If the startup succeeds after configuration download but has errors, these errors are reported in
the RTU Error Logger. It is, therefore, recommended to check for errors after downloading a
configuration file to the RTU. Errors can be retrieved from the RTU using the ACE3600 STS
Error Logger utility.

For information on retrieving errors from the RTU Error Logger, see the Operation chapter of
the ACE3600 STS User Guide.

Restart after Erase Flash

After the User Flash is erased, the RTU will restart successfully with the default site
configuration.

4-6

Power-down

When the voltage provided to the CPU module drops below the minimum level, the CPU will
shut down in an orderly fashion. This level is configurable for all power supply modules other
than the 12V DC power supply low-tier. See the ‘Minimum DC operation voltage’ parameter
in Appendix A: Site Configuration Parameters of the ACE3600 STS User Guide.

CPU Status and Diagnostics

The CPU status is indicated on the front panel LED. Detailed CPU status and diagnostics
information can be retrieved from the module using the CPU Hardware Test utility. For more
details, see the Hardware Test section of the ACE3600 STS User Guide.

CPU Warnings and Errors

CPU warnings and errors are logged in the CPU memory to indicate issues or errors during
power-up, restart, user application program execution and other modes of CPU operation. The
existence of CPU warnings and errors are indicated in the ERR LED on the front panel of the
module. Green indicates a message, orange indicates a warning and red indicates an error.

CPU Module

The CPU error logger information can be retrieved using the STS Error Logger utility. For
more details, see the Error Logger section of the ACE3600 STS User Guide.

CPU Serial Number

Each CPU has a unique serial number. This number is printed on a label on the side of the
CPU module front panel. The serial number can be read using the STS Hardware. For more
information, see the Hardware Test section of the ACE3600 STS User Guide.

Connecting Plug-In Ports to the CPU Module

In general, the plug-in ports are ordered as options with the RTU and are installed in the
factory. However, it is also possible to add plug-in ports to the CPU after it is shipped from
the factory. Several plug-in ports are available. See Communication Ports above.

Note: A TORX screwdriver is required for installation of the plug-in ports.

4-7

Figure 4-3 depicts a plug-in port board attached to the ACE3600 CPU module.

Supporting
Pins

Plug-in 1

Supporting
Pins

CPU Module

Plug-in 2

Figure 4-3 Plug-In Port in CPU Module

Procedure 4-1 describes how to connect a plug-in port to the CPU.

Procedure 4-1 How to Connect a Plug-in Port to the CPU

1) Remove the CPU module from the RTU.

2) Remove the cover from the desired opening on the front panel.

3) Connect two supporting pins with screws to the plug-in port.

4) Place the plug-in board with the RJ-45 connector facing the panel. Carefully insert the

plug-in board connector into the appropriate connector on the CPU board.
For Ethernet 10/100 MB,
For all other plug-in ports,

5) Connect the two supporting pins with screws to the other side of the CPU board.

6) Replace the CPU module in the slot.

use the J14 connector on the CPU (Plug-in 1 only.)

use the J5 (Plug-in 1) or J6 (plug-in 2) connector.

4-8

Connecting SRAM Expansion Memory to the CPU Module

In general the plug-in SRAM is ordered as an option with the RTU and is installed in the
factory. However, it is also possible to add plug-in SRAM to the CPU after it is shipped from
the factory.

Note: A TORX screwdriver is required for installation of the SRAM.
Figure 4-4 depicts the user SRAM Plug-in memory in the ACE3600 CPU module.

CPU Module

Figure 4-4 SRAM Expansion in CPU Module

Procedure 4-3 describes how to connect a plug-in SRAM memory card to the CPU.

Procedure 4-2 How to Connect a Plug-in SRAM Memory Card to the CPU

1) Remove the CPU module from the RTU.

2) Remove the cover from the connector marked P12 on the CPU board.

3) Place the plug-in SRAM memory card with the connector facing the panel. Carefully

insert the plug-in board connector into the connector on the CPU board.

