RuggedCom RuggedMC RMC20 Installation Manual

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Rugged

™ RMC20

Installation Guide

RuggedCom Inc. 30 Whitmore Road, Woodbridge, Ontario Canada L4L 7Z4

Web: http://www.ruggedcom.com/ Tel: (905) 856-5288 Fax: (905) 856-1995 Toll Free: (888) 264-0006

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Federal Communications Commission Radio 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 on his own expense.

Warning: user’s authority to operate the equipment.

Caution – 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.

Should this device require service see the “Warranty and Service” section of this installation guide.

Changes or modifications not expressly approved by RuggedCom Inc. could void the

Caution – This product contains a laser system and is classified as a

“CLASS 1 LASER PRODUCT”

Important:

The RuggedMCTM 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.

Trademarks:

Ethernet is a trademark of Xerox Corporation Rugged MediaConverter and RuggedMC is a registered trademark of RuggedCom Inc.

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Table of Contents

1 Product Overview.................................................................................................................... 4

1.1 RMC20 Front Panel Description..................................................................................... 5

1.2 RMC20 Side and Bottom View........................................................................................ 6

2 Installation............................................................................................................................... 7

2.1 DIN Rail Mounting........................................................................................................... 7

2.2 Panel Mounting............................................................................................................... 8

2.3 Power Supply Wiring and Grounding..............................................................................9

2.4 Serial Ports – Signal Description...................................................................................10

2.4.1 RS232 Data Ports.....................................................................................................10

2.4.2 RS422 and RS485 Data Ports...................................................................................11

2.5 RMC20 Configuration....................................................................................................13

2.5.1 Serial-to-Fiber Conversion: Point-to-Point.................................................................14

2.5.2 Serial Standard Conversion.......................................................................................15

2.5.3 Serial-to-Fiber Conversion: Loop Topology..............................................................16

3 Specifications.........................................................................................................................17

3.1 Power Supply Specifications..........................................................................................17

3.2 Fiber Optical Port Specifications....................................................................................17

3.3 Mechanical Specifications .............................................................................................18

4 Type Test Specifications........................................................................................................19

4.1 Operating Environment..................................................................................................20

4.2 Agency Approvals..........................................................................................................20

5 Warranty.................................................................................................................................20

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1 Product Overview

INTRODUCTION

The RuggedMC™ series of media converters are industrial hardened and specifically designed to operate reliably in electrically harsh and climatically demanding environments.

The RMC20 is a utility-grade, protocolindependent, serial-to-fiber and serial standards converter for all your serial communication requirements. The RMC20 allows RS485, RS422, or RS232 devices or networks to communicate over secure, noise immune, optically isolated, fiber optic cabling at extended distances as well convert RS232 to either RS485 or RS422 serial standards.

The RMC20 was designed specifically to provide years of maintenance free operation for all your mission-critical, real-time control applications. To ensure the utmost in reliability, the RMC20 is tested to the most stringent international EMI and environmental standards for use in HV/MV electric utility substations and factory floor applications. All RMC™ products are packaged with a high reliability, built-in power supply (24V, 48V, or HI Voltage options) and enclosed in a rugged galvanized steel enclosure suitable for panel or DIN-rail mounting.

All RuggedCom Inc. products are backed by a five-year warranty and unsurpassed technical support.

PORT OPTIONS

 Protocol independent RS485, RS422, or

RS232 (user selectable) conversion to multimode fiber optics (ST connector only)

 RS232 to RS485/RS422 conversion mode  Fully EIA/TIA RS485, RS422, RS232

compliant communications

 Built-in, defeatable, RS485/RS422

termination networks

 Point-to-point, or optical loop configurations  Full or half duplex configurable

 Support for high-speed serial baud rates

from 300 to 115200 baud

UNIVERSAL POWER SUPPLY OPTIONS

 24VDC, 48VDC or HI (88-300VDC / 85 -

264Vac) options for worldwide operability

 Integrated high-reliability power supply

eliminates the need for external power transformer

 Screw down terminal blocks ensure reliable

maintenance-free connections

 All power supplies CSA/UL 60950 approved

for +85°C (185°F) operation

DESIGNED FOR HARSH ENVIRONMENTS

 Exceeds IEC 61850-3 and IEEE 1613

Standards for communication equipment in electric power substations

 Operates over a temperature range of -40 C

to +85 C without the use of fans for improved reliability

 18 AWG galvanized steel enclosure suitable

for DIN or panel mounting provide secure mechanical reliability

SIMPLE PLUG AND PLAY OPERATION

 Simple, externally-accessible configuration  Transmit and receive data LED indicators

for quick and easy troubleshooting

 Fully integrated power supply connects

directly to power source permanently for reliable maintenance-free operation

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1.1 RMC20 Front Panel Description

Fig. 1.1.1 RMC20 Front Panel Detail The RMC20 LED definitions are as follows:

ITEM Activity Comments

Tx LED Blinking (Yellow) Transmitting Serial Data

RX LED Blinking (Yellow) Receiving Serial Data

Power LED Solid (Green) Power On

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1.2 RMC20 Side and Bottom View

Fig. 1.2.1 RMC20 Side and Bottom View

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2 Installation

2.1 DIN Rail Mounting

Fig. 2.1.1 RuggedMCTM DIN Rail Mounting

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2.2 Panel Mounting

With the use of an optional panel-mount adapter, the RuggedMCTM series of media converters can be panel mounted. The drawing shown in Figure 2.2.1 shows an example of an RMC unit panel mounted using the optional panel mount adapter.

The panel mount adapter can be secured to a panel with three screws. The RuggedMCTM product is easily mounted onto the panel mount adapter via the two metal clips on either side of the unit, and a single screw located on the bottom.

Figure 2.2.1: RuggedMC

panel mounted using optional panel mount mounting adapter.

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2.3 Power Supply Wiring and Grounding

Fig. 2.2.1 RuggedMCTM Power Supply Inputs The RuggedMCTM power supply inputs are identical and are connected as follows:

1. +/L = DC (+) / AC (Hot) is connected to the positive (+) terminal if the power source is DC or to the (Hot) terminal if the power source is AC.

2. -/N = DC (-) / AC (Neutral) is connected to the negative (-) terminal if the power source is DC or to the (Neutral) terminal if the power source is AC.

3. Surge Ground is connected to the Safety Ground via a braided cable or other appropriate grounding wire. Surge Ground is used as the ground conductor for all surge and transient

suppression circuitry internal to the RuggedMC

4. Safety Ground should be connected to the power supply ground. This should be the safety ground for AC inputs or the equipment ground bus for DC inputs.

Note: Surge Ground must be disconnected from Chassis Ground during HIPOT

(Dielectric strength) testing.

Notes:

1. For 125/250VDC rated equipment: An appropriately rated 300VDC circuit breaker must be installed within 3 meters of unit.

2. For 110/230VAC rated equipment: An appropriately rated 250VAC circuit breaker must be installed within 3 meters of the unit

3. A circuit breaker is not required for 48 or 24VDC rated equipment.

4. For multiple supplies, separate circuit breakers must be installed. Equipment must be installed according to the applicable country wiring codes.

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2.4 Serial Ports – Signal Description

The RMC20 is equipped with a seven-terminal phoenix style connector. This connector can accommodate one RS232 connection, and one RS485/422 connection. Figure 2.4 shows the connections for RS232, RS485, and RS422 communications. The following sections describe installation details for respective ports.

Figure 2.4: Serial RS232, RS485, and RS422 terminal block connections

2.4.1 RS232 Data Ports

The RMC20 is equipped with a single EIA/TIA RS232 compliant port, consisting of three terminals: Transmit, Receive, and Common. The RS232 port is intended for point-to-point applications only. The EIA/TIA guidelines for RS232 communications include (but are not limited to) the following:

1. To minimize the effects of ambient electrical noise, shielded cabling is recommended.

2. Reliable communications within 15m. Greater distances are possible.

3. Communications of up to 120kbaud signal rate.

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2.4.2 RS422 and RS485 Data Ports

The RMC20 is equipped with a single RS485 / RS422 data port. In half duplex mode (See section

2.5 for RMC20 DIP switch settings) the RS485 connections (Rx +, Rx -, COM) should be connected. In full-duplex mode the RS422 connections (Rx+, Rx -, Tx+, Tx-, COM) should be connected. Both RS485 and RS422 can accommodate multi-drop networks, for master-slave serial network communications. For both RS485 / RS422 connections, the following general guidelines should be followed:

1. To minimize the effects of ambient electrical noise, shielded cabling is recommended

2. The correct polarity must be observed throughout the daisy chain

3. The number of devices wired should not exceed 32, and total distance should be less than 4000 feet (at 100Kbps)

4. The COM terminal should be connected to the common wire inside the shield.

5. The shield/COM should be grounded at ONE single point to avoid loop currents

6. The twisted pair should be terminated at each end of the chain. (Typically with a 120Ohm resistor and a 10nF capacitor in series across the twisted pair)*

* Both data terminal pairs (Rx +/- and Tx +/-) are terminated by default from the factory. To remove termination: Open the cover and remove jumper JP1 and/or JP2 (JP1 for Rx+, Rxterminals, JP2 for Tx+, Tx- terminals) depending on which port termination is NOT required. Termination provided is a 120 Ohm resistor in series with a 10nF capacitor as per the ModBus 1.0 specification. In general termination should be left in place unless it is detrimental to communications.

Note: Transient protection is provided on all RMC20 terminals. Lightning strikes and ground surge currents can cause large momentary voltage differences between ends of communication links. To ensure maximum reliability of the entire link, all equipment should have similar transient protection installed.

Figure 2.4.2.1 details an example RS485 wiring diagram.

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Fig 2.4.2.1 Conceptual RS485 wiring diagram

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2.5 RMC20 Configuration

The RMC20 can be configured using the DIP switches located at the bottom of the enclosure. The DIP switches are shown in Figure 2.5.1. Using the switches one can change the operating mode of the RMC20.

Figure 2.5.1. RMC20 8-Position DIP switch location for configuration

RMC20 DIP Switch Configuration Settings Defined

Position ON OFF

1 RS232 to fiber mode RS485/422 to fiber mode 2 RS232 to RS485/422 conversion mode Serial (RS232/485/422) to fiber mode

3 Full Duplex Serial (RS232 / RS422) Half Duplex Serial (RS485) 4 Fiber Repeat ON Fiber Repeat OFF 5 RESERVED

6 > 57600 baud 7 19200 – 57600 baud

300 – 2400 baud

8 4800 – 14400 baud

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The RMC20 is equipped to provide conversion from serial (RS232, RS485, or RS422) to fiber optics, or between serial standards (RS232 to RS485 / RS422). Serial to fiber optic conversion connections can be further implemented in point-to-point, as well as optical loop configurations. To better illustrate all working modes, figure Section 2.5.1 through 2.5.3 will show example configuration options, and relevant DIP switch settings.

2.5.1 Serial-to-Fiber Conversion: Point-to-Point

Figure 2.5.1.1 Serial-to-Fiber point-to-point topology Figure 2.5.1.1 illustrates the serial-to-fiber conversion mode of operation. In this mode serial data

is converted directly into light impulses, and transmitted over multimode fiber optics. The serial standard is selected by position 1 of the DIP switches: OFF (default) is for RS485 / RS422, and ON is for RS232. Position 2 should be OFF for serial to fiber conversion. Position 6-8 should be configured if RS485 communications are used, in order to have the appropriate turn-around timer selected. Positions 6-8 do not impact communications in full-duplex mode.

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2.5.2 Serial Standard Conversion

Figure 2.5.3 In serial conversion mode, one can convert from RS232 to RS485 / RS422 Figure 2.5.3 illustrates the connections for conversion between RS232 and RS485 / 422 devices.

In this mode of operation, RS232 voltage levels are converted to the appropriate RS485 or RS422 signaling levels depending on the DIP switch configuration. In this mode of operation position 2 of the DIPswitches must be in the ON position. Figure 2.5.3 illustrates a RS232 device, connected to an RS485 device or network. Since RS485 requires automatic turn-around, position 3 must be set to the OFF state, and position 6 – 8 of the DIP switches must reflect the proper operating baud rate.

Note: In this mode of operation, no isolation is provided between RS232 device and the

RS485/422 network – both devices share the same common terminal. It should be noted that the common terminal on RS232 devices are connected to ground. In some instances (ie when connecting to large RS485 networks), it may be preferential for the user to leave the RS485/RS422 shield terminal unconnected to the RMC20 in this mode.

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2.5.3 Serial-to-Fiber Conversion: Loop Topology

Figure 2.5.4 Serial-to-fiber conversion in example optical loop topology Figure 2.5.4 illustrates the optical loop topology that utilizes the RMC20 repeat mode function. The

repeat function will optically re-transmit any data received on the optical receiver, in addition to any connected serial devices. As a result, any data transmitted from the master, will be re-transmitted optically to all the slaves. This mode of operation requires that the master device tolerate receiving echoes of transmitted data since any transmissions will be received once again via the optical ring.

This topology can be used for RS232, RS485, or RS422 multi-drop networks. In all cases, all slaves have the repeat function (DIP position 4) ON, while the master is configured with the repeat function OFF. This topology can allow for the mixture of RS232, RS485, and RS422 devices, operating on the same baud rate, on a single optical serial network because the RMC20 utilizes a common optical signaling protocol for all serial standards.

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3 Specifications

3.1 Power Supply Specifications

Power Supply Type Minimum

Input

24 VDC 18 VDC 36 VDC 3.15A(T) 2 48 VDC 36 VDC 72 VDC 3.15A(T) 2

HI (88/300 VDC) 1

HI (120/240 VAC)

Notes: 1 – This is the same power supply for both AC and DC. 2 – (T) Denotes time-delay fuse

88 VDC 85 VAC

CAUTION: For continued protection against risk of fire, replace only with same type and rating of fuse.

3.2 Fiber Optical Port Specifications

Parameter Specifications

Maximum

Input

300 VDC 264 VAC

Fuse

Rating

3.15A(T)

Maximum Power

Consumption

3 W

Mode Multimode

Connector ST

Typical Dist. (km) 5

Optical Wavelength (nm) 820

Cable Size

Core/Cladding (um)

50/125

62.5/125

Tx Power (dBm) -13 Rx Sensitivity (dBm) -33.5 Rx Saturation (dBm) -11

Typical Budget (dB) 17.5

Notes:

1. Maximum segment length is greatly dependent on factors such as fiber quality, and number of patches and splices. Please consult RuggedCom sales associates when determining maximum segment distances.

2. All optical power numbers are listed as dBm averages.

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3.3 Mechanical Specifications

Parameter Value Comments

Dimensions

Weight 1.5 lb (0,68 Kg)

Enclosure 18 gauge Galvanized Steel

4.30 x 2.40 x 3.30 inches

(110) x (61) x (84) mm

(Length x Width x Height)

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4 Type Test Specifications

Electrical Safety Levels Comments

Dielectric Withstand 2 kV rms for 1 minute ANSI/IEEE C37.90 (1989)

IEC 60255-5 (Section 6) High Voltage Impulse 5 kV peak IEC 60255-5 (Section 8) Insulation Resistance 500 VDC for 1 minute IEC 60255-5 (Section 6

Electrical Environment Levels Comments

High Frequency Disturbance

(Oscillatory)

IEC Surge 4 kV / 2 kV

IEC Fast Transient 2 kV / 1 kV

ANSI/IEEE Fast Transient 4 kV ANSI/IEEE C37.90.1

IEC Radiated RFI Immunity 10 V/m IEC 61000-4-3

ANSI/IEEE Radiated RFI

Immunity

ESD

(Electrostatic Discharge)

Atmospheric Environment Levels Comments

Temperature (Dry Cold)

Temperature (Dry Heat)

Humidity

2.5 kV @ 1MHz for 2s

35 V/m ANSI/IEEE C37.90.2

15 kV (air discharge)

8 kV (contact)

-40°C 85°C

95%

Non-condensing

Test Ad: 16 hrs @ -40°C

Test Db: 6 cycles, 55°C, 95%

ANSI/IEEE C37.90.1

IEC 60255-22-1

IEC 61000-4-5

(Level 4)

IEC 61000-4-4

(Level 4)

IEC 61000-4-2

(Level 4)

IEC 60068-2-1 IEC 60068-2-2

Test Bd: 16 hrs @ 85°C

IEC 60068-2-30

Humidity

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4.1 Operating Environment

Parameter Range Comments

Ambient Operating

Temperature

Ambient Relative Humidity 5% to 95% Non-condensing

Ambient Storage

Temperature

-40 to 85°C

Ambient Temperature as measured from a 30cm radius surrounding the

center of the RuggedMC

4.2 Agency Approvals

Agency Standards Comments

CSA, CE CSA C22.2 No. 60950, UL 60950,

EN 60950

EN 61000-6-2

FCC FCC Part 15, Class A

CISPR EN55022, Class A Approved

FDA/CDRH 21 CFR Chapter 1, Subchapter J Compliant

IEC/EN

EN60825-1:1994 + A11:1996 +

A2:2001

Approved Approved

Compliant

enclosure.

5 Warranty

RuggedCom warrants this product for a period of five (5) years from date of purchase. For warranty details, visit

Should this product require warranty or service contact the factory at: RuggedCom Inc.

30 Whitmore Road Woodbridge, Ontario Canada L4L 7Z4 Phone: (905) 856-5288 Fax: (905) 856-1995

http://www.ruggedcom.com/ or contact your customer service representative.