Rugged Outback RS416 User Manual

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RuggedServer

RuggedServer RS

RuggedServerRuggedServer

Modular Serial Device Server with Integrated Managed

Ethernet Switch

RS416

RS RS

416

416416

Installation Guide

www.ruggedcom.com

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

Tel: (905) 856-5288 I Fax: (905) 856-1995 I Toll Free: (888) 264-0006

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.

Trademarks:

Ethernet is a trademark of Xerox Corporation RuggedSwitch, RuggedRated, ROS and eRSTP are trademarks of RuggedCom® Inc.

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Table of Contents

1 Table of Figures ...................................................................................................................... 4

2 Table of Tables........................................................................................................................ 4

3 Product Overview.................................................................................................................... 6

3.1 Functional Overview........................................................................................... 6

3.2 Feature Highlights............................................................................................... 6

3.3 Display Panel Description................................................................................... 8

4 Installation ............................................................................................................................. 10

4.1 Mounting........................................................................................................... 10

4.1.1 Rack Mounting.......................................................................................... 11

4.1.2 Panel and DIN Rail Mounting .................................................................. 12

4.2 Power Supply Wiring and Grounding............................................................... 13

4.2.1 AC Power Supply Wiring Examples ........................................................ 15

4.2.2 DC Power Supply Wiring Examples ........................................................ 16

4.2.3 Dual Power Supplies Wiring Examples.................................................... 17

4.3 Dielectric Strength (HIPOT) Testing................................................................ 18

4.4 Failsafe Alarm Relay Wiring ............................................................................ 19

4.5 Console Port Wiring ......................................................................................... 20

4.6 Serial Ports ........................................................................................................ 21

4.6.1 Fiber Serial Interface................................................................................. 21

4.6.2 RS232/RS485/RS422 via DB9 ................................................................. 22

4.6.3 RS232/RS485/RS422 via RJ45 ................................................................ 23

4.6.4 RS485 Wiring ........................................................................................... 24

4.6.5 Serial Port Transient Protection ................................................................ 25

4.7 Ethernet Ports.................................................................................................... 26

4.7.1 Copper Ports.............................................................................................. 26

4.7.2 Fiber Optic Ports ....................................................................................... 27

4.7.3 Ethernet Panel Description ....................................................................... 28

5 Technical Specifications........................................................................................................ 29

5.1 Power Supply Specifications ............................................................................ 29

5.2 Failsafe Relay Contact Ratings......................................................................... 29

5.3 Data Port Specifications.................................................................................... 30

5.3.1 Serial Ports ................................................................................................ 30

5.3.2 Ethernet Ports............................................................................................ 31

5.4 Type Test Specifications................................................................................... 33

5.5 Operating Environment..................................................................................... 34

5.6 Mechanical Specifications ................................................................................ 34

6 Agency Approvals ................................................................................................................. 36

7 Warranty................................................................................................................................ 36

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1 Table of Figures

Figure 1: RS416 LED Display Panel ............................................................................................... 8

Figure 2: RS416 Series Rack mount chassis orientation options – Front and rear mount. ............ 10

Figure 3: 19” Rack Mount Adapters .............................................................................................. 11

Figure 4: Rack mount adapter mounting location.......................................................................... 11

Figure 5: RS416 Series PANEL/DIN RAIL mounting diagram with ............................................... 12

Figure 6: RS416 Series Philips Screw Terminal Block ................................................................... 13

Figure 7: RS416 Series Phoenix Plug Terminal Block ................................................................... 13

Figure 8: AC Power supply wiring examples .................................................................................. 15

Figure 9: DC Power supply wiring examples................................................................................. 16

Figure 10: DC And AC power supply wiring examples .................................................................. 17

Figure 11: Dielectric Strength (HIPOT) Testing.............................................................................. 18

Figure 12: Failsafe Alarm Relay Wiring.......................................................................................... 19

Figure 13: Console port location on display board ........................................................................ 20