4) Secure the memory card to the CPU board with the supplied screw.

5) Replace the CPU module in the slot.

4-9

Pushbutton Functionality

The table below describes the use of the two pushbuttons in various scenarios, during power­up and run-time. To press a pushbutton during startup, first press the pushbutton(s), then turn
on the RTU using the On/Off switch on the front panel. Keep the pushbutton(s) depressed for
the required number of seconds, as specified in the scenarios below.

Table 4-2 ACE3600 Pushbutton Functionality

Scenario Trigger Action

CPU Module

LEDs Test During run-time, press PB1

for five or more consecutive
seconds (but less than 30).

RTU Restart During run-time, press PB1

for 30 consecutive seconds.

All the LEDS on the CPU and I/O modules
will be lit until let go of PB1 and then
returned to their previous states.

All the LEDs will be lit. Then all the LEDs
will blink once.

The buzzer will buzz several short beeps.
(If PB1 is released during this time the
restart will not be performed.)

At the long beep, release PB1 and the RTU
will restart (and the buzzer will buzz.)

Turn LEDs ON During run-time, press PB1

for one second.

Those LEDs which are currently active
will be turned on for a period of time
(configured in the RTU configuration
using the STS.)

RAM Test During startup, press PB1. A detailed memory test of SDRAM and

SRAM plug-in is performed.

- At the beginning of the RAM test, the
four indicator LEDs (see LEDs Location in
Table 4-3) will blink three times. During
the RAM test, the LEDs may blink or be
lit.

If the RAM test succeeds, the four LEDs
will blink three times and turn off and the
restart sequence will continue.

If the RAM test fails, the RTU will freeze
(restart sequence stops), the PWR LED
will blink and the four LEDs will blink
seven times. The failure error code will
then be displayed on the LEDs, in binary
code, as described in Table 4-3.

- To exit/abort the RAM test in the middle,
restart the RTU using the On/Off switch
on the front panel.

4-10

Scenario Trigger Action

Ethernet LEDs
in CPU3640

ERR Code 1

ERR Code 2

ERR Code 3

ERR Code 4

ERR Code 6

CPU Module

Erase User
Flash

During startup, press both
PB1 and PB2
simultaneously until the
buzzer buzzes five times
quickly, then continuously

All the user Flash memory content
excluding logging files (files tagged as
data logging files) is erased, including the
site configuration, user application
programs, user tables, etc.

for three seconds.

Bootstrap During startup, press PB2

continuously for five
seconds.

Note: Before initiating
bootstrap, the CPU must be
connected directly to the
STS PC in standalone mode.
No other components can be
on the network which might

The RTU will start up in diagnostic mode.
Communication with the RTU is for
diagnostic purposes only (Error Logger/
SW Diagnostics.) You cannot download
to the RTU and no application will run.

If the bootstrap fails, the four indicator
LEDs (see LEDs Location in Table 4-3)
will display the failure error in binary

code, as described in Table 4-3.
create a conflict with the
default IP address.

Table 4-3 ACE3600 Failure – Error Code Display on LEDs

LEDs Location LED Error Code Description

On CPU 3640/3680,
the four LEDs begin
with the group
marked E1, as above.

ERR Code 1 = Error in Flash

ERR Code 2 = Error in SDRAM

ERR Code 3 = Error in SRAM

ERR Code 4 = Unable to boot.

Corrupted bootstrap.

ERR Code 6 = Low voltage under 12V

Where OFF LED = ‘0’;

ON LED = ‘1’ (very fast blink,

almost

continuous);

The highest LED is the most significant.

4-11

CPU LEDs Behavior

The table below describes the behavior of the LEDs on the CPU module.

Table 4-4 ACE3600 CPU LEDs Behavior

LED Name Description Status

CPU Module

PWR Power LED

Bicolor LED (Red, Green)

ERR Error Logger Status LED

Bicolor LED (Red, Green)

RST Reset LED

Bicolor LED (Red, Green)

APPL Application LED

Bicolor LED (Red, Green)

Flashing Red – Power exists; CPU FPGA not
loaded.

