RuggedCom RuggedServer RS400, RuggedServer RS401 Installation Manual

RuggedServer RS400 Family

4-Port Serial Device Server with Integrated 4-Port Managed

Ethernet Switch

Installation Guide

RuggedCom Inc. I 300 Applewood Cres., Unit 1, Concord, Ontario, Canada L4K 5C7

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

October 14, 2009

www.ruggedcom.com

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COPYRIGHT © 2009 RuggedCom Inc. ALL RIGHTS RESERVED
Dissemination or reproduction of this document, or evaluation and communication of its

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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.

Contacting RuggedCom

Corporate Headquarters US Headquarters Europe Headquarters

RuggedCom Inc.
300 Applewood Cres., Unit 1
Concord, Ontario
Canada, L4K 5C7

Tel: [phone]
Fax: [phone]
Toll-free: 1 [phone]

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

Tel: [phone] x103
Fax: [phone]
Toll-free: 1 [phone]

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

Tel: [phone]
Fax: [phone]

Email: [e-mail]

Technical Support

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

RuggedCom

®

Web: www.RuggedCom.com

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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 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.

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

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.

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Table of Contents

Table of Contents

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

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

1 Product Overview.................................................................................................................... 5

1.1 Functional Overview..........................................................................................5

1.2 Feature Highlights.............................................................................................5

1.3 RS400 Series Description.................................................................................7

1.1.1 RS400........................................................................................................7

1.1.2 RS401........................................................................................................9

2 Installation............................................................................................................................. 11

2.1 Mounting..........................................................................................................11

2.1.1 RS400......................................................................................................11

2.1.2 RS401......................................................................................................12

2.2 Power Supply Wiring and Grounding ..............................................................13

2.2.1 Power Supply - AC Input.........................................................................14

2.2.2 Power Supply – DC Inputs ......................................................................14

2.3 HIPOT (Dielectric Strength) Testing................................................................15

2.4 Failsafe Relay Outputs....................................................................................16

2.5 RS232 Console Port Wiring ............................................................................17

2.6 Serial Ports......................................................................................................18

2.6.1 4 x RS232 via DB9..................................................................................19

2.6.2 4 x RS485 via Phoenix............................................................................20

2.6.3 4 x RS232/RS485/RS422 via DB9 ..........................................................21

2.6.4 4 x RS232/RS485/RS422 via RJ-45........................................................22

2.6.5 RS485 Wiring ..........................................................................................23

2.6.6 Serial Port Transient Protection...............................................................24

2.7 Ethernet Ports .................................................................................................25

2.7.1 RJ-45 Twisted-Pair Ports.........................................................................26

2.7.2 Ethernet Port Transient Protection..........................................................26

2.7.3 Fiber Optic Ports......................................................................................27

2.8 V.90 Modem Port (Optional)............................................................................28

3 Technical Specifications ....................................................................................................... 29

3.1 Operating Environment ...................................................................................29

3.2 Power Supply Specifications...........................................................................29

3.3 Failsafe Relay Specifications ..........................................................................30

3.4 Data Port Specifications..................................................................................30

3.5 Fiber Optical Specifications.............................................................................31

3.6 Type Test Specifications.................................................................................32

3.7 Physical Dimensions.......................................................................................33

3.7.1 RS400......................................................................................................33

3.7.2 RS401......................................................................................................35

4 Agency Approvals................................................................................................................. 36

5 Warranty................................................................................................................................ 36

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Product Overview

1 Product Overview

1.1 Functional Overview

The RuggedServer RS400 Series is an industrially hardened, serial device server with
an integrated, fully managed, Ethernet switch, designed to operate reliably in electrically
harsh and climatically demanding environments. The RS400 Series consists of the
RS400 and RS401 which are functionally equivalent differing only mechanically in
shape. Featuring an integrated 4 port serial server, a 4 port managed Ethernet switch,
and an optional v.90 modem, the RS400 Series is able to interconnect multiple types of
intelligent electronic devices (IEDs) that have different methods of communications.
Using the RS400 Series results in fewer connectivity devices (which reduces overall
system costs) and extends the useful life of existing legacy IEDs (which minimizes
capital expenditure for new equipment).

The RS400 Series 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 RS400 Series meets or exceeds
a wide range of industry standards including IEC61850, IEEE1613, IEC61000-6-2,
IEEE61800-3, and NEMA TS-2. The RS400 Series also features a wide operating
temperature range of -40°C to +85°C allowing it to be installed in virtually any location.

1.2 Feature Highlights

Serial device server

 Fully compliant EIA/TIA RS485, RS422, RS232 serial ports
 (software selectable) - DB9, RJ-45, Phoenix style connectors
 Baud rates up to 230 kbps
 Point-to-point and multi-point modes
 Convert Modbus RTU to Modbus TCP
 Supports multiple Modbus masters
 Serial IP' port redirection software to support Personal Computer (PC)

applications statistics and built-in 'sniffer' for troubleshooting

Ethernet Ports

 Integrated Ethernet Switch – up to 4 ports
 High performance and throughput Ethernet switching
 Fully IEEE 802.3, IEEE 802.3u, IEEE 802.3x compliance
 Non-blocking, store and forward switching
 10/100BaseTX, 10BaseFL, 100BaseFX options

Remote Dial Up Access

 Integrated v.90 modem and PPP server
 Provides remote access to serial devices and Ethernet LAN

RuggedRated™ for Reliability in Harsh Environments

 Immunity to EMI and heavy electrical surges

o Meets IEEE 1613 (electric utility substations)
o Exceeds IEC 61850-3 (electric utility substations)
o Exceeds IEEE 61800-3 (variable speed drive systems)

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Product Overview

o

Exceeds IEC 61000-6-2 (generic industrial)

o Exceeds NEMA TS-2 (traffic control equipment)

 Fully independent 2kV (RMS) isolated serial ports
 40°C to +85°C operating temperature (no fans)
 8 AWG galvanized steel enclosure

Universal Power Supply Options

 Fully integrated power supplies (no external adaptors)
 Popular low-voltage DC ranges: 12, 24 and 48 VDC
 Universal high-voltage range: 88-300 VDC or 85-264 VAC
 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) and Enhanced Rapid Spanning Tree (eRSTP™) network

fault recovery (<5ms).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

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Product Overview

1.3 RS400 Series Description

1.1.1 RS400

Serial Data Ports (RS232/RS485/RS422)

Serial Port

Indicators

DC (+) / AC (L)
DC (-) / AC (N)

Surge Ground

Integrated 4-Port Switch

RS232

Console Port

Optional V.90

Modem Port

Normally Open
Normally Closed

Figure 1: RS400 Top View

ITEM Activity Comments

LINK LED (Orange)

Blinking – Once per second Tx, Rx Activity

Solid Link Established

Tx LED (Orange) Blinking Tx (Transmit) Activity
Rx LED (Orange) Blinking Rx (Receive) Activity

POWER LED (Green) Solid Power On

Fault LED (Red) Solid Fault has occurred

Table 1: RS400 LED description

Ethernet Port

Indicators

Common

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Product Overview

Front

Rear

Integrated 4-Port Switch

Serial Data Ports (RS232/RS485/RS422)

Din Rail Mounting

Bracket

DC (+) / AC (L)

DC (-) / AC (N)

Surge Ground

Safety Ground

Stud

Figure 2: RS400 Front and Rear View

RS232

Console Port
Optional V.90

Modem Port

Failsafe Relay

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Product Overview

1.1.2 RS401

Top

Failsafe Relay

Normally Open

Common

Normally Closed

Bottom

Surge Ground

DC (-) / AC (N)
DC (+) / AC (L)

RS232

Console Port

Optional V.90

Modem Port

Integrated 4-Port Switch

Serial Port

Indicators

Serial Data Ports (RS232/RS485/RS422)

Figure 3: RS401 Top and Bottom View

ITEM Activity Comments

LINK LED (Orange)

Blinking – Once per second Tx, Rx Activity

Solid Link Established

Tx LED (Orange) Blinking Tx (Transmit) Activity
Rx LED (Orange) Blinking Rx (Receive) Activity

POWER LED (Green) Solid Power On

Fault LED (Red) Solid Fault has occurred

Table 2: RS401 LED Description

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Product Overview

Figure 4: RS401 Front View

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Installation

2 Installation

2.1 Mounting

2.1.1 RS400

Figure 5: RS400 Front & Side Panel/DIN Mounting

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