Figure 14: Console cable .............................................................................................................. 20

Figure 15: Fiber Serial Interface (ST Connector) ........................................................................... 21

Figure 16: DB9 Female DCE Port pin-out ...................................................................................... 22

Figure 17: RJ45 Port pin-out .......................................................................................................... 23

Figure 18: Conceptual recommended RS485 wiring diagram ........................................................ 24

Figure 19: RJ45 port pins configuration. ........................................................................................ 26

Figure 20: 10FL ST connector....................................................................................................... 27

Figure 21: 100FX MTRJ connector ............................................................................................... 27

Figure 22: 100FX ST connector .................................................................................................... 27

Figure 23: 100FX LC connector .................................................................................................... 27

Figure 24: 100FX SC connector.................................................................................................... 27

Figure 25: Ethernet panel LED description.................................................................................... 28

Figure 26: Mechanical Drawing...................................................................................................... 35

2 Table of Tables

Table 1: LED Display – Device status LED behavior definition ....................................................... 8

Table 2: LED Display - Port LED behavior definition....................................................................... 9

Table 3: RS416 Power terminal block connection description........................................................ 14

Table 4: RS232 over RJ45 console cable pin-out ......................................................................... 20

Table 5: DB9 Female DCE Port pin-out ......................................................................................... 22

Table 6: RJ45 Port pin-out ............................................................................................................. 23

Table 7: Power Supply Specifications ............................................................................................ 29

Table 8: Failsafe Relay Contact Ratings ........................................................................................ 29

Table 9: Copper Port Specification................................................................................................. 30

Table 10: Fiber Optic Port Specification......................................................................................... 30

Table 11: Ethernet Ports - Copper Specifications .......................................................................... 31

Table 12: Ethernet Ports – Fiber Optic Specifications ................................................................... 31

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Table 13: Type Test Specification - Electrical Safety ..................................................................... 33

Table 14: Type Test Specification - Electrical Environment ........................................................... 33

Table 15: Type Test Specification - Atmospheric Environment ...................................................... 33

Table 16: Operating Environment .................................................................................................. 34

Table 17: Mechanical Specifications .............................................................................................. 34

Table 18: Agency Approvals .......................................................................................................... 36

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3 Product Overview

3.1 Functional Overview

The RuggedServer™ RS416 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. Featuring a modular design that can support up to 16 serial ports and up to 4 Ethernet ports, the RS416 is able to interconnect multiple types of intelligent electronic devices (IEDs) that have 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.

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. Coupled with the ruggedized hardware design, the RS416 is 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.

3.2 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 multple Modbus masters

• Converts DNP3.0 to DNP over UDP/TCP

Ethernet Ports

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• Integrated Ethernet Switch - 2 or 4 port options

• (copper and/or fiber)

• High performance and throughput Ethernet switching

• Fully IEEE 802.3, IEEE 802.3u, IEEE 802.3x compliance

• Non-blocking, store and forward switching

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

Universal Power Supply Options

• Fully integrated, dual-redundant (optional) power supplies

• Universal high-voltage range: 88-300 VDC or 85-264 VAC

• Popular low voltage DC ranges: 12 VDC, 24 VDC, 48 VDC

• 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) 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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3.3 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 colours and the corresponding description.

LED Colour Description

Power 1 / 2

Alarm

Table 1: LED Display – Device status LED behavior definition

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Green Power supply operating normal Red Power supply failure Red Alarm exist – login to console to determine alarm code Off No alarms exist

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 and Table 3 define the possible port LED colours and the corresponding description.

Mode Colour

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

Speed

Green (Solid) 10 0Mbps 19200 bps – 57600 bps Orange (Solid) 10 Mbps < 19200 bps Off No link No link

Table 2: LED Display - Port LED behavior definition

Serial Port Status

LEDs

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4 Installation

4.1 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: RS416 Series Rack mount chassis orientation options – Front and rear mount.

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4.1.1 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 Philips 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 high-vibration, 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.