Green – Power exists; CPU is running from a
recognized power supply (one of the six
power supply options.)

Red – Failure on power-up. CPU is running
from an unrecognized power supply.

OFF – No new errors or warnings.
Green – New message logged.
Orange – New warning logged.
Red – New error logged.
Note: In systems with I/O expansion, the ERR

LED can indicate an error in either the main
or expansion frame.

Green – On startup
OFF – Successful power-up or restart.
Red – Power-up or restart failed.
OFF – No user application program in the

Flash memory.
Green – User application program is running.

CONF Configuration LED

Bicolor LED (Red, Green)

*

H1 LNK1

USB Host1 LNK (link)
Green LED

*

The LED names I1 ACTV, I1 L/RX, H1 LNK1/LNK2, and D1 RX appear only in CPU 3680.

Orange – User application program was
paused by user (during Hardware Test.)

OFF – Configuration was not loaded.
Green – Configuration was loaded.
Red – Configuration error.
ON – A USB device is connected.
OFF – No link exists between the CPU and

the MotoTrbo radio.

4-12

LED Name Description Status

*

H1 LNK2

USB Host2 LNK (link)
Green LED

ON – A USB device is connected.
OFF – No link exists between the CPU and

the MotoTrbo radio.

CPU Module

PI1 TX Plug-in Port 1 – TX

(transmit)
Green LED

PI1 RX Plug-in Port 1– RX (receive)

Green LED

PI1 CM Plug-in Port 1 – CM (channel

monitor)
Green LED

SI1 TX Serial Port 1 – TX (transmit)

Green LED

SI1 RX Serial Port 1 – RX (receive)

Green LED

SI1 CM Serial Port 1 – CM (channel

monitor)
Green LED

S2 TX Serial Port 2 – TX (transmit)

ON- Transmitting Data

ON – Receiving Data

ON – Channel Busy (if port is in use by radio,
RS485, or RS232)
– Network Connected (if an IP plug-in is
used)

ON – Transmitting Data

ON – Receiving Data

ON – Channel Monitor is ON.

ON – Transmitting Data

Green LED

S2 RX Serial Port 2 – RX (receive)

ON – Receiving Data

Green LED

S2 CM Serial Port 2 – CM (channel

ON – Channel Monitor is ON

monitor)
Green LED

E1 LNK

Ethernet Port 1 (link)
Green LED

ON – Network Connected
In case of RAM test and startup failure, see

**

Table 4-2 and Table 4-3.

*

The LED names I1 ACTV, I1 L/RX, H1 LNK1/LNK2, and D1 RX appear only in CPU 3680.

**

The LED names E1 LNK and RX appear only in CPU 3640 and CPU 3680.

4-13

LED Name Description Status

E1 RX

**

I1 ACTV

Ethernet Port 1 – RX
(receive)

Green LED

*

Internal Port 1 (INTR1) for
Redundancy (active)
Green LED

ON – Receiving Data
In case of RAM test and startup failure, see

Table 4-2 and Table 4-3.
ON – This CPU is the active CPU.
OFF – This CPU is the standby CPU or the

system does not include Redundancy.

CPU Module

I1 L/RX**

Internal Port 1 (INTR1) for
Redundancy (link/receive)
Green LED

PI2 TX Plug-in Port 2 – TX

(transmit)
Green LED

PI2 RX Plug-in Port 2 – RX (receive)

Green LED

PI2 CM Plug-in Port 2 – CM (channel

monitor)
Green LED

D1 RX**

USB Device Port – RX
(receive)

USR1­USR4

User application program
LEDs

Green LED

ON – There is a link between the active and
standby CPUs.

Blinking – There is a link between the active
and standby CPUs and data is being
received.

OFF – The system does not include
Redundancy.

ON – Transmitting Data

ON – Receiving Data

ON – Channel Busy (if port is in use by radio,
RS485, or RS232)
– Network Connected (if an IP plug-in is
used)

ON – Receiving Data

Controlled by the user application program.
Light consecutively and repeatedly one after

the other when entering boot mode.

**

The LED names E1 LNK and RX and D1 RX appear only in CPU 3640 and CPU 3680.

*

The LED names I1 ACTV, I1 L/RX, H1 LNK1/LNK2, and D1 RX appear only in CPU 3680.

4-14

CPU Module

CPU 3610

Microprocessor

*

/CPU 3640 Module Specifications

Freescale – Power PC II MPC8270, 32-bit, extended communication

capability, DMA and floating point calculation support
Microprocessor Clock 200 MHz
Memory Flash: 16 MB/3 MB free for user

DRAM: 32 MB/10 MB free for user

SRAM plug-in (Optional): 4 MB total, all free for user
Real-Time Clock Full calendar with leap year support (year, month, day, hours, minutes,

seconds).

Time drift: max. 2.5 Seconds per day (when power is on)
SRAM and RTC

3 V Rechargeable lithium backup battery
Retention

Serial Port 1 Configurable RS232 or RS485 port:

- RS232: Asynch, Full Flow Control, up to 230.4 kb/s, GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s
Serial Port 2 RS232, Asynch, Full Flow Control, up to 230.4 kb/s, GPS receiver interface
Ethernet Port 1 10/100 Mb/s (on CPU 3640 only)
Plug-In Port 1 Supports the following plug-in ports:

- Radio Modem, DPSK 1.2 kb/s, FSK 1.2/1.8/2.4 kb/s,

DFM 2.4/3.6/4.8 kb/s

- RS232, Sync/Asynch, Full Flow Control, up to 230.4 kb/s,

GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s

- Ethernet 10/100 Mb/s
Plug-In Port 2 Supports the following plug-in ports:

- Radio Modem, DPSK 1.2 kb/s, FSK 1.2/1.8/2.4 kb/s,

DFM 2.4/3.6/4.8 kb/s

- RS232, Sync/Asynch, Full Flow Control, up to 230.4 kb/s,

GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s

- Ethernet 10 Mb/s
LEDs Display 4 CPU diagnostic LEDs, Port status LEDs and user application LEDs
Power Consumption Refer to Appendix D: ACE3600 Maximum Power Ratings.
Operating Voltage 10.8-16 V DC (from the motherboard connector)
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)
Weight Approx. 0.38 Kg (0.84 Lb)

Specifications subject to change without notice.

*

The CPU 3610 model has been discontinued.

4-15

CPU Module

CPU 3680 Module Specifications

Microprocessor Freescale – Power PC II MPC8270, 32-bit, extended communication capability,

DMA and floating point calculation support
Microprocessor Clock 200 MHz
Memory Flash: 32 MB/19 MB free for user

SDRAM: 128 MB/100 MB free for user

SRAM plug-in (Optional): 4 MB total, all free for user
Real-Time Clock Full calendar with leap year support (year, month, day, hours, minutes, seconds).

Time drift: max. 2.5 Seconds per day (when power is on)
SRAM, RTC, and

Security Repository
Retention

USB Host Port 1, 2

Serial Port 1 Configurable RS232 or RS485 port:

Serial Port 2 RS232, Asynch, Full Flow Control, up to 230.4 kb/s, GPS receiver interface
Ethernet Port 1 Ethernet 10/100 Mb/s
USB Device Port 1 USB device port, Type B connector
Internal Ethernet Port 1 Internal 100 Mb/s Ethernet port (for redundant CPU interconnection)
Plug-In Port 1 Supports the following plug-in ports:

3 V Rechargeable lithium backup battery

Type A host full speed 12 Mbs ports

over IP communication via the MotoTrbo digital mode radio system (on CPU 3680

only). For MotoTrbo radio only; No other USB devices or USB Hubs are

supported.

- RS232: Asynch, Full Flow Control, up to 230.4 kb/s, GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s

- Radio Modem, DPSK 1.2 kb/s, FSK 1.2/1.8/2.4 kb/s,

DFM 2.4/3.6/4.8 kb/s

- RS232, Sync/Asynch, Full Flow Control, up to 230.4 kb/s,

GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s

- Ethernet 10/100 Mb/s

(HU1 on left and HU2 on right) for MDLC

Plug-In Port 2 Supports the following plug-in ports:

- Radio Modem, DPSK 1.2 kb/s, FSK 1.2/1.8/2.4 kb/s,

DFM 2.4/3.6/4.8 kb/s

- RS232, Sync/Asynch, Full Flow Control, up to 230.4 kb/s,

GPS receiver interface

- RS485, multi-drop 2-Wire up to 230.4 kb/s

- Ethernet 10 Mb/s
LEDs Display 4 CPU diagnostic LEDs, Port status LEDs and user application LEDs
Module Replacement Hot swap replacement – module extraction/insertion under voltage in redundant

systems only.

Power Consumption Refer to Appendix D: ACE3600 Maximum Power Ratings.

4-16

Operating Voltage 10.8-16 V DC (from the motherboard connector)
Dimensions 56 mm W x 225 mm H x 180 mm D (2.2" W x 8.7" H x 7.1" D)
Weight Approx. 0.38 Kg (0.84 Lb)

Specifications subject to change without notice.

CPU Module

4-17

E

R

R

O

F

U

F

O

F

U

F

O

F

U

F

O

F

U
F

O

F

U

F

O

F

U

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O

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O

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2

4

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1

2

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R

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F

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U
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2

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O

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F

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1

0

1

1

1

2

1

3

1

4

1

5

1

6

2

4

V

I/O MODULES

General Description

The ACE3600 RTU can include up to eight I/O modules, depending on the frame size. A
variety of I/O modules are available. Additional I/O modules can be added using the I/O
Expansion frame. For information, see the I/O Expansion chapter below.

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.)

Figure 5-1 provides a general view of an ACE3600 I/O module.

I/O Module with Two TBs I/O Module with Three TBs I/O Module with Four TBs

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.

Figure 5-2 provides a detailed view of the I/O front panel.

Figure 5-1 ACE3600 I/O Module – General View

5-1

I/O Modules

ERR

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

24V

1

2

3

4

5

6

7

8

1

2

33

4

5

6

7

8

9

10

11

12

13

14

15

16

ERR

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

24V

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

OF

UF

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

24V

Figure 5-2 ACE3600 I/O Module – Front Panel (without TB Holder)

I/O Module LEDs

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. For more information, see the ACE3600
STS User Guide.

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).
In the 8 DO Select Before Operate (SBO) module, the Controlled DO LED (CDO) indicates
whether 12V is controlled or not.

Note: In the 8 DO SBO module, if the DO LED is blinking, this indicates that the two relays of

I/O Module Test

this output are not in the same state. This means that there is a malfunction.

The I/O modules can be tested using the STS Hardware Test utility. For more information, see
the ACE3600 STS User Guide.

The I/O module LEDs can be tested using the STS Hardware Test utility– all the LEDS are lit
for a number of seconds, and then turned back to their previous state.

5-2

Panel Terminal Block (TB) Connectors

Each I/O module is equipped with a set of two, three or four TB connectors. Each TB
connector has 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). A TB holder can also be ordered for all I/O module types. (See TB Holder
and Cables below.) 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.

I/O Modules

Procedure 5-1 Extracting the TB Connector from the I/O Module

1) Open the door of the I/O module to expose the TB connectors (2-4).

2) Position the TB extractor over the desired TB connector, with the small notch facing to the

right. (See Figure 5-4.)

3) Press the center of the TB extractor from both sides to open the two sides of the clamp

end.

Figure 5-3 TB Connector-Male/Female

5-3

I/O Modules

4) Clamp the open TB extractor over the desired TB connector and pull on the back handle to

extract the TB connector from the I/O module.

TB Holder and Cable s

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.

Note that a Philips screwdriver is required for assembling the TB holder and a flat screwdriver
is required for setting the code key pin.

Figure 5-4 TB Extractor

5-4

Figure 5-5 Terminal Block (TB) Holder-Front and Back View

Assembling the TB Holder Parts

Procedure 5-1 Assembling the TB Holder Parts

If the TB holder kit is ordered, follow the procedure below. (See Figure 5-6.)

I/O Modules

1) Prepare the cable by cutting the wires to fit the TBs. Connect the wires of the user-

assembled cables to the TBs, following the pin descriptions on the module panel label
(where pin 1 is at the top of first TB and so on downwards.)

2) Place the TBs onto the left part of the TB holder plastic.

3) Add the top ejector handle, the code key and the positioner.

4) Close the right side of the plastic TB holder over the left side.

5) Screw together the assembly using the three screws provided in the kit.

Note the lower screw holds the positioner into place.)

6) Insert the lower ejector handle at the bottom of the TB holder.

7) Slide the metal axis into lower ejector handle from the side.
Once the TB holder is assembled, it can be connected to the I/O module.

5-5

Figure 5-6 provides an exploded view of the TB holder assembly for four TBs.

I/O Modules

Figure 5-6 Terminal Block (TB) Holder Assembly – Exploded View with Coding

Attaching the TB Holder Clip to the I/O Module

An optional TB holder clip can be added to the I/O module to secure the cable.

Procedure 5-2 Attaching the TB Holder Clip to the I/O Module

1) Remove the I/O module from the ACE3600 RTU.

5-6

I/O Modules

2) Using the supplied screw, attach the TB holder clip to the bottom of the I/O module. (See

Figure 5-7.)

3) Replace the I/O module in the RTU slot.

I/O Module

TB Holder
Clip Screw

Figure 5-7 I/O Module with Terminal Block (TB) Holder Clip

Connecting the TB Holder to the I/O Module

Procedure 5-3 Connecting the TB Holder to the I/O Module

1) Open the door of the I/O module.

2) On the TB holder, loosen the screw and turn the positioner so that the arrow points to

either A or B.

3) Tighten the screw.

4) With a flat screwdriver, set the code key pin to a number from 1 to 6.

TB Holder
Clip

Cable Pipe

5) On the I/O module, using a flat screwdriver, set the pin to the same number (from 1 to 6.)

This ensures that the TB holder will not be accidentally connected to the wrong I/O
module.

6) Slide the plastic lip on the bottom of the I/O module to either A (up) or B (down) (as in

Step 2).

7) Align the plastic lip with the flat edge of positioner on the TB holder and snap the TB

holder into the I/O module, (see Figure 5-8), fitting the code key pin into the code key.

8) If the ejector handles are extended, push them inwards, against the TB holder (see Figure

5-8.)

9) If a TB holder clip was attached to the I/O module, slide the cable between the two edges

of the clip, and press the clip closed to secure the TB holder to the module. See Figure 5-7.

5-7

I/O Modules

TB Holder

Terminal
Blocks (TB)

Ejector
Handles

Code Key

O

F

O

F

U

F

1
6

24V

Positioner

Terminal Block (TB)

I/O Module

Code Key

Positioner

Terminal Block (TB)

TB Holder

Screw

I/O Module

10) Label the TBs wires with any desired user notes. The wires are numbered 1-20 or 1-40

depending on the model. The wire numbers correspond to the module pins.

11) To extract the TB holder from the I/O module front panel, extend the ejector handles

outward away from the module and pull on the handles.

Figure 5-8 provides a general view of the TB holder and an I/O module.

Figure 5-8 Terminal Block (TB) Holder on I/O Module – General View with Coding

Wired Cable Braid

The optional three-meter cable braid is completely wired with a TB holder and either 20 wire
or 40-wire cable. Each wire in the cable is labeled with the corresponding pin number. This
information is useful when connecting the PGND to the grounding strip. See the Connecting
I/O Modules to Ground section of the Installation chapter.

5-8

PIN

WIRE COLOR

1

Black

2

Red 3 Green

4

White

5

Brown

6

Blue 7 Orange

8

Yellow

9

Purple

10

Gray

11

White/Black

12

White/Red

13

White/Green

14

White/Yellow

15

White/Blue

16

White/Brown

17

White/Orange

18

White/Gray

19

White/Purple

20

White/Black/Red

21

White/Black/Green

22

White/Black/Yellow

23

White/Black/Blue

24

White/Black/Brown

25

White/Black/Orange

26

White/Black/Gray

27

White/Black/Violet

28

White/Red/Green

29

White/Red/Yellow

30

White/Red/Blue

31

White/Red/Brown

32

White/Red/Orange

33

White/Red/Gray

34

White/Red/Violet

35

White/Green/Yellow

36

White/Green/Blue

37

White/Green/Brown

38

White/Green/Orange

39

White/Green/Gray

40

White/Green/Violet

20-wire
cable

40-wire

cable

I/O Modules

Each wire is color coded according to the color code pin table below.

30-wire
cable

User Label

Each I/O module is provided with a blank label on the module door for user notes.

Inserting/Removing an I/O Module from the Frame

I/O modules support hot-swap and can be inserted and extracted while the system is powered
up. For instructions on removing/inserting an I/O module from/into a frame, see the Replacing
an I/O Module section of the Break-Fix Procedures chapter below.

5-9

Note: The hot-swap of an I/O module in the expansion frame of an RTU which is running
without a configuration from the STS (i.e. running the default configuration as from the
factory) will not be successful in the following situation: If the expansion module restarts
while the main CPU is running and during this restart, a I/O module is removed. In such a
case, when the expansion module powers up, it will not recognize the removed I/O module and
will not report the hot-swap to the main CPU when the I/O module is replaced in the slot.

Automatic M odule ID

Each I/O module has a unique module type ID number. When the RTU is powered up or when
an I/O module is inserted into a slot (hot-swap), the CPU automatically identifies the module
type.

The module ID can be viewed from the STS Hardware Test utility. For more information, see
the Hardware Test section of the ACE STS User Guide.

24V DC Floating Plug-In Power Supply

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 power supply module. (For guidelines on remaining within the maximum system power
consumption, see Appendix D: ACE3600 Maximum Power Ratings below.)

I/O Modules

Table 5-1 Number of Plug-In Power Supplies in ACE3600 I/O Modules

Module Type Number of Power

Supplies

32 DI Fast 24V/IEC TYPE 2 2
16 DI Fast 24V/IEC TYPE 2 1

16 AI 1

8 AI 1

Mixed I/O 1

Mixed Analog 1

The plug-in power supply is ordered separately.
Before installing the 24V DC floating plug-in power supply card on the I/O module, please

verify that the FPGA version of the I/O module is as follows:

I/O Module Type FPGA Version

AI module (all types) Version 1.5.002 or higher.
DI module (all types) Version 2.1.004 or higher.
Mixed I/O module (all types) Version 1.5.004 or higher.

5-10

I/O Modules

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1

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1

2

1

3

1

4

1

5

1

6

2

4

V

Optional 24V
Floating
Power Supply
Plug-In

Spacers

Motherboard
Location PIN

Motherboard
Connector

Use the ACE36000 STS Hardware Test utility to retrieve the FPGA version from the unit. If
the FPGA version listed in the Module Diagnostics is lower than the version in the chart
above, you must upgrade the I/O version by downloading a higher version FPGA file using the
STS. Contact your local support team for the updated FPGA file.

Procedure 5-4 Attaching the Power Supply to the I/O Module

Attach the power supply to the I/O module using the following procedure. Note that a TORX
screwdriver is required.

1) Remove the cap from the 40-pin connector on the power supply plug-in.

2) Place the plug-in onto the board with the connector attached and the spacers over the holes

on the board.

3) Screw the four supplied metals screws into the spacers to secure the plug-in.

The RTU will automatically recognize the 24V power supply.

Each plug-in power supply output is controlled by the CPU module. By default, the plug-in
power supply is ON and can supply up to 150mA. The power supply plug-in can be turned
ON/OFF via the user application program or Hardware Test utility.

Figure 5-9 provides a general view of an I/O module with one plug-in.

Figure 5-9 ACE3600 I/O Module with a 24V Floating Power Supply Plug-In

5-11

24V DC Floating Plug-In Power Supply Module Detailed

Weight

Approx. 0.04Kg (0.09 Lb)

Specifications

Input Voltage 10.8-16 V (from I/O module)
Outputs 24V floating, max. 150 mA
Power Consumption Refer to Appendix D: ACE3600 Maximum Power Ratings.
Efficiency 75% typical
Protection Automatic output shut down on overvoltage and overcurrent
Insulation Input to output: 1500 V AC
Dimensions 78 mm W x 15 mm H x 68 mm D (3.1" W x 0.6" H x 2.7" D)

Specifications subject to change without notice.

I/O Modules

5-12

DIGITAL INPUT MODULE

General Description

The ACE3600 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

• 32 DI Fast 48V

Two types of voltage (“wet”) inputs are supported, IEC 61131-2 Type II compliant inputs and
24V “MOSCAD compatible” inputs. In the 32 DI module, the first 20 inputs can function as
fast counters. In the 16 DI module, 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. All DI modules except the 32 DI 48V module support
optional 24V DC floating plug-in power supplies (for contact “wetting” or other purposes).

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 (refer
to the STS Application Programmer manual.)

For a description of I/O module construction, location, LEDs, TBs, and other common I/O
module features, see the I/O Modules chapter above.

Figure 6-1 provides a general view of the ACE3600 DI module.

6-1

Digital Input Module

16 DI Module 32 DI Module
Figure 6-1 ACE3600 DI Module – General View

Figure 6-2 provides a detailed view of the ACE3600 DI module front panel.

6-2

16 DI Module 32 DI Module
Figure 6-2 ACE3600 DI Module – Front Panel

Digital Input Module

DI Module Configuration

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. The 32 DI 48V modules
can handle DC input signals only.

Fast Capture (DC Configuration)

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.)

Input Filters (DC Configuration)

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).

6-3

Event Time Tagging

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.

Keep Last Value (KLV) and Predefined Value (PDV)

Each input can be configured to KLV or to a PDV (0, 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.

DI Module Configuration Options

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

Table 6-1 ACE3600 DI Module Configurable Features

Feature Parameter

Settings

Default Setting Per Module /

Input

Digital Input Module

Parameter Setup
Location

DC or AC
operation

∗

Fast Capture Disabled

DI Filter (DC) 0-254 (x 0.2

AC / DC

/Enabled

mS)

DC Module STS site

configuration

Disabled Input STS site

configuration

50 * 0.2 mS
(=10 mS)

Module STS site

configuration;
‘C’ User Program

Counter Filter
(DC)

0-255 (x 0.05
mS)

20 * 0.2 mS
(= 1 ms)

Module STS site

configuration
‘C’ User Program

Event Time
Tagging

Keep Last Value
and Predefined

Disabled/
Enabled

KLV/PDV
PDV=0/1

Disabled Input User Program I/O

link table

KLV Input User Program I/O

link table

Value
Mask No /Yes No Input User Program I/O

link table

∗

in Fast 24V IEC TYPE II modules –only DC

6-4

Sleep Mode

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.

Module Status and Diagnostics

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

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 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.

Digital Input Module

For details on configuring the DI modules, see the Site Configuration section, and the
Application Programming section of the STS User Guide.

6-5

I/O Circuit Diagram

M

Digital Input Module

DI - Typical Input Circuit

DI Status

Fast 24V

R

z

V

Current
Limiter

3.5mA

Fast 48V

255 3.32K

33V 68V

3mA



Current Limiter

+

+

R

DI

Full
Diode

V

z

Bridge
Rectifier

-

-

CO

6-6

Module Block Diagram

16 DI

Digital Input Module

6-7