Although every effort has been made to insure that this manual is current
and accurate as of date of publication, no guarantee is given or implied
that this document is error free or accurate with regard to any specification. TC Communications, Inc. reserves the right to change or modify
the contents of this manual at any time without prior notification.
General ..............................................................................................................................................14
Power On LEDs Flash .....................................................................................................................14
General ..............................................................................................................................................16
The TC1540 Fiber Optic Modem interconnects a host controller with RTUs (Remote Terminal Units) with
RS-232, RS-422 or RS-485 (2 or 4-wire) interfaces for point-to-point communication. TC1540T is the
extended temperature version of TC1540. Asynchronous data rates up to 500 Kbps are supported (contact
factory for higher data rate requirements). The RS-422/485 interface is standard; RS-232 interfaces are
optional. Different interfaces can be interconnected.
The TC1540 is equipped with eight DIP switches and eight LED indicators (on the top cover) to facilitate
installation and troubleshooting.
Optic options include 850nm and 1310nm Multimode wavelengths; 1310nm or 1550nm Single Mode
wavelengths. The optional optic redundancy feature can provide maximum reliability for crucial applications.
Fiber optic connectors are ST; FC is optional (ST is a trademark of AT&T). The electrical connector is a
removable terminal blocks. Power is 9V to 12V DC at 250mA. Optional power sources are also available
(see Chapter 5 - Specifications).
for Electrical & Optical
Input/Output Status
RS-232 input
terminal block
(only left pin is used)
(only left pin is used)
TCCOMM.COM
RS232
IN
RS-232 output
terminal block
ON(1)
OUT
DIP Switches for Diagnostics
and Application Setup
SIG
GND
+
DC Power Input
9V to 12V DC@250mA
Signal Ground
Optic Receiver "RxA"
Figure 1. TC1540 with RS-232 Interface
- 3 -
Page 4
TC1540D User's Manual
DC Power Input
9V to 12V DC@250mA
terminal block
DIP Switches for Diagnostics
LED Indicators
Optic Transmitter "TxA"
36-72VDC
18-36VDC
10-14VDC
Rev. 1.2
for Electrical & Optical
Input/Output Status
RS-422/485 input
terminal block
TCCOMM.COM
IN
RS422
RS485
+
ON(1)
OUT
and Application Setup
SIG
GND
+
+
Optic Receiver "RxA"
RS-422/485 output
Signal Ground
(2-wire RS-485)
Figure 2. TC1540 with RS-422/RS-485 Interface
- 4 -
Page 5
DIP Switch Functions
Set the RS-485 transition timer (see Table 1)
DIP Switch Functions
- RS-422 mode.
Off
(actual logic status on output terminal block depend on electrical interface),
Power Indicator:
SW1 -
Left: Normal Operation
Right: Electrical Local Loopback (for diagnostics)
SW2 -
Internally loopback optic signal
SW3 -
Generate 1Hz blink TD signal to verify optic connectivity
SW4 -
Only used for advanced diagnose, see related section
for detail. It should be kept at left position for normal
operation.
SW5 -
Not used
SW6, SW7, SW8 -
Figure 3. TC1540's DIP Switch Functions
TC1540D User's Manual
Rev. 1.2
LED Functions
Unit's power supply is adequate
On -
Power is not reaching the unit
Off -
Optic Sync Indicators:
Flashing On -
Transmit Data Indicator:
(actual logic status on Terminal Block pins depend on electrical interface)
Off:
RS422 - Voltage on “+” terminal > “-” terminal’s voltage.
RS232 - Negative input voltage.
On:
RS422 - Voltage on “+” terminal < “-” terminal’s voltage.
RS232 - Positive input voltage.
Receive Data Indicator:
same logic state as input terminal blocks.
Collision Indicator:
Refer to Chapter 3 - Troubleshooting Section for detail.
Reverse Polarity:
Optic signal lost or below sensitivity level.
Optic signal is valid.
Input
Logic “1” or “Mark” (this is idle state)
Logic “0” or “Space”,
The input RS422/RS485 signal’s polarities are reversed.On -
Figure 4. TC1540's LED Indicator Functions
Driver Mode:
When in RS-485 mode, the output terminals are
On in driver mode
- the output termnal terminals are in receive mode.
Off
RS485/RS422 Mode:
RS-485 mode.
On -
- 5 -
Page 6
Theory of 2 and 4-Wire RS-485 Operation
Fiber Cable
Figure 5. 2-Wire RS-485 Logic Diagram
TC1540D User's Manual
Rev. 1.2
Two-wire RS-485 is a half-duplex operation, which means transmit and receive operations take turns; they
do not function concurrently. From the user’s point-of-view, the channel is in receiving mode when no data
is transmitted from the remote unit.
Four-wire RS-485 is a full-duplex operation, which means transmit and receive operations function
concurrently. From the user's point-of-view, both channels are in the receiving or transmitting mode at all
times.
The RS-485 Driver/Receiver transition time is determined by three DIP switches on the TC1540. The local
unit's RS-485 transceiver changes to transmit (Tx) mode upon receiving the first bit of data from the remote
unit. The transition time is the amount of time before the local unit's RS-485 transceiver will revert to the
high-impedance receiver mode after the last bit is received from the remote unit. The RS-485 transition time
should be set according to Table 1 on the following page.
Fiber Cable
Figure 6. 4-Wire RS-485 Logic Diagram
- 6 -
Page 7
TC1540D User's Manual
When SW6,7,8 are all at left side, the electrical interface is set for RS-422
100Kbps
250Kbps
500Kbps
xxxxxxxxx
x
xxx
36-72VDC
18-36VDC
10-14VDC
remove two screws, then remove the top cover
Opening the unit without prior consent from
TCCI will result in voiding the warranty.
Rev. 1.2
RS-485 Transition Timer Setup
The following table provides setup information for configuring the front panel's DIP switches for an RS-485
application. To use the table, determine the baud rate of your application and set SW6, SW7, & SW8
accordingly. For example, if you know the async data baud rate of your application is 9600, then set SW6
to the Right; SW7 and SW8 to the Left (on each unit). You may also want to try the 25Kbps or 50Kbps settings
for a 9600 baud rate as a test to make sure you have the correct data rate (sometimes the best results come
from trial and error). For RS-232 and RS-422 interfaces, these three switches should be kept in the Left
position.
SW-6
SW-7
SW-8
4-wire
RS-422
x
x
10Kbps25Kbps50Kbps
400 ms1msec
x
x
x
x
xx
200 ms100 ms40 ms20 ms4 ms
x
x
x
1Mbps
Table 1. RS-485 Transition Timer Setup Table
RS-422 & RS-485 Termination Resistor
A termination resistor is usually necessary for RS-422 and RS-485 applications. Without proper termination,
the error rate of data transmission may be high due to an "echo" effect on the electrical connection. With
the addition of a termination resistor at the beginning or end of the electrical bus, this echo effect is greatly
reduced. The termination resistors are 100 to 130 ohm resistors located inside the TC1540. Two jumpers,
identified as board locations "W1" & "W5," control the termination resistance on each unit (installed by
default). "W1" controls the resistance for the unit's receiver (IN), while "W5" controls the transmitter's
(OUT) resistance. Proper line termination is required when TC1540 is placed at the end of RS-422/RS-485
bus. There is no termination resistor required for RS-232 applications.
Figure 7. TC1540's Termination Resistor Locations
Note:
W1W5
OUT
IN
RS422
SIG
RS485
GND
+
+
+
- 7 -
Page 8
TC1540D User's Manual
RS-422/RS-485 4-Wire Termination/Connection
Transition
Termination
To/From
120
Termination
Drv/Rcv
2-wire RS-485 Termination/Connection
Transition
Termination
To/From
Rev. 1.2
Pin Assignments and Connection
The removable terminal blocks on the TC1540 factory configured as DCE. The pin assignments for each
type of interface are illustrated below. Pins IN(-) & IN(+) are inputs and Pins OUT(-) & OUT(+) are outputs
(or input/output for 2-Wire RS-485).
The TC1540 is compatible with all popular sizes and types of fiber. Transmission distances up to 3km* are
typical over Multimode fiber at 850nm and 4km* at 1310nm. Distances to 35m* are typical over Single Mode
fiber at 1310nm.
Launch Power & Sensitivity
Transmitter:LED/ELED; typical Launch Power --20dBm* (850nm/1310nm MM, @62.5/125µm)
-16dBm* (1310nm Single Mode, @9/125µm)
Receiver:PIN Diode; typical Sensitivity --36dBm* (850nm/1310nm MM, @62.5/125µm)
-36dBm* (1310nm Single Mode, @9/125µm)
*Launch power, sensitivity and distance are listed for reference only. These numbers may vary.
Power Supply
Typically, a 9V to 12V DC power supply @250mA is adequate for the TC1540. The power plug is a terminal
block connector with positive & negative polarity indicated on the top panel of the unit. Alternate power
sources are available as an option (see Chapter 5 - Specifications).
- 10 -
Page 11
TC1540D User's Manual
Rev. 1.2
Chapter 2 - Installation
Unpacking the Unit
Before unpacking any equipment, inspect all shipping containers for evidence of external damage caused
during transportation. The equipment should also be inspected for damage after it is removed from the
container(s). Claims concerning shipping damage should be made directly to the pertinent shipping agencies.
Any discrepancies should be reported immediately to the Customer Service Department at TC Communications, Inc.
Equipment Location
The TC1540 should be located in an area that provides adequate light, work space and ventilation. Avoid
locating it next to any equipment that may produce electrical interference or strong magnetic fields, such as
elevator shafts and heavy duty power supplies. As with any electronic equipment, keep the unit from
excessive moisture, heat, vibration and freezing temperatures.
Installation Procedure Summary
The TC1540 is designed for quick and easy installation. Before installing, however, double-check the polarity
at the DC power's terminal block connector.
A. If power indicator is not on after power is connected then the polarity of DC power connections may be
reversed. Reversed power polarity will not cause any damage to the unit.
B. Connect fiber optic cables between the local & remote units as shown in Figure 12; the local unit's optic
"Tx" connects to the remote unit's optic "Rx".
C. Connect the local device's RS-232, RS-422 or RS-485 signal to the terminal blocks of TC1540. Observe
that all the LED flashes (except "POWER" LED) for 2 to 3 second when power first is applied.
D. Connect the remote device's RS-232, RS-422 or RS-485 signal to the DB25 connector on the rear panel
of a second TC1540. Connect power to the unit. Observe that the "TD" LED flashes when an incoming
signal is transmitted from that unit's local device. Verify that the "RD" LED on the remote TC1540 also
flashes when an incoming signal is received from the remote unit.
E. Run an Optic Loopback, Local Loopback and Remote Loopback Test (see pages 16, 17 & 18) for each
kind of test.
F. Verify System Integrity:
At each unit, check the "O-SYNC" indicator. The "O-SYNC" LED indicateS the optic signal has been
received and synchronized. If the optic cable is broken, the related "O-SYNC" (on the receiving side) will
flash.
Verify and record the optical cable loss for each link in the application after installation is complete. This
reading will both verify the integrity of the circuit and provide a benchmark for future troubleshooting efforts
(see Chapter 3 - Troubleshooting).
- 11 -
Page 12
TC1540D User's Manual
SW1-4 is off and master TC2100 is in OPERATION mode
2-wire RS-485 Quick Installation
Rev. 1.2
Installation Example (for 2-wire RS-485 application)
Figure 11 depicts a typical 2-wire RS-485 application. The host controller polls the status of the remote RTU
through a 2-wire RS-485 bus. Once the remote RTU receives the polling message, it answers with a response
signal. The communication is half-duplex: the polling device and responding RTU take turns transmitting.
Electrical Interface:2-wire RS-485
Data Rate:9600 Baud (Async)
Optic Redundancy:Utilized
DIP Switch settings:SW1, SW2, SW3, SW4, SW5, SW7 and SW8 to Left; SW6 to Right (on both
units)
LEDs to observe:Local & remote unit's "TxD" and "RxD" LEDs should flash in an alternating
pattern (due to half-duplex communication)
(local & remote Units)
Figure 11. 2-Wire RS-485 Installation Diagram
- 12 -
Page 13
4-wire RS-485 Quick Installation
(local & remote Units)
TC1540D User's Manual
Rev. 1.2
Figure 12. 4-Wire RS-485 Installation Diagram
- 13 -
Page 14
TC1540D User's Manual
The optic cable is broken or the cable connector is not inserted
The “IN-” and “IN+” are reversed, also maybe “OUT-” and “OUT+”.
Power Indicator:
Rev. 1.2
Chapter 3 - Troubleshooting
General
Alarm conditions occur whenever an optical problem or "fault" condition is detected by the TC1540. Under
normal operation, following LEDs should be lit
"POWER," "O-SYNC," "TD," and " RD."
Following LEDs may be "ON" or "OFF" depend on applications:
"COLL"- for trouble-shoot, not used. It should be off at all times.
"DRVMD"- turned on only when "OUT" terminal blocks are in "driver" mode.
"RS-485"- turned on when TC1540 is configured as RS-485 interface. (see DIP switch settings).
Power On LEDs Flash
When power first applied to TC1540, all the LEDs flah for two to three seconds.
Alarm Conditions
When alarm condition
Unit's power supply is adequate
On -
Power is not reaching the unit
Off -
Optic Sync Indicators:
Flashing -
Optic signal lost or below sensitivity level.
correctly.
Optic signal is valid.
On -
Reverse Polarity:
The input RS422/RS485 signal’s polarities are reversed.
On -
Optic Cable Types
Conventionally, fiber optic cable with yellow-colored insulation is used for Single Mode applications; gray
or orange-colored insulated cable is for Multimode use. If Multimode cable is used in a Single Mode
application, the test results could be erroneous and confusing.
Calculating the Fiber Optic Loss Budget
The fiber optic link and/or connectors are frequently the source of various problems. Check out the
connectors and the integrity of the link first. Ideally, the link should be calibrated for total loss after the
installation has been completed.
To calculate the loss budget:
Multimode 850nm:3 dB loss per km on 62.5/125µm cable*
Multimode 1310nm:2 dB loss per km on 62.5/125µm cable*
Single Mode 1310nm:0.5 dB loss per km on 9/125µm cable*
Single Mode 1550nm:0.4 dB loss per km on 9/125µm cable*
- 14 -
Page 15
TC1540D User's Manual
Conduct a
Test from
Direction
Yes
Does the "TD"
LED Light when
Check Pin
Assignments
ination Resistor,
Conduct a Local
(-13dBm to -22dBm)
Conduct an Optical
(-13dBm to -37dBm)
Check Signal
Polarity and
DIP Switches
Yes
Contact
Factory for
Replacement
Rev. 1.2
The TC1540 is designed with easy troubleshooting in mind. The LED indicators and DIP switches on the
top cover will support various diagnostic functions. The first step in troubleshooting is to determine whether
the problem is optical or electrical in nature. Figure 12 describes the steps required to isolate the problem.
The tests related to each block are explained in Chapter 4 - Bench Tests.
Check Power
Source, Polarity &
Power Connection
Check Optic Cable
Type, Connectors,
and Verify Optic
Connections
No
Pass
Is the unit's
Power LED Lit ?
Check Term-
DIP Switches &
Signal Polarity
Loopback Test
Fail
Transmitting?
No
Conduct a Signal
Generator Test
Measure Optical
Launch Power
Measure Optical
Receive Power
Loopback Test
Repair or
of Unit
FailFail
Conduct a
Pass
Remote
Pass
Loopback Test
Figure 13. Troubleshooting Flowchart
Remote
Loopback
Opposite
- 15 -
Page 16
TC1540D User's Manual
TC1540
TC1540
RxD
TxD
Set Sw5 to right
(Remote loopback)
Rev. 1.2
Chapter 4 - Bench Tests
General
It is highly recommended to conduct bench tests before actual installation. Bench testing allows the user to
become familiar with all the functions and features of the TC1540 in a controlled environment. Knowledge
of the TC1540's functions and features will ease installation and troubleshooting efforts later on.
Testing Considerations
Most of the following bench tests specify a BERT (Bit Error Rate Tester) Test Set be used to perform the
test. You may substitute the BERT with a PC (with a terminal emulation program that matches your devices
RS-232, RS-422, or RS-485 interface) if necessary. For RS-485 interfaces, make sure the baud rate on the
BERT or PC matches the baud rate DIP switch settings (SW6, SW7 and SW8) on the units tested.
The connection diagrams in this chapter are typical for all three types of interfaces; however, the DIP switch
settings will vary depending on the type of interface, baud rate, and whether your unit is a single or dual optic
model. The loopback tests can not be performed on a TC1540 unit with a 2-wire RS-485 interface due to
its half-duplex operation; however, the Signal Generator feature can be used to facilitate troubleshooting.
The DIP switch illustrations on each unit are typical for a dual optic TC1540 with a 4-wire RS-485 interface
communicating at 9600 baud rate (Async).
Bench Test With Built-In Signal Generator
The TC1540 has a built-in signal generator to simulate a polling device's or RTU's incoming electrical signal.
The built-in signal generator is a pulse signal indicated by a blinking LED. The flash rate is intentionally
reduced for easy visual confirmation.
1. Set up the bench test as shown in Figure 14. At the local TC1540 unit, turn on the "SIGGEN" by sliding
SW3 to the Right. The "TD" LED on the local TC1540 should start blinking. Likewise, the "RD" LED
on the remote TC1540 should also blink, indicating receipt of the local unit's simulated polling message.
2. At the remote TC1540, turn on the "SIG-GEN" by sliding SW3 the Right. The "TD" LED should start
blinking. Verify that the local unit's "RD" also blinks, indicating receipt of the remote unit's simulated
response.
Optic Cable
TxD
RxD
RS-232
Set SW3 to left
Figure 14. Signal Generator Bench Test Connection Diagram
- 16 -
Page 17
TC1540D User's Manual
Connect TC1540 to RS-530 DTE device
SIG
GND
TC1540
Optical loopback
Connect TC1540 to RS-449 DTE device
SIG
GND
Rev. 1.2
Optic Loopback Bench Test
Purpose:This test loops the optic signal transmitted by the TC1540 back to the unit's receiver in
order to test the transmit and receive capabilities of the unit without any other units
attached.
Equipment
Requirements:One (1) Bit Error Rate Test (BERT) Set with appropriate interface module.
One (1) optical jumper cable (patch cord) with appropriate connectors.
Procedure:Set up the bench test as shown in Figure 15. To test the "Tx" to "Rx" loop, connect an
optic patch cord from optic "Tx" to optic "Rx." Set all the DIP switchs to the Left position.
Connect a BERT tester to the TC1540 according to Fig. 15. Set the tester up as a DTE
device. The BERT tester should indicate a "SYNC" signal.
Remove the patch cord from "Tx" and "Rx", the "O-SYNC" LED on the TC1540 should
flash.
RS-530
DTE DEVICE
(DB25)
Tx-
Tx+
Rx-
Rx+
SIG
GND
TC1540
2
14
3
16
7
IN-
IN+
OUT-
OUT+
RS-449
DTE DEVICE
(DB37)
Tx-
Tx+
Rx-
Rx+
SIG
GND
4
22
6
24
19
Figure 15. connect TC1540 to RS-530 or RS-449 Devices
Rx
Tx
BERT
or
ASCII Terminal
All the SW to the left
RS-422
485/232
TC1540
IN-
IN+
OUT-
OUT+
Figure 16. Optic Loopback Bench Test Connection Diagram
- 17 -
Page 18
TC1540D User's Manual
TC1540
Local loopback
to/from TTL conversion
Connect TC1540 to RS-530 DTE device
SIG
GND
Connect TC1540 to RS-232 DTE device
SIG
GND
Connect TC1540 to RS-449 DTE device
SIG
GND
Rev. 1.2
Local Electrical Loopback Bench Test
Purpose:This test loops the incoming RS-232, RS-422 or RS-485 electrical signal back to the
output terminal blocks in order to verify the cable connections, the electrical interface
driver, signal polarity (for RS-422/RS-485) and the receiver's Integrated Circuitry.
Equipment
Requirements:One (1) Bit Error Rate Test (BERT) Set with appropriate interface module.
Procedure:Set up the bench test as shown in Figure 15. Set SW1 (LOCLB) to the Right position.
Connect a BERT tester to the IN(-) and IN(+) terminal blocks. Set the tester up as a
DTE device if RS-530 or RS-449 interface is used. "TD" and "RD" LEDs should light
on the TC1540, indicating the status of the looped signal. The BERT tester should
indicate a "SYNC" signal. This test should be performed on each individual unit in the
application.
RS-530
DTE DEVICE
(DB25)
RS-449
DTE DEVICE
(DB37)
Tx-
Tx+
Rx-
Rx+
SIG
GND
Tx+
Rx-
Rx+
SIG
GND
Tx-
TC1540
2
14
3
16
7
IN-
IN+
OUT-
OUT+
TC1540
4
22
6
24
19
IN-
IN+
OUT-
OUT+
RS-232
DTE DEVICE
(DB25)
Tx-
Rx-
SIG
GND
To BERT tester
2
3
7
RS-232,RS-422,RS-485
SW1 to right
TC1540
IN-
OUT-
Figure 17. Local Loopback Bench Test Connection Diagram
- 18 -
Page 19
TC1540D User's Manual
TC1540
TC1540
RxD
TxD
Set Sw5 to right
(Remote loopback)
Rev. 1.2
Remote Loopback Bench Test
Purpose:This test loops the composite optical & electrical signal at the remote unit back to the local
unit (via fiber) in order to test each unit's optic functions and LED indicators and to verify
the integrity of the fiber optic link.
Equipment
Requirements:One (1) Bit Error Rate Test (BERT) Set with appropriate interface module.
At least two (2) optical jumper cables (patch cords) with appropriate connectors.
Procedure:Set up the bench test as shown in Figure 16. On the remote unit, set SW2 (RMTLB)
to the Right position and connect a BERT tester to the local unit. Set the tester up as
a DTE device (refer Fig. 15 for DTE device connection). The "TD" and "xD" LEDs (on
both TC1540 units) should light, indicating the status of the looped signal. The BERT
tester should indicate a "SYNC" signal. This test can be performed from either (or both)
direction(s).
BERT
or
ASCII Terminal
Figure 18. Remote Loopback Bench Test Connection Diagram
Optic Cable
TxD
RxD
RS-232
Set SW3 to left
- 19 -
Page 20
Chapter 5 - Specifications
Data Rates
Async .................................................................................................. up to 500 Kbps**