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4.1.2 Panel and DIN Rail Mounting

The RS416 can be ordered as a Panel/DIN mount chassis. Both options involve the use of the panel/DIN adapters to be mounted on each side of the chassis enclosure. The adapter allows the chassis to be mounted on the standard 1” DIN rail using the grooves in the adapter, secured using the included Philips screw. See Figure 5 for a PANEL/DIN mount diagram.

Figure 5: RS416 Series PANEL/DIN RAIL mounting diagram with

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4.2 Power Supply Wiring and Grounding

Philips Screw Terminal without Cover

Philips Screw Terminal with Cover

Phoenix Plug Terminal without Cover

Phoenix Plug Terminal with Cover

Safety Cover

Screws

Chassis Ground

Connection

Surge / Chassis Ground Jumper

Terminal

Figure 6: RS416 Series Philips Screw Terminal Block

Safety Cover

Screws

Chassis Ground

Connection

Surge / Chassis Ground Jumper

Terminal

Figure 7: RS416 Series Phoenix Plug Terminal Block

The RS416 supports dual redundant power supplies – “Power Supply 1 (PS1)” and “Power Supply 2 (PS2)”. The connections for PS1, PS2 and the fail-safe relay are located on the terminal block as shown in Figure 6 and Figure 7.

The RS416 can be equipped with either a Philips Screw Terminal Block or a Phoenix Plug Terminal Block. The Philips Screw Terminal Block has Philips screws with a compression plate allowing either bare wire connections or crimped terminal lugs. We recommend the use of #6 size ring lugs to ensure secure, reliable connections under severe shock or vibration. Both terminal blocks have a safety cover which must be removed via two Phillips screws before connecting any wires. The safety cover must be re-attached after wiring to ensure personnel safety. Refer to Table 3 below for a description of each terminal as well as sections 4.2.1 through 4.2.3 for wiring examples.

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Terminal # Description Usage

PS1 Live / + is connected to the positive (+) terminal if the

1 PS1 Live / +

2 PS1 Surge Ground

3 PS1 Neutral / -

4 Chassis Ground

5 PS2 Live / +

6 PS2 Surge Ground

7 PS2 Neutral / -

8 Relay NO Contact Normally open, failsafe relay contact. 9 Relay Common Failsafe relay common contact.

10 Relay NC Contact Normally closed, failsafe relay contact.

Table 3: RS416 Power terminal block connection description

power source is DC or to the (Live) terminal if the power source is AC. PS1 Surge Ground is connected to the Chassis Ground via a jumper on the terminal block. Surge Ground is used as the ground conductor for all surge and transient suppression circuitry. PS1 Neutral / - is connected to the negative (-) terminal if the power source is DC or to the (Neutral) terminal if the power source is AC. Chassis Ground is connected to the Safety Ground terminal for AC inputs or the equipment ground bus for DC inputs. Chassis ground connects to both power supply surge grounds via a removable jumper. PS2 Live / + is connected to the positive (+) terminal if the power source is DC or to the (Live) terminal if the power source is AC. PS2 Surge Ground is connected to the Chassis Ground via a jumper on the terminal block. Surge Ground is used as the ground conductor for all surge and transient suppression circuitry. PS2 Neutral / - is connected to the negative (-) terminal if the power source is DC or to the (Neutral) terminal if the power source is AC.

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4.2.1 AC Power Supply Wiring Examples

Figure 8: AC Power supply wiring examples

NOTES:

1. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be

installed within 3m of unit.

2. Equipment must be installed according to the applicable country wiring codes.

3. When equipped with two HI voltage power supplies, independent AC sources can be used

to power the product for greater redundancy. However, separate circuit breakers must be installed and separately identified (not shown in above figure).

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4.2.2 DC Power Supply Wiring Examples

Figure 9: DC Power supply wiring examples

NOTES:

1. 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker must be

installed within 3m of unit.

