Owner’s Manual ab ACE3600 RTU 6802979C35-A MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their respective owners.
COMPUTER SOFTWARE COPYRIGHTS The Motorola products described in this instruction manual may include copyrighted Motorola computer programs stored in semi conductor memories or other media. Laws in the United States and other countries preserve for Motorola certain exclusive rights for copyrighted computer programs including the exclusive right to copy or reproduce in any form the copyrighted computer program.
CONTENTS GLOSSARY ............................................................................................................................................................ III DESCRIPTION ..................................................................................................................................................... 1-1 PRODUCT OVERVIEW ...........................................................................................................................................
Contents GENERAL DESCRIPTION ........................................................................................................................................ 7-1 MODULE CONFIGURATION ................................................................................................................................... 7-2 MODULE STATUS AND DIAGNOSTICS ................................................................................................................... 7-4 MODULE BLOCK DIAGRAM ..............
Contents APPENDIX C: RS232/RS485 ADAPTOR CABLES ........................................................................................ C-1 GENERAL..............................................................................................................................................................
GLOSSARY ACE Advanced Control Equipment AI Analog Input AO Analog Output AWG American Wire Gauge DCD Data Carrier Detect DFM Direct Frequency Modulation DI Digital (Discrete) Input DNP Distributed Network Protocol DO Digital (Discrete) Output DPSK Differential Phase Shift Keying EPP Environmentally Preferred Product ESD Electrostatic Discharge EU European Union FCC Federal Communication Commission FEP Front End Processor (MCP-M, MCP-T, or FIU) FET Field Effect Transistor FPGA
Glossary MCP-M Motorola Communication Processor – MODBUS MDLC Motorola Data Link Communication MODBUS MODICON BUS Protocol MOSCAD Motorola SCADA MOSCAD-L Motorola SCADA-Light NEMA National Electrical Manufacturers Association (issues enclosure standards) NTP Network Time Protocol OPC Open Connectivity OVF Overflow PC Personal Computer PLC Programmable Logic Controller PPC Power PC PPH Pulse per Hour PPM Particle Per Million PPP Point-to-Point Protocol PPS Pulse per Second PS
Glossary TCP Transmission Control Protocol TDPSK Trunked Differential Phase Shift Keying TX Transmit UDF Underflow UDP User Datagram Protocol USB Universal Serial Bus WAN Wide Area Network WB Wire Break v
DESCRIPTION Product Overview The ACE3600 is a programmable Remote Terminal Unit (RTU). Almost any automation task can be implemented with a suitable choice of ACE3600 components. Typically the RTU monitors and controls local equipment and communicates with a control center and with other RTUs in the system. The ACE3600 is the newest Motorola SCADA (MOSCAD) RTU, a member of MOSCAD family of RTUs and Control Center Front End Processors.
Description The basic (default) model includes one power supply and one CPU module. The number of I/O modules is selected as an option of the base model. Figure 1-1 provides a general view of the ACE3600 RTU with five I/O modules.
Description • RS232 • RS485 • General radio interface (Conventional or Trunking, DPSK 1200, FSK 2400, DFM 4800, Duo-binary 9600) • Ethernet 10 Mb/s • Ethernet 10/100 Mb/s (on plug-in Port 1 only) ACE3600 RTU Construction The ACE3600 is available in various structures: • Frame which can accommodate a varied number and type of modules • Metal chassis which accommodates the frame, and optional radios, backup battery and communication interfaces • Protective housing which accommodates the frame,
Description RTU Options Each RTU can include a number of options, including portable and mobile radios, and plastic boxes with interface card for communication, etc. Housing/Mounting Type Capacity/Options No I/O slot frame Basic (default) model. Power supply and CPU Can be installed on a wall. 3 I/O slot frame Can be installed on a wall. Can be ordered with metal chassis or housing options. Power supply and CPU, up to 3 I/Os Can be ordered with metal chassis or housing.
Description Housing/Mounting Type Capacity/Options Large painted metal chassis Power supply and CPU, up to 7 I/Os, 1 plastic interface box, up to 2 mobile/portable radios, 6.5 or 10 Ah Lead-Acid backup battery Enables installation of radio, backup battery and other accessories. Can be installed on a wall or in housing. Small NEMA 4X/IP65 housing Enables installation of radio, backup battery and other accessories. Can be installed on a wall.
Description RTU Components The ACE3600 RTU can include the following components. Component Function Power supply module Converts the main AC or DC See Power Supply Module and Backup Battery chapter. power source to the voltages required by the modules, radio/modems and accessories. Charges the backup battery and switches to the battery voltage when the main power fails (in models with charger.
Description Component Function Notes Radio installation kit Mechanical support and cables that enable installation of radio. See Radio Types and Installation Kits chapter. RS485 Junction Box Enables connection of up to 5 devices to the RS485 port on the CPU (2W multi-drop). See Connecting Power and Ground in the Installation chapter. RTU to PC RS232 cable Enables connection of the RTU to a PC via the RS232 port.
INSTALLATION General The ACE3600 RTU is shipped from the factory with the modules and plug-in ports assembled. The RTU frame is ready for mounting directly on a wall or in a customer's enclosure. The eight I/O frame can be installed on a 19” rack. Modules can be added to the slots in a frame before or after mounting the RTU on a wall/enclosure. Installation of the ACE3600 should be done only by authorized and qualified service personnel in accordance with the US National Electrical Code.
Installation External wiring which connects an I/O module to instruments/devices may not exceed 42.67m (140 feet). If the ACE3600 is subject to high levels of shock or vibration, you must take suitable measures to reduce the acceleration or amplitude. We recommend that you install the ACE3600 on vibration-damping materials (for example, rubber-metal anti-vibration mountings). METAL PARTS OF THE POWER SUPPLY MAY BE VERY HOT.
Installation 117 234 82 209 124 244 124 199.6 0 I/O Frame 3 I/O Frame Figure 2-2. No I/O and 3 I/O Frame Installation Dimensions and Screw Holes for Installation 244 124 391 356.9 124 244 314 278.5 5 I/O Frame 7 I/O Large Frame Figure 2-3. 5 I/O and 7 I/O Frame Installation Dimensions and Screw Holes for Installation The following screw mount installation procedure should be used to install all ACE3600 frames (with or without a metal chassis) on a wall, except the 8 I/O (19”) frames.
Installation 6) Tighten all four screws with a screwdriver to secure the frame firmly against the wall. 7) Replace the removed modules in their slots. Installing the ACE3600 in a 19" Rack The following screw mount installation procedure should be used to install the ACE3600 8 I/O (19”) frame in a 19" rack. Note: The brackets for 19" rack installation are not provided with the RTU and should be ordered separately.
Installation Figure 2-5. Installation of ACE3600 RTU 19" Rack- Exploded View 6) From the standard rack unit, remove the two modules from the leftmost slots and the two modules from the rightmost slots. For the 19” accessories metal chassis, no accessories need to be removed. (See Figure 2-6.) 7) Using two supplied M5 (X6) screws and a 16 cm (6.3") long screwdriver, from inside the slot secure the 19" metal chassis to the small bracket. Repeat on the second side. See Figure 2-5.
Installation Portable Radio Plastic Boxes Mobile Radio Battery Figure 2-6 Installation of ACE3600 RTU 19" Rack Accessories - General View Mounting the ACE3600 8 I/O Frame on a Wall 453 93 128 450 Figure 2-7. RTU Metal Chassis Installation Dimensions Procedure 2-3 How to Mount the RTU 19" Metal Chassis on a Wall The following installation procedure should be used to install the 8 I/O (19”) frame on a wall, using the special wall mount brackets provided with the RTU.
Installation 4) Hang the metal chassis on brackets so that the 2 teeth of the metal chassis hook onto the groove of the brackets. (See Figure 2-8.) 5) Using two M4 screws (not supplied) with head size DIN 7981C/ST4, 2x38mm screws, secure the top and bottom of the rack to the left bracket. Repeat for the right bracket. Figure 2-8.
Installation 17.40º (44.2 cm) 20.86º (53.0 cm) 20.86º (53.0 cm) 17.40º (44.2 cm) Horizontal Bracket Installation Vertical Bracket Installation Figure 2-9. Large NEMA 4 Housing - Installation Dimensions 12.6º (32.0 cm) 16.2º (41.2 cm) 16.2º (41.2 cm) 12.6º (32.0 cm) Figure 2-10.
Installation MOUNTING BRACKET PRE±INSTALLED (WELDED) ON SOME HOUSING BRANDS Figure 2-11. Mounting the NEMA 4 Housing Connecting Power and Ground All internal electrical connections except for the main power, ground and battery are performed in the factory and supplied with the RTU. The electrical interconnection diagrams are provided in the Break-Fix Procedures chapter. The procedures for the main power, ground and battery connections are provided below.
Installation Make sure that the ground wire on the user cable is long enough to reach the grounding strip. Connecting AC/DC Main Power The power connection to all the ACE3600 power supply types is via the power junction box located on the frame beneath the power supply slot. Safety standards require that the power cable be attached to the unit at two anchor points: • Anchor point 1 for all units is inside the power junction box. (See Figure 2-12 below.
Installation Anchor Point 2 Clamp Figure 2-13. RTU on Metal Chassis – Cable Anchor Point 2 Procedure 2-5 How to Connect the RTU to Main Power Source (Units with Frames and Metal Chassis) 1) Using a screwdriver, open the power junction box cover (save the screws) and unscrew the power terminals screws inside the power junction box. 2) Thread the user's main power cable through the two supplied clamps. 3) Attach the wires of the user cable, according to the labels (~/0 for AC and +/- for DC.
Installation Cable to Power Supply Power Supply Cable Inlet User Power Cable Wire Terminals 0 ~ 0 ~ Anchor Point 1 Ground Cables Junction Box Figure 2-15. RTU Power and Ground Connections – All Other Installations 4) Pass the power cable to the right of the wire terminals inside the junction box, over the horizontal ridge. 5) Close the first clamp around the user cable and screw it onto the junction box, into the hole next to wire terminals (anchor point #1).
Installation Procedure 2-6 How to Connect the RTU to Main Power Source (Units with Housing) 1) Using a screwdriver, open the power junction box cover (save the screws) and unscrew the power terminals screws inside the power junction box. 2) Insert the rubber grommet (supplied) into the threaded plastic cable gland, and place it into the hole on the bottom of the housing (from the outside.) (See Figure 2-16.
Installation 10) Secure the junction box cover with the two saved screws. 11) For all installations except the No I/O frame, loosen two screws on the grounding strip at the bottom of the metal chassis/housing and connect the ground cable to the protective ground. Tighten the screws firmly. 12) Screw the top of the cable gland tightly to the cable gland to secure the cable (anchor point #2). 13) Open the door of the power supply module and release the cable holder (press downward).
Installation 2) Check the battery terminal voltage level before connecting it. If the battery voltage is less than 10V DC, DO NOT use the battery and replace it with a charged battery that measures at least 10V DC. 3) If the battery passes a visual inspection and the terminal voltage is correct, plug the battery cable (3089927V10) into the Battery In/Out connector on the power supply module. 4) Fully charge the battery prior to initial use (~10 hours).
POWER SUPPLY MODULE AND BACKUP BATTERY General Description/Module Overview The ACE3600 power supply module provides the other modules in the RTU with their operating voltages via the motherboard bus. The following power supply options are available: • DC power supply (10.
Power Supply Module and Backup Battery • Over-discharge protection • Battery test and diagnostics, including battery controlled discharge Figure 3-1 below depicts a general view of the power supply. AC-DC/DC-DC Converter (in AC or 18-72V DC PS only) P WR AUX1 AUX2 DO BATT ON OFF 1A AUX AUX 1B 2A AUX AUX 12V 2B _ DO k Ex Rac e Batt p ry p Tem er In Pow 2 18-7 VDC Figure 3-1 ACE3600 Power Supply – General View METAL PARTS OF THE POWER SUPPLY MAY BE VERY HOT.
Power Supply Module and Backup Battery Figure 3-2 below depicts a detailed view of the power supply front panel. PWR Indication LEDs AUX1 AUX2 DO BATT On/Off Switch Auxiliary Output 1A Auxiliary Output 1B Auxiliary Output 2A Auxiliary Output 2B 12V DO Control 12V Out (Reserved) Battery In/Out Temperature Sensor AC/DC Main Power Input Figure 3-2 ACE3600 Power Supply – Front Panel ON/OFF Switch The front panel of the power supply module includes an ON/OFF switch for the module.
Power Supply Module and Backup Battery Input/Output Connectors The front panel of the power supply module includes the following connectors. Connector Name Description Notes Auxiliary Output 1A 13.2V DC (±20%) User controlled power output. Short protected. This output is used for powering radios, modems, etc. The output can be switched ON/OFF either by user application program or by a using the STS hardware test.
Power Supply Module and Backup Battery Connector Name Description Notes 12V DO Control Control input that enables centralized disabling of Electrically Energized (EE)/ Magnetically Latched (ML) relay outputs in selectable DO modules. This input controls a dedicated 12V power line that is available to all the slots in the frame. In each relay DO module, the user can mechanically select to power the relay coils from this dedicated 12V power line. Input open = Relays are disabled.
Power Supply Module and Backup Battery LEDs The front panel of the power supply module includes five indication LEDs. LED Name Description Status PWR Power LED Indicates the existence of AC or DC main power in the Main Power input. When the ON/OFF switch is in ON position the LED is lit in Green. When the ON/OFF switch is in OFF position, but there is AC or DC input - the LED is lit in Red. When there is no AC or DC input - the LED is OFF.
Power Supply Module and Backup Battery Battery Charger Power supply modules with a battery option support a 6.5 or 10 Ah Lead-Acid battery. The power supply automatically switches to the backup battery as a 12V DC power source for the RTU and communications when the main AC or DC power source fails. Power supply modules with a 12 VDC smart battery charger option charge the backup battery when not in use, and protect the battery from over-discharge.
Power Supply Module and Backup Battery 3. If the battery temperature is outside the specified range (-30˚ to 60˚C), 4. If the battery is not fully loaded. Connecting the Power Supply to a Power Source The power supply can be connected to an AC or DC power source. For instructions on connecting the power supply to a power source, see the Power and Ground Connections section of the Installation chapter above. All power and ground connections must be in accordance with local standards and laws.
Power Supply Module and Backup Battery Power Supply Detailed Specifications Input voltage DC 10.5-16 V (Default) DC18-72 V DC (option V251) 18-72 V DC with 12V smart battery charger (option V367) 85-264 V AC , 50/60 Hz (option V346) 85-264 V AC, 50/60 Hz with 12V smart battery charger (option V261) Total Power Maximum 60 W continuous; maximum 105 W peak @ 25% duty cycle Outputs To motherboard (for CPU and I/O modules): 13.2 V DC ±20%, max. 8A AUX1A/AUX1B user connectors: 13.2V D ±20% C, max.
Power Supply Module and Backup Battery Backup Battery Overview The ACE3600 backup 12V Lead-Acid battery provides backup for the main input power. The battery is available in two capacities: 6.5 Ah and 10 Ah. Switching from main input power to the battery and charging of the battery is performed by the ACE3600 power supply module. Sealed Lead Acid technology batteries can be recharged and discharged at a temperature range of -40º to +70ºC.
Power Supply Module and Backup Battery Under various state or local laws, the batteries must be recycled or disposed of properly and cannot be disposed of in landfills or incinerators. Environmental protection regulations classify used Lead Acid batteries as hazardous waste, unless certain exemptions apply. Consideration should be given to the methods of collecting, labeling, handling and shipping used Lead Acid batteries.
Power Supply Module and Backup Battery Table 3-1: Recommended Time between Periodic Battery Recharge vs. Storage Temperature Average Storage Temp (°C) Recharge Interval (Months) 25 12 45 4 60 1 Replacing the Backup Battery A battery contains diluted sulfuric acid, a toxic and corrosive substance. Avoid any bodily contact with the leaking liquid when handling leaking batteries and affected parts.
Power Supply Module and Backup Battery 3) Remove the old battery from the RTU. 4) Check the replacement battery visually. If the battery looks deformed, if you notice corrosion on the battery terminals, or the battery leaks, DO NOT use the replacement battery; get another replacement battery. 5) Check the replacement battery terminal voltage level before connecting it. If the battery voltage is less than 10V DC, DO NOT use the battery and replace it.
CPU MODULE General Description The main element of the ACE3600 is the CPU module. It controls the I/O modules, processes the gathered data and communicates with the outside world. The core of the module is Freescale’s MPC8270 32-bit microprocessor which has extended communication capabilities, high speed core, DMA and floating point calculation support. The module includes on-board memory, communication ports, I/O bus interface and other circuits.
CPU Module Figure 4-2 provides a detailed view of the CPU front panel. PWR Pushbuttons ERR RST CPU Status LEDs APPL CONF USB 2.0 A/B (Models 3660 and Plug-in 1 * Serial 1 Serial 2 Ethernet 1 (Model 3640) Ethernet 2 (Models 3660 and a Plug-in 2 * USB 1.
CPU Module Buzzer The CPU module includes a buzzer (audio indication), which is used to indicate task completion (such as end of download/upload, restart etc.) and can also be controlled from the user application program. Pushbuttons The CPU includes two pushbuttons on the front panel, PB1 and PB2. These pushbuttons are used for activating and testing the modules LED, restarting the unit, erasing the user Flash memory and activating memory test. Table 4-2 describes the pushbuttons functionality.
CPU Module Table 4-1 ACE3600 CPU Memory Model 3610 Model 3640 Flash memory 16 Mb 16 Mb SDRAM memory: 32 Mb 32 Mb User FLASH: 3 Mb 3 Mb User SDRAM: 10 Mb 10 Mb SRAM Plug-In 4 Mb 4 Mb Real Time Clock (RTC) The CPU includes a low drift RTC. The date and time are retained using an on-board rechargeable lithium battery. The CPU date and time can be set using the ACE3600 STS. The CPU can also be synchronized with other RTUs in the system, using the system clock.
CPU Module Power-up and Restart The CPU requires DC voltage provided by the power supply module via the motherboard (when the PS switch is ON). The CPU will power-up and restart in the range of 10.5 to 16 V DC. During power-up, the processor performs fast memory tests, initiates the RTU and starts the user program (if it was downloaded). The end of power-up sequence is indicated by the buzzer.
CPU Module Figure 4-3 depicts a plug-in port board attached to the ACE3600 CPU module. Supporting Pins Plug-in 1 Supporting Pins Plug-in 2 Figure 4-3 Plug-In Port in CPU Module Procedure 4-1 describes how to connect a plug-in port to the CPU. Procedure 4-1 How to Connect a Plug-in Port to the CPU 1) Remove the CPU module from the RTU. 2) Remove the cover from the desired opening on the front panel. 3) Connect two supporting pins with screws to the plug-in port.
CPU Module Connecting SRAM Expansion Memory to the CPU Module *Future option* In general the plug-in SRAM is ordered as an option with the RTU and is installed in the factory. However, it is also possible to add plug-in SRAM to the CPU after it is shipped from the factory. Figure 4-4 depicts the user SRAM Plug-in memory in the ACE3600 CPU module. Figure 4-4 SRAM Expansion in CPU Module Procedure 4-3 describes how to connect a plug-in SRAM memory card to the CPU.
CPU Module Pushbutton Functionality The table below describes the use of the two pushbuttons in various scenarios, during power-up and run-time. Table 4-2 ACE3600 Pushbutton Functionality Scenario Trigger Action LEDs Test During run-time, press PB1 for five consecutive seconds. All the LEDS on the CPU and I/O modules will be lit for up to 20 seconds and then returned to their previous states. RTU Restart During run-time, press PB1 for 30 consecutive seconds. All the LEDs will be lit.
CPU Module Scenario Trigger Action RAM Test During startup, press PB1. A detailed memory test of SDRAM and SRAM plug-in is performed. - At the beginning of the RAM test, the four Ethernet LEDs (see left) will blink three times. During the RAM test, the LEDs will be lit. If the RAM test succeeds, the four LEDs will blink three times and turn off and the restart sequence will continue.
CPU Module CPU LEDs Behavior The table below describes the behavior of the LEDs on the CPU module. Table 4-3 ACE3600 CPU LEDs Behavior LED Name Description Status PWR Power LED Flashing Red – Power exists; power-up in progress. Bicolor LED (Red, Green) Green – Power exists; power-up completed. Red – Failure on power-up. (AC fail, Bat Error, etc.) Orange - Battery test in progress. ERR Error Logger Status LED OFF – No new errors or warnings. Bicolor LED (Red, Green) Green – New message logged.
CPU Module LED Name Description Status SI1 RX Serial Port 1 – RX (receive) ON – Receiving Data Green LED SI1 CM Serial Port 1 – CM (channel monitor) ON – Channel Monitor is ON.
CPU Module CPU 3610/CPU 3640 Module Specifications Microprocessor Freescale – Power PC II MPC8720, 32-bit, extended communication capability, DMA and floating point calculation support Microprocessor Clock 200 MHz User Memory FLASH: 3 MB DRAM: 10MB Optional plug-in SRAM: 4 MB Real-Time Clock Full calendar with leap year support (year, month, day, hours, minutes, seconds, milliseconds). Time drift: max. 2.
I/O MODULES General Description The ACE3600 RTU can include up to eight I/O modules, depending on the frame size. A variety of I/O modules are available. The I/O modules can be positioned in the slots to the right of the CPU. As with all ACE3600 modules, the I/O modules can be replaced while the power is on (hot swap.) Figure 5-1 provides a general view of an ACE3600 I/O module.
I/O Modules ERR ERR 1 UF 1 UF OF OF 2 UF 2 UF OF OF 3 UF 3 UF OF OF 4 UF 4 UF OF OF 5 UF 5 UF OF OF 6 UF 6 UF OF OF 7 UF 7 UF OF OF 8 UF 8 UF OF OF 24V 24V 9 UF OF 10 UF OF 11 UF OF 12 UF OF 13 UF OF 14 UF OF 15 UF OF 16 UF OF 24V Figure 5-2 ACE3600 I/O Module – Front Panel (without TB Holder) I/O Module LEDs The ERR LED indicates an I/O module fault and errors. It will remain lit until all the errors have been eliminated.
I/O Modules TB Holder and Cables The TB holder secures the male TBs neatly in place and forms a single connector plug per module. The wires connected to the TBs are concealed in the holder. The module and the TB holder provide a coding mechanism to prevent cabling errors. Extractor handles enable easy release of the TB holder connector from the module. An optional three-meter cable braid, completely wired with holder and cable, is available. A TB holder kit is available to enable self-assembly of cables.
I/O Modules Figure 5-4 provides an exploded view of the TB holder assembly. Figure 5-4 Terminal Block (TB) Holder Assembly – Exploded View with Coding Attaching the TB Holder Clip to the I/O Module An optional TB holder clip can be added to the I/O module to secure the cable. Procedure 5-2 Attaching the TB Holder Clip to the I/O Module 1) Remove the I/O module from the ACE3600 RTU. 2) Using the supplied screw, attach the TB holder clip to the bottom of the I/O module.
I/O Modules 3) Replace the I/O module in the RTU slot. I/O Module TB Holder Clip Screw TB Holder Clip Cable Pipe Figure 5-5 I/O Module with Terminal Block (TB) Holder Clip Connecting the TB Holder to the I/O Module Procedure 5-3 Connecting the TB Holder to the I/O Module 1) Open the door of the I/O module. 2) On the TB holder, loosen the screw and turn the positioner so that the arrow points to either A or B. 3) Tighten the screw. 4) With a screw driver, set the code key pin to a number from 1 to 6.
I/O Modules Figure 5-6 provides a general view of the TB holder and an I/O module. TB Holder Extractor Handles I/O Module Terminal Blocks (TB) Terminal Block (TB) Terminal Block (TB) Positioner Positioner Screw OF 16 UF OF 24V Code Key Code Key TB Holder I/O Module Figure 5-6 Terminal Block (TB) Holder on I/O Module – General View with Coding User Label Each I/O module is provided with a blank label on the module door for user notes.
I/O Modules 24V DC Floating Plug-In Power Supply *Future option* Up to two 24V DC floating plug-in power supplies can be added to certain I/O modules, as detailed in the table below. Table 5-1 Number of Plug-In Power Supplies in ACE3600 I/O Modules Module Type Number of Power Supplies 32 DI 2 16 DI 1 16 AI 1 8 AI 1 Mixed I/O 1 The plug-in power supply is ordered separately.
I/O Modules Spacers ERR 1 UF OF 2 UF OF Optional 24V Floating Power Supply Plug-In 3 UF OF 4 UF OF 5 UF OF 6 UF Motherboard Location PIN OF 7 UF OF 8 UF OF 24V 9 UF Motherboard Connector OF 10 UF OF 11 UF OF 12 UF OF 13 UF OF 14 UF OF 15 UF OF 16 UF OF 24V Figure 5-7 ACE3600 I/O Module – General View 5-8
DIGITAL INPUT MODULE General Description The ACE3600 Digital Input (DI) module can have 16 or 32 inputs. The following DI modules are available. • 16 DI Fast 24V • 32 DI Fast 24V • 16 DI Fast 24V IEC TYPE 2 • 32 DI Fast 24V IEC TYPE 2 Two types of voltage (“wet”) inputs are supported, IEC 61131-2 Type II compliant inputs and 24V “MOSCAD compatible” inputs. In the 32 DI module, the first 20 inputs can function as fast counters. In the 16 DI module, all inputs can function as fast counters.
Digital Input Module 16 DI Module 32 DI Module Figure 6-1 ACE3600 DI Module – General View Figure 6-2 provides a detailed view of the ACE3600 DI module front panel.
Digital Input Module 16 DI Module 32 DI Module Figure 6-2 ACE3600 DI Module – Front Panel DI Module Configuration The 16 DI Fast 24V and 32 DI Fast 24V modules can handle AC and DC input signals. The user can select DC or AC operation per module. When AC configuration is selected, the Fast Capture, Counter Function and Input Filters (see below) are disabled. Fast Capture (DC Configuration) When the DI module is in DC mode, each DI can be configured as a Fast Capture DI.
Digital Input Module Keep Last Value (KLV) and Predefined Value (PDV) Each input can be configured to KLV or to a PDV (0, 1). This value is shown to the user application program in the event of DI module failure. The PDV can also be used during normal operation to force a value that masks the actual input value. In this case the user program will get the PDV instead of the actual input value. DI Module Configuration Options The DI module features which can be configured are listed in the table below.
Digital Input Module Module Status and Diagnostics In the event of DI Module failure, the I/O module ERR LED will be lit. This event is registered by the CPU in the Error Logger. DI Module failure status is also visible to the user application program. The DI module can be diagnosed and monitored using the STS Hardware Test utility. This test verifies that the module is operational, presents the module configuration and shows the actual value of each input.
Digital Input Module Module Block Diagram 16 DI 6-6
Digital Input Module 32 DI 6-7
Digital Input Module DI Module Specifications 16/32 DI FAST 24V Module Total Number of Inputs 16 DI (Option V265); 32 DI (Option V379) Input Arrangement Isolated groups of 16 inputs with shared common Fast Counter Inputs Inputs that can be used as fast counter: - All inputs in 16 DI module; - First 20 inputs in 32 DI module AC Input Frequency 45 – 65 Hz AC Input Delay Maximum 0.2 mS Fast Counter Input Frequency 0 - 12.5 KHz, minimum pulse width 40 µS Max. DC Input Voltage Max.
Digital Input Module 16/32 DI FAST 24V IEC 61131-2 TYPE II Module Total Number of Inputs 16 DI (Option V117) 32 DI (Option V959) Input Arrangement Isolated groups of 16 inputs with shared common Fast Counter Inputs Inputs that can be used as fast counter: - All inputs in 16 DI module - First 20 inputs in 32 DI module Fast Counter Input Frequency 0 - 10 KHz, minimum pulse width 40 µS Max. DC Input Voltage Max.
DIGITAL OUTPUT/DIGITAL INPUT FET MODULE General Description The Digital Output/Digital Input (DO/DI) FET module has 16 or 32 configurable user connections, organized in four groups. Each group can be configured as an 8 DO group or as an 8 DI group. The following Digital Output/Digital Input (DO/DI) FET modules are available. • 16 (DO/DI) FET • 32 (DO/DI) FET The outputs are optically isolated current sink FET type with back indication.
Digital Output/Digital Input FET Module Figure 7-2 provides a detailed view of the ACE3600 DO/DI FET module front panel. 16 DO/DI FET Module 32 DO/DI FET Module Figure 7-2 ACE3600 DO/DI FET Module – Front Panel Module Configuration Input/Output The following combinations can be configured in the STS site configuration (16 DO/DI).
Digital Output/Digital Input FET Module The appropriate combination is selected as the I/O module type, when configuring the I/Os in the ACE3600 STS site configuration. DI Fast Capture Each DI can be configured as Fast Capture DI in the STS advanced I/O configuration. Fast capture causes the SCAN ladder output operation to get the first change that occurred since the previous scan.
Digital Output/Digital Input FET Module Table 7-1 ACE3600 DO/DI FET Module Configurable Features Parameter Selection Default Setup Per Module/ Input Parameter Setup Location DI Fast Capture Disabled /Enabled Disabled Input RTU configuration DI Filter 0-254 (x 0.2 mS) 50 (10 mS) Module RTU configuration; ‘C’ Program DI Counter Filter 0-255 (x 0.
Digital Output/Digital Input FET Module shows the actual value of each input and output. It is also possible to change the input filter setup for the duration of the Hardware test and change the value of the DOs. In the Hardware Test utility, it is possible to set the module to Freeze Mode. In this mode the user application program will get the KLV/PDV of each input in the module instead of the actual input value. The DO values will keep the last value they had when the module was switched to Freeze Mode.
Digital Output/Digital Input FET Module 32 DO/DI FET 7-6
Digital Output/Digital Input FET Module DO/DI FET Module Specifications Total Number of I/Os 16 (Option V480); 32 (Option V481) I/O Arrangement Two or four group of 8 I/Os with shared common Each group can be configured as FET DO or dry contact DI Selectable combinations (32 DO/DI): 32 DO/8 DI+24 DO/ 16 DI+16 DO/24 DI+8 DO/32 DI Selectable combinations (16 DO/DI): 16 DO/8 DI+8 DO/16 DI+16 DI Counter Inputs 20 first inputs can be used as counter inputs Counter Input Frequency 0 - 1 KHz, minimum pulse
DIGITAL OUTPUT RELAY MODULE General Description The DO Relay modules have 8 or 16 outputs. There are two types of DO relays: • Electrically Energized (EE) - the outputs return to the non-energized state in case of power off or module failure. • Magnetically Latched (ML) - Relay outputs are magnetically latched, the outputs maintain their state in case of power off or module failure.
Digital Output Relay Module 8DO Relay 16 DO Relay Figure 8-1 ACE3600 DO Relay Module – General View Figure 8-2 provides a detailed view of the ACE3600 DO Relay Module front panel.
Digital Output Relay Module In the 8 DO modules, the relays of outputs 1 through 5 are Single Pole Single Throw (SPST) normally open (NO) and are referred to as the “Form A” relays. The relays of outputs 6 through 8 are Single Pole Double Throw (SPDT) and are referred to as the “Form C” relays. In the 16 DO modules, the relays of outputs 1 through 5 and 9 through 13 are Single Pole Single Throw (SPST) normally open (NO) “Form A” relays.
Digital Output Relay Module A dual selector dipswitch (S3) on the DO Relay module has 4 selectable positions as described in the following table: Table 8-1 DO Relay Module- Dipswitch Settings S3 SW 1 S3 SW 2 Configuration mode O (OFF) N (OFF) 12V_DO – Relay inhibiting enabled 1 (ON) N (OFF) Software selectable – inhibiting is set in site configuration O (OFF) 2 (ON) 12_DO– Relay inhibiting enabled 1 (ON) 2 (ON) 12 V – (factory default) Relay inhibiting disabled 1 O 2 N Figure 8-3 12V DO
Digital Output Relay Module Reset DO at Startup It is possible to configure the module to reset all the ML relays positions on startup. This is set in the STS site configuration.
Digital Output Relay Module Module Block Diagram 8 DO 8-6
Digital Output Relay Module 16 DO 8-7
Digital Output Relay Module DO Relay Module Specifications Total Number of Outputs 8 EE relay outputs (Option V508) 16 EE relay outputs (Option V616) 8 ML relay outputs (Option V314) 16 ML relay outputs (Option V516) Output Arrangement 8 DO : 3 X Form C (SPDT) and 5 X Form A (SPST) 16 DO: 6 X Form C (SPDT) and 10 X Form A (SPST) Contact Voltage Ratings Max. 60 V DC or 30 V AC RMS (42.4 V peak). Contact Power Ratings 2A @ 30 V DC, 0.6A @ 60V DC or 0.
ANALOG INPUT MODULE General Description The Analog Input (AI) modules have 8 or 16 inputs. The modules sample and convert analog data into digital format and transfer the digital data to the CPU module. The following modules are available: • 8 AI, ±20 mA (supports 4-20 mA) • 16 AI, ±20 mA (supports 4-20 mA) • 8 AI, ±5 V (supports 0-5 V and 1-5 V) • 16 AI, ±5 V (supports 0-5 V and 1-5 V) The module’s analog-to-digital conversion resolution is 16 bit (including sign).
Analog Input Module Figure 9-1 provides a general view of the ACE3600 AI module.
Analog Input Module Figure 9-2 provides a detailed view of the AI module front panel.
Analog Input Module In the current input modules, the ranges that can be selected are: ±20 mA (default) and 4-20 mA. In voltage input modules, the ranges that can be selected are ± 5V (default), 0-5 V and 1-5 V. Keep Last Value (KLV) and Predefined Value (PDV) Each input can be configured to KLV or to a PDV. This value is shown to the user application program in the event of AI module failure. The predefined value can also be used during normal operation to force a value that masks the actual input value.
Analog Input Module Module Status and Diagnostics In the event of AI Module failure, the I/O module ERR LED will be lit. The event is registered by the CPU in the Error Logger. AI Module failure status is also visible to the user application program. In addition to the ERR LED, the module includes an Underflow (UDF) and Overflow (OVF) LED for each input. • When the UDF LED is lit, it indicates that the signal level in the corresponding input is below the nominal range.
Analog Input Module In 4 - 20 mA current inputs In ± 5 V current inputs In 0 - 5 V current inputs In 1 - 5 V current inputs Decimal Value Input Current Indication < 6144 < 3.84 mA Underflow LED ON 6400 +4 mA 0 0 mA 32000 +20 mA > 32256 > +20.16 mA Decimal Value Input Voltage < -32256 <-5.04V -32000 -5 V 0 0V 32000 +5 V > 32256 > +5.04 V Decimal Value Input Voltage < -256 < -0.04 V 0 0V 32000 +5 V > 32256 > +5.04 V Decimal Value Input Voltage < 6144 < 0.
Analog Input Module Module Block Diagram 8 AI 9-7
Analog Input Module 16 AI 9-8
Analog Input Module AI Module Specifications