RuggedCom RS416 User Manual

RuggedServer

RS416 Family

Modular Serial Device Server with

Integrated Managed Ethernet Switch

Installation Guide

December 18, 2012

www.ruggedcom.com

RuggedCom Inc. I 300 Applewood Crescent, Concord, Ontario, Canada L4K 5C7

Tel: [phone] I Fax: [phone] I Toll Free: 1 888 264 0006

Copyright

COPYRIGHT © 2012 RuggedCom Inc. ALL RIGHTS RESERVED
Dissemination or reproduction of this document, or evaluation and communication of its contents, is not

authorized except where expressly permitted. Violations are liable for damages. All rights reserved, particularly for
the purposes of patent application or trademark registration.

This document contains proprietary information, which is protected by copyright. All rights are reserved. No part of
this document may be photocopied, reproduced or translated to another language without the prior written
consent of RuggedCom Inc.

Disclaimer of liability

We have checked the contents of this manual against the hardware and software described. However, deviations
from the description cannot be completely ruled out.

RuggedCom shall not be liable for any errors or omissions contained herein or for consequential damages in
connection with the furnishing, performance, or use of this material.

The information given in this document is reviewed regularly and any necessary corrections will be included in
subsequent editions. We appreciate any suggested improvements. We reserve the right to make technical
improvements without notice.

Registered Trademarks

RuggedServer™ is a trademark of RuggedCom Inc. RuggedSwitch®is a registered trademark of RuggedCom Inc.
Other designations in this manual might be trademarks whose use by third parties for their own purposes would
infringe the rights of the owner.

Third Party Copyrights

RuggedCom recognizes the following third party copyrights:
Copyright © 2004 GoAhead Software, Inc. All Rights Reserved.

Contacting RuggedCom

Corporate Headquarters US Headquarters Europe Headquarters

RuggedCom Inc.
300 Applewood Crescent
Concord, Ontario
Canada, L4K 5C7

Tel: [phone]
Fax: [phone]
Toll-free: 1 888 264 0006

Technical Support

Toll Free (North America): 1 [phone]
International: [phone]
Email: [e-mail]

RuggedCom
1930 Harrison St., Suite 209
Hollywood, Florida
USA, 33020

Tel: [phone] ext. 103
Fax: [phone]
Toll-free: 1 888 264 0006

Email: [e-mail]

Web: www.RuggedCom.com

RuggedCom
Unit 41, Aztec Centre,
Aztec West, Almondsbury, Bristol
United Kingdom BS32 4TD

Tel: [phone]
Fax: [phone]

RuggedCom

®

RuggedServer™ RS416 Family Installation Guide rev118

2

Federal Communications Commission Radio

Should this device requi

re service see the “Warranty

” section of this installation guide.

Frequency Interference Statement

This equipment has been tested and found to comply with the limits for a Class A digital device
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case
the user will be required to correct the interference at his expense.

Caution

This product contains a laser system and is classified as a “CLASS 1 LASER PRODUCT”.
Use of controls or adjustments or performance of procedures other than those specified herein may

result in hazardous radiation exposure. This product contains no user-serviceable parts. Attempted
service by unauthorized personnel shall render all warranties null and void.

Important

This unit should be installed in a restricted access location where access can only be gained by
service personnel or users who have been instructed about the reasons for the restrictions applied
to the location and about any precautions that shall be taken; and access is through the use of a tool
or lock and key, or other means of security, and is controlled by the authority responsible for the
location.

RuggedCom

®

3

RuggedServer™ RS416 Family Installation Guide rev118

Table of Contents

Table of Contents

Federal Communications Commission Radio Frequency Interference Statement ...........3

Table of Contents............................................................................................................4

Table of Figures..............................................................................................................5

Table of Tables ...............................................................................................................5

1 Product Overview....................................................................................................7

1.1 Functional Overview ........................................................................................7

1.2 Feature Highlights............................................................................................8

1.3 Display Panel Description..............................................................................10

2 Installation.............................................................................................................12

2.1 Mounting........................................................................................................12

2.1.1 Rack Mounting.......................................................................................13

2.1.2 Panel and DIN Rail Mounting.................................................................14

2.2 Power Supply Wiring and Grounding .............................................................15

2.2.1 AC Power Supply Wiring Examples........................................................17

2.2.2 DC Power Supply Wiring Examples.......................................................18

2.2.3 Dual Power Supplies – DC and AC Inputs..............................................19

2.2.4 Dual Power Supplies – AC Input and 48VDC for PoE............................20

2.3 Dielectric Strength (HIPOT) Testing...............................................................21

2.4 Failsafe Alarm Relay Wiring...........................................................................22

2.5 Console Port Wiring.......................................................................................23

3 Serial Ports............................................................................................................24

3.1 Fiber Serial Interface......................................................................................24

3.2 RS232/RS485/RS422 via DB9.......................................................................25

3.3 RS232/RS485/RS422 plus IRIG-B via DB9 ...................................................26

3.4 RS232/RS485/RS422 via RJ45 .....................................................................27

3.5 RS232/RS485/RS422 plus IRIG-B via RJ45..................................................28

3.6 RS485 Wiring.................................................................................................29

3.7 Serial Port Transient Protection .....................................................................30

4 Time Synchronization............................................................................................31

4.1 IRIG-B Ports ..................................................................................................31

4.2 IRIG-B Connection Considerations................................................................32

5 Ethernet Ports .......................................................................................................32

5.1 Copper Ports..................................................................................................32

5.2 Fiber Optic Ports............................................................................................34

5.3 Ethernet Panel Description............................................................................35

6 Technical Specifications........................................................................................36

6.1 Power Supply Specifications..........................................................................36

6.2 Failsafe Relay Contact Ratings......................................................................36

6.3 Data Port Specifications.................................................................................37

6.3.1 Serial Ports ............................................................................................37

6.3.2 IRIG-B Ports...........................................................................................37

6.3.3 Ethernet Ports........................................................................................38

6.4 Operating Environment..................................................................................39

6.5 Mechanical Specifications..............................................................................40

7 Type Tests.............................................................................................................41

7.1 IEC 61850-3 Type Tests................................................................................41

7.2 IEEE 1613 Type Tests...................................................................................42

RuggedCom

®

4

RuggedServer™ RS416 Family Installation Guide rev118

Table of Figures

7.3 IEC Environmental Type Tests ......................................................................42

8 Agency Approvals..................................................................................................43

9 Warranty................................................................................................................43

Table of Figures

Figure 1: RS416 LED Display Panel..............................................................................10

Figure 2: Rack mount chassis orientation options – Front and rear mount. ...................12

Figure 3: 19” Rack Mount Adapters...............................................................................13

Figure 4: Rack mount adapter mounting location ..........................................................13

Figure 5: RS416 Series PANEL/DIN RAIL mounting diagram .......................................14

Figure 6: RS416 Series Phillips Screw Terminal Block..................................................15

Figure 7: RS416 Series Phoenix Plug Terminal Block...................................................15

Figure 8: Chassis Ground Connection...........................................................................15

Figure 9: AC Single Power Supply Wiring Example.......................................................17

Figure 10: AC Dual Redundant Power Supply Wiring Example.....................................17

Figure 11: DC Power Supply Wiring Examples..............................................................18

Figure 12: DC and AC Power Supply Wiring Examples.................................................19

Figure 13: AC Input to PS1 and 48VDC Input to PS2 for PoE .......................................20

Figure 14: Dielectric Strength (HIPOT) Testing .............................................................21

Figure 15: Failsafe Alarm Relay Wiring .........................................................................22

Figure 16: Console port location on display board.........................................................23

Figure 17: Console cable ..............................................................................................23

Figure 18: Fiber Serial Interface (ST Connector)...........................................................24

Figure 19: DB9 female port pin-out................................................................................25

Figure 20: DB9 female port pin-out................................................................................26

Figure 21: RJ45 port pin-out..........................................................................................27

Figure 22: RJ45 port pin-out with IRIG-B.......................................................................28

Figure 23: Conceptual recommended RS485 wiring diagram........................................29

Figure 24: IRIG-B daughter board BNC connections.....................................................32

Figure 25: IRIG-B Output Simplified Schematic.............................................................32

Figure 26: RJ45 port pins configuration.........................................................................33

Figure 27: 10FL ST connector.......................................................................................34

Figure 28: 100FX MTRJ connector................................................................................34

Figure 29: 100FX ST connector ....................................................................................34

Figure 30: 100FX LC connector ....................................................................................34

Figure 31: 100FX SC connector....................................................................................34

Figure 32: Ethernet panel LED description....................................................................35

Figure 33: Mechanical Drawing.....................................................................................40

Table of Tables

Table 1: LED Display – Device status LED behavior definition......................................10

Table 2: LED Display - Port LED behavior definition......................................................11

Table 3: RS416 Power terminal block connection description .......................................16

Table 4: RS416/RS416P power supply connection differences.....................................16

Table 5: RS232 over RJ45 console cable pin-out..........................................................23

Table 6: DB9 Female DCE Port pin-out.........................................................................25

Table 7: DB9 Female DTE Port pin-out with IRIG-B......................................................26

Table 8: RJ45 Port pin-out.............................................................................................27

Table 9: RJ45 Port pin-out.............................................................................................28

5

RuggedServer™ RS416 Family Installation Guide rev118

RuggedCom

®

Table of Tables

Table 10: RS416 Time Synchronization Sources ..........................................................31

Table 11: RS416 Time Synchronization Services..........................................................31

Table 12: IRIG-B Daughter Board LED..........................................................................32

Table 13: Main Power Supply Specifications.................................................................36

Table 14: PoE Power Supply Specifications..................................................................36

Table 15: Failsafe Relay Contact Ratings......................................................................36

Table 16: Copper Port Specification..............................................................................37

Table 17: Fiber Optic Port Specification ........................................................................37

Table 18: IRIG-B PWM Input.........................................................................................37

Table 19: IRIG-B Port Output Specifications .................................................................37

Table 20: Ethernet Ports - Copper Specifications..........................................................38

Table 21: Ethernet Ports – Fiber Optic Specifications.......Error! Bookmark not defined.

Table 22: Operating Environment..................................................................................39

Table 23: Mechanical Specifications .............................................................................40

Table 24 - IEC 61850-3 Type Tests...............................................................................41

Table 25 - IEEE 1613 Type Tests..................................................................................42

Table 26 - Environmental Type Tests............................................................................42

Table 27: Agency Approvals..........................................................................................43

RuggedCom

®

6

RuggedServer™ RS416 Family Installation Guide rev118

Product Overview

1 Product Overview

1.1 Functional Overview

RuggedServer™ RS416 represents a family of industrially hardened serial device

servers with integrated, fully managed, Ethernet switches. The RS416 is designed to
operate reliably in electrically harsh and climatically demanding environments. Featuring
a modular design that can support up to 16 serial ports, up to 4 Ethernet ports, and
optional IRIG-B support, the RS416 is able to interconnect multiple types of intelligent
electronic devices (IEDs) that require different methods of communications. Using the
RS416 results in fewer connectivity devices (which reduces overall system costs) and
also extends the useful life of existing legacy IEDs (which minimizes capital expenditure
for new equipment).

The RS416 provides a high level of immunity to electromagnetic interference and heavy
electrical surges typical of environments found in electric utility substations, factory floors
or in curb side traffic control cabinets. The RS416 meets or exceeds a wide range of
industry standards including IEC 61850, IEEE 1613, IEC 61000-6-2, IEC 61800-3, and
NEMA TS-2. The RS416 also features a wide operating temperature range of -40°C to
+85°C allowing it to be installed in virtually any location.

For applications requiring high availability, the RS416 provides the option for integrated
dual redundant power supplies, each capable of accommodating a wide range of input
voltages for worldwide operability. Also unique is the ability to have each power supply
fed from different voltage levels and/or sources thereby providing great flexibility in
creating high availability systems. The RS416P provides IEEE 802.3af standard Power
over Ethernet (PoE) on its 10/100BaseTx ports.

The embedded Rugged Operating System (ROS®) within the RS416 provides advanced
layer 2 and layer 3 networking functions, advanced cyber security features, and a full
array of intelligent functionality for high network availability and manageability. These
features, in addition to the ruggedized hardware design, make the RS416 ideal for
creating mission-critical, real-time, control applications in any harsh environment. The
RS416 is also backed by RuggedCom's all inclusive five year warranty and unsurpassed
technical support.

The RS416 implements both the Precision Time Protocol (PTP - IEEE 1588 v2) and
IRIG-B for high-precision time synchronization across both Ethernet and legacy
networks.

RuggedCom

®

7

RuggedServer™ RS416 Family Installation Guide rev118

Product Overview

1.2 Feature Highlights

Serial Device Server

 Modular design allows for 4, 8, 12, or 16 serial ports
 Fully compliant EIA RS422 / TIA RS485, RS422, RS232 serial ports (software

selectable)

 DB9 or RJ45 connectors
 Transmit serial data over an IP network
 Support for Modbus TCP, DNP 3, TIN serial protocols
 Baud rates up to 230 kbps
 Raw socket mode allows conversion of any serial protocol
 Point-to-point and multi-point modes
 Converts Modbus RTU to Modbus
 Supports multiple Modbus masters
 Converts DNP3.0 to DNP over UDP/TCP

Ethernet Ports

 Integrated Ethernet Switch - 2 or 4 port options - (copper and/or fiber)
 High performance, high throughput Ethernet switching
 Fully IEEE 802.3, IEEE 802.3u, IEEE 802.3x compliant
 Non-blocking, store and forward switching

Precision Time Protocol (PTP – IEEE1588v2)

 Support for IEEE 1588 v2 on all Ethernet ports
 Supports master and slave clock modes
 Accuracy on the order of 100µs

IRIG-B Ports

 Optional IRIG-B module (receive/transmit on BNC)
 Optional serial port modules for RS232, RS485, or RS422 provide IRIG-B on

either DB9 or RJ45 connectors.

 IRIG-B PWM (B006 or B007) or PPS output per port, selectable via software

RuggedRated™ for Reliability in Harsh Environments

 Immunity to EMI and heavy electrical surges
 Meets IEEE 1613 (electric utility substations)
 Exceeds IEC 61850-3 (electric utility substations)
 Exceeds IEC 61800-3 (variable speed drive systems)
 Exceeds IEC 61000-6-2 (generic industrial)
 Exceeds NEMA TS-2 (traffic control equipment)
 Fully independent 2 kV (RMS) isolated serial ports
 -40°C to +85°C operating temperature (no fans)
 18 AWG galvanized steel enclosure

Power Supply Options

 Fully integrated, dual-redundant (optional) power supplies (RS416)
 Power over Ethernet (PoE) on 10/100BaseTx ports (RS416P)
 Universal high-voltage range: 88-300 VDC or 85-264 VAC
 Popular low voltage DC ranges: 12 VDC, 24 VDC, 48 VDC

RuggedCom

®

8

RuggedServer™ RS416 Family Installation Guide rev118

Product Overview

 Terminal blocks for reliable maintenance free connections
 CSA/UL 60950 safety approved to +85°C

Rugged Operating System (ROS®) Features

 Simple plug and play operation - automatic learning, negotiation, and crossover

detection

 Integrated Cyber Security features
 RSTP (802.1w), Enhanced Rapid Spanning Tree (eRSTP™) network fault

recovery (<5ms), and Multiple Spanning Tree (MSTP – 802.1s)

 Quality of Service (802.1p) for real-time traffic
 VLAN (802.1q) with double tagging and GVRP support
 IGMP Snooping for multicast filtering
 Port Rate Limiting and Broadcast Storm Limiting
 Port configuration, status, statistics, mirroring, security

Management Tools

 Web-based, Telnet, CLI management interfaces
 SNMP v1/v2/v3
 Remote Monitoring (RMON)
 Rich set of diagnostics with logging and alarms

RuggedCom

®

9

RuggedServer™ RS416 Family Installation Guide rev118

Product Overview

1.3 Display Panel Description

The RS416 is equipped with a versatile display panel, shown in Figure 1, which is
designed to provide quick status information for each port, as well as the entire device to
allow for simple diagnostics and troubleshooting. It features:

 RS232 console port for ‘out of band’ console access and configuration
 Power supply and Alarm status indicators
 Convenient port status indicators conveying Link-Activity, Duplex, or Speed via

push-button control.

 System reset via push-button if held for 5 seconds

Figure 1: RS416 LED Display Panel

Device status LEDs exist to provide a quick visual indicator to operators for operational
status of the unit. Table 1 defines the possible LED colors and the corresponding
description.

LED Color Description

Green Power supply operating normal

Power 1 / 2

Red Power supply failure
Red Alarm exist – login to console to determine alarm

Alarm

code

Off No alarms exist

Table 1: LED Display – Device status LED behavior definition

The port-based LEDs can be cycled between three display modes: Status, Duplex, and
Speed. Pushing the mode button causes the display mode to be cycled. Table 2
defines the possible port LED colors and the corresponding description.

10

RuggedServer™ RS416 Family Installation Guide rev118

RuggedCom

®

Product Overview

Mode Color

Ethernet Port

Status LEDs

Green (Solid) Link -

Status

Green (Blinking) Activity Traffic
Off No link No Traffic
Green (Solid) Full-Duplex Full-Duplex

Duplex

Orange (Solid) Half-Duplex Half-Duplex
Off No link No link
Green Blinking - > 57600 bps
Green (Solid) 100Mbps > 19200 bps,

Speed

Orange (Solid) 10 Mbps ≤ 19200 bps

Off No link No link

Table 2: LED Display - Port LED behavior definition

Serial Port Status

LEDs

≤ 57600 bps

RuggedCom

®

11

RuggedServer™ RS416 Family Installation Guide rev118

Installation

2 Installation

2.1 Mounting

The RS416 has been designed with maximum mounting and display flexibility.
Customers can order an RS416 that can be mounted in a standard 19” rack, 1” DIN Rail,
or directly onto a panel. For rack mount installations, the RS416 can be ordered with
connectors on the front of the unit, or located on the rear of the chassis to allow for all
data and power cabling to be installed and connected at the rear of the rack. See Figure
2 for rack mount orientation examples.

Figure 2: Rack mount chassis orientation options – Front and rear mount.

12

RuggedServer™ RS416 Family Installation Guide rev118

RuggedCom

®

Installation

2.1.1 Rack Mounting

The RS416 can be rack mounted using the included rack mount adapter assemblies
shown in Figure 3. Secure the one rack mount adapter to the front of each side of the
chassis using the included black PAN head Phillips screws in the positions shown in
Figure 4. The entire chassis can then be mounted to a standard 19” rack. An additional
two rack mount adapters are included to optionally secure the rear of the chassis in high­vibration, or seismically active locations.

Figure 3: 19” Rack Mount Adapters

Figure 4: Rack mount adapter mounting location
NOTE: Since heat within the RS416 is channeled to the enclosure, it is recommended that 1 rack

unit of space (1.75”) be kept unpopulated and free of equipment above each RS416 product to
allow for a small amount of convectional airflow. Although forced airflow is not necessary, any
increase in airflow will result in a reduction of ambient temperature that will improve long-term
reliability of all equipment mounted within the rack space.

RuggedCom

®

13

RuggedServer™ RS416 Family Installation Guide rev118