2. A circuit breaker is not required for 12, 24 or 48 VDC rated power supplies.

3. Equipment must be installed according to the applicable country wiring codes.

4. When equipped with two HI voltage power supplies, independent AC sources can be

used to power the product for greater redundancy. However, separate circuit breakers must be installed and separately identified.

5. When equipped with two DC voltage power supplies (88-300VDC rated); independent

DC sources may be used to power the product for greater redundancy. However, separate circuit breakers must be installed and separately identified (as shown in the above figure).

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4.2.3 Dual Power Supplies Wiring Examples

Figure 10: DC And AC power supply wiring examples

NOTES:

1. 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker must be

installed within 3m of unit.

2. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be

installed within 3m of unit.

3. A circuit breaker is not required for 12, 24 or 48 VDC rated power supplies.

4. Separate circuit breakers must be installed and separately identified.

5. Equipment must be installed according to the applicable country wiring codes.

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4.3 Dielectric Strength (HIPOT) Testing

For dielectric strength (HIPOT) testing in the field, users must remove the metal jumper located on terminal 2, 4, and 6 of the power supply terminal block. This metal jumper connects transient suppression circuitry to chassis ground and must be removed in order to avoid damage to transient suppression circuitry during HIPOT testing. Figure 11 shows the proper HIPOT test connections and should be followed to avoid damage to the device.

Figure 11: Dielectric Strength (HIPOT) Testing

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4.4 Failsafe Alarm Relay Wiring

The “Failsafe” output relay is provided to signal critical error conditions that may occur on the RS416. The contacts are energized upon power up of the unit and remain energized until a critical error occurs. The proper relay connections are shown in Figure 12. One common application for this output is to signal an alarm if a power failure or removal of control power occurs. The failsafe relay current and power handling capabilities are defined in

Figure 12: Failsafe Alarm Relay Wiring

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4.5 Console Port Wiring

Signal Name (PC is DTE)

Female

DB9 Male

RJ45

DCD

–

Carrier detect

1 2

TxD

–

Transmit Data

2 5

RxD

–

Receive Data

3 6

DTR

–

Data terminal ready

4 3

Signal GND

5 4

DSR –

Data set ready

6 1*

RTS

–

Ready to send

7 8

CTS

–

Clear to send

8 7

RI – Ring Indicator

9 1*

A RS232 console port for configuration and management of the device is located on the LED display module shown in Figure 13. This port is intended to be a temporary connection during initial configuration or troubleshooting and allows for direct access to the serial-based management console. The connection is made using the DB9-Female to RJ45 console cable included in the device packaging shown below. Console connection settings are 57600 baud, no parity bits, 8 data bits, and 1 stop bit.

Figure 13: Console port location on display board Figure 14: Console cable

For user reference, the console cable pin-out is show in the table below.

RuggedCom RS232 over RJ45 pin-out specification

Table 4: RS232 over RJ45 console cable pin-out

After initial configuration, the RS416 can be configured via a number of mechanisms such as Telnet, and the built-in web server. Consult the RuggedSwitch ROS User Guide for further details.

NOTE: This port is not intended to be a permanent connection and the cable shall be less than 2m (6.5 ft) in length.

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4.6 Serial Ports

The RS416 can be equipped with a Fiber Serial Interface, RS232/RS485/RS422 DB9 serial ports or RS232/RS485/RS422 RJ45 serial ports.

4.6.1 Fiber Serial Interface

The RS416 can be equipped with a Fiber Serial Interface (ST connector only) which allows RS485, RS422, or RS232 devices to communicate over secure, noise immune, optically isolated, fiber optic cabling at extended distances as well as protocol independent conversion to multimode fiber optics.

Figure 15: Fiber Serial Interface (ST Connector)

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4.6.2 RS232/RS485/RS422 via DB9

Each port is individually selectable via software to be RS232, RS485 or RS422. The DB9 port and pin-out is shown below.

Figure 16: DB9 Female DCE Port pin-out

Pin RS232 Mode RS485 Mode RS422 Mode

1 CD - 2 TX TX/RX+ TX+ 3 RX

4 DTR - 5 Common (Isolated Ground) 6 DSR - RX7 CTS TX/RX - TX8 RTS -

(No Connection) - -

Shield Chassis Ground

Table 5: DB9 Female DCE Port pin-out

RX+

NOTES:

1. No internal termination is provided.

2. Pins 1, 4, and 6 are connected internally. Pins 7 and 8 are connected internally. The pins are

permanently asserted to 5V so that DTE devices that require DCD, DTR, or CTS signals will operate. However, hardware flow control via RTS is not recognized.

3. The Common terminals are optically isolated; however, there is transient voltage protection

circuitry between the Common terminals and chassis ground.

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4.6.3 RS232/RS485/RS422 via RJ45

Each port is individually selectable via software to be RS232, RS485 or RS422. The RJ45 port and pin-out is shown below.

Figure 17: RJ45 Port pin-out

Pin RS232 Mode RS485 Mode RS422 Mode

1 DSR - RX2 DCD - 3 DTR - 4 Common (Isolated Ground) 5 RX - RX+ 6 TX TX/RX + TX + 7 CTS - 8 RTS TX/RX - TX -

Shield Chassis Ground

Table 6: RJ45 Port pin-out

NOTES:

1. No internal termination is provided.

2. Pins 1, 2, and 3 are connected internally. Pins 7 and 8 are connected internally. The pins are

permanently asserted to 5V so that DTE devices that require DCD, DTR, or CTS signals will operate. However, hardware flow control via RTS is not recognized.

3. The Common terminals are optically isolated; however, there is transient voltage protection

circuitry between the Common terminals and chassis ground.

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4.6.4 RS485 Wiring

Each RS485 port can communicate to multiple RS485 devices by daisy chaining devices over a single twisted pair with transmit and receive signals on the same two wires (half duplex). The following guidelines should be followed to ensure reliable continuous communication:

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

2. The correct polarity must be observed throughout a single daisy chain.

3. The number of devices wired should not exceed 32, and total distance should be less than

4000 feet (at 100 kbps).

4. The Common terminals should be connected to the common wire inside the shield.

5. The shield should be connected to earth ground at a single point to avoid loop currents

6. The twisted pair should be terminated at each end of the chain.

The figure below shows the recommended RS485 wiring.

Figure 18: Conceptual recommended RS485 wiring diagram

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4.6.5 Serial Port Transient Protection

RuggedCom does not recommend the use of copper cabling of any length for critical real-time substation automation applications. However, transient suppression circuitry is present on all copper ports to protect against damage from electrical transients and to ensure IEC 61850-3 and IEEE 1613 Class 1 conformance. This means that during the transient event communications errors or interruptions may occur but recovery is automatic.

RuggedCom also does not recommended to use these ports to interface to field devices across distances which could produce high levels of ground potential rise, (i.e. greater than 2500V) during line to ground fault conditions.

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4.7 Ethernet Ports

4.7.1 Copper Ports

The RS416 may have up to 4 10/100BaseTX ports that allow connection to standard CAT-5 UTP cable with RJ45 male connectors. All RJ45 Ethernet ports feature auto-negotiating, auto-polarity, and auto-crossover functions. The RJ45 receptacles can also accept and take advantage of screened (commonly known as “shielded”) cabling. Figure 19 shows the RJ45 port pins configuration.

Pin Signal

1 +Rx 2 -Rx 3 +Tx 4 No Connection 5 No Connection 6 -Tx 7 No Connection 8 No Connection

Figure 19: RJ45 port pins configuration.

NOTE: RuggedCom does not recommend the use of copper cabling of any length for critical realtime substation automation applications. However, transient suppression circuitry is present on all copper ports to protect against damage from electrical transients and to ensure IEC 61850-3 and IEEE 1613 Class 1 conformance. This means that during the transient event communications errors or interruptions may occur but recovery is automatic. RuggedCom also does not recommended to use these ports to interface to field devices across distances which could produce high levels of ground potential rise, (i.e. greater than 2500V) during line to ground fault conditions.

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4.7.2 Fiber Optic Ports

Depending on the order code of the product, the RS416 can be equipped with several different types of fiber optic ports. The Transmit (TX) and Receive (RX) connections of each port must be properly connected and matched for proper link and operation. Modules populated on the top row of the device typically have locking mechanisms or tabs towards the top of the unit. Modules located on the bottom row of the device have locking mechanisms or tabs towards the bottom of the device.

The drawings in the following figures show each fiber optical connector style with a side and top view to allow the user to identify the proper cable connection orientation. If modules are populated on the bottom row of the device, the transceiver orientation will be reversed (i.e. RX and TX will be reversed).

Figure 20: 10FL ST connector

Figure 23: 100FX LC connector

Figure 21: 100FX MTRJ connector

Figure 24: 100FX SC connector

Figure 22: 100FX ST connector

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4.7.3 Ethernet Panel Description

Each Ethernet module is equipped with two LEDs that indicate link/activity status information. The LED will be solid for ports with link, and will blink for activity. The diagram in Figure 25 highlights the port and the associated link/activity LED.

Figure 25: Ethernet panel LED description

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5 Technical Specifications

5.1 Power Supply Specifications

Input Range Power Supply

Type

Min Max

12 – 24 VDC 10 VDC 36 VDC 6.3A(F) 2

24 VDC 18 VDC 36 VDC 5A(F) 2 48 VDC 36 VDC 59 VDC 2A(T) 2

HI (125/250 VDC) HI (110/230 VAC)

88 VDC 85 VAC

300 VDC 265 VAC

Table 7: Power Supply Specifications

NOTES:

1. This is the same power supply for both AC and DC.

2. (F) Denotes fast-acting fuse, (T) denotes time-delay fuse

3. Power consumption varies based on configuration. 10/100Tx ports consume roughly 1W less than fiber optic ports

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

Fuse

Rating

2A(T)

1,2

Max. Power Consumption

15 W

5.2 Failsafe Relay Contact Ratings

Parameter Value (Resistive Load)

Max Switching Voltage 240VAC, 125VDC Rated Switching Current 2A @ 240VAC

0.15A @ 125VDC, 2A @ 30VDC Max Switching Capacity 150W, 500VA Table 8: Failsafe Relay Contact Ratings

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5.3 Data Port Specifications

5.3.1 Serial Ports

5.3.1.1 Copper Ports

Parameter Specifications Notes

Baud Rate 300 bps – 230 kbps

Connector DB9 or RJ45

Isolation 2.5 kV

Table 9: Copper Port Specification

5.3.1.2 Fiber Optic Ports

Parameter Specifications

Mode Multimode

Connector ST

Typical Dist. (km) 5

Optical Wavelength (nm) 820

Cable Size

Core/Cladding (um)

Table 10: Fiber Optic Port Specification

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.

50/125

62.5/125

RMS 1-minute

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5.3.2 Ethernet Ports

5.3.2.1 Copper Ports

Parameter Specification Notes

Speed 10/100 Mbps Auto-negotiating Duplex FDX / HDX Auto-negotiating Cable-Type > Category 5 Shielded/Unshielded Wiring Standard TIA/EIA T568A/B Auto-Crossover, Auto-polarity Max Distance 100 m Connector RJ45 Isolation 1.5 kV RMS 1-minute

Table 11: Ethernet Ports - Copper Specifications

5.3.2.2 Fiber Optic Ports

The following sections detail fiber optic specifications on ports that can be ordered with the RS416. The user determines the type of optics at time of ordering and can determine the modules installed on a particular unit by reading the factory data file via the ROSTM user interface. The following section provides detailed specifications of fiber optic modules.

The dual-port fast Ethernet optical specifications for slots 5 and 6 are shown in Table 12 organized by module order code. Module order codes are contained within each product’s factory data when assembled and configured at the factory. Consult ROSTM to determine the optical assemblies installed in a particular product.

Optics

Order Code

12-11-0011 MM / ST 850 50/125 -16.5/-10.6 -34 -11.2 2 21 12-11-0012 SM / ST 1310 9/125 12-11-0007 MM / ST 12-11-0009 MM / SC 12-11-0008 MM / MTRJ 12-11-0046 MM / LC 1310 50/125 -19 / -14 -32 -14 2 15 12-11-0006 SM / ST 12-11-0005 SM / SC 12-11-0004 SM / LC 12-11-0031 SM / SC 12-11-0032 SM / LC 12-11-0033 SM / SC 12-11-0034 SM / LC

Mode /

Connector

λλλλ

(nm)

1310 50/125 -15.7 -33.5 -11 2 17

1310 9/125 -15/-8 -32 -7 20 16.5

1310 9/125 -5 / 0 -35 -3 50 32.5

1310 9/125 0 / 5 -37 0 90 39.5

Cable Type2

(

µµµµm)

Tx Pwr

(dBm) 3

(Min/Max)

-27 / -14

Sensitivity

(dBm) 3

-35 -3 5 8

Saturation

(dBm) 3

Typical

Distance

(km) 1

Power

Budget

(dB)

Table 12: Ethernet Ports – Fiber Optic Specifications

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NOTES:

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

3. All cabling is duplex type unless otherwise specified.

4. These transceivers utilize a distributed feedback (DFB) type laser and are rated for -20°C to +85°C operation only.

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5.4 Type Test Specifications

Electrical Safety Levels Comments

Dielectric Withstand 2 kV rms for 1 minute

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

Table 13: Type Test Specification - Electrical Safety

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)

Table 14: Type Test Specification - Electrical Environment

2.5 kV @ 1MHz for 2s

35 V/m ANSI/IEEE C37.90.2

15 kV (air discharge)

8 kV (contact)

ANSI/IEEE C37.90 (1989)

IEC 60255-5 (Section 6)

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)

Atmospheric Environment Levels Comments

Temperature (Dry Cold)

Temperature (Dry Heat)

Humidity

Table 15: Type Test Specification - Atmospheric Environment

-40°C

85°C

95%

non-condensing

Test Db: 6 cycles, 55°C, 95% Humidity

IEC 60068-2-1

Test Ad: 16 hrs @ -40°C

IEC 60068-2-2

Test Bd: 16 hrs @ 85°C

IEC 60068-2-30

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5.5 Operating Environment

Parameter Range Comments

Ambient Temperature as

Ambient Operating

Temperature

Ambient Relative Humidity 5% to 95% Non-condensing

Ambient Storage

Temperature

Table 16: Operating Environment

-40 to 85°C

measured from a 30cm

radius surrounding the

center of the RS1600

enclosure.

5.6 Mechanical Specifications

Parameter Value Comments

Dimensions

Weight 10 lb (4.5 Kg)

Enclosure 18 AWG galvanized steel

Table 17: Mechanical Specifications

18.29 x 10.17 x 1.74 inches

(464,57) x (258,32) x (44,20) mm

(Length x Width x Height)

with mounting brackets

installed

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Figure 26: Mechanical Drawing

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6 Agency Approvals

Agency Standards Comments

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

CE EN 60950, EN 61000-6-2 Approved

FCC FCC Part 15, Class A Approved

CISPR EN55022, Class A Approved

FDA/CDRH 21 CFR Chapter 1, Subchapter J Compliant

IEC/EN EN60825-1:1994 + A11:1996 + A2:2001 Compliant

Table 18: Agency Approvals

7 Warranty

RuggedCom warrants this product for a period of five (5) years from date of purchase. For warranty details, visit http://www.ruggedcom.com or contact your customer service representative.

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

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Rugged Outback RS416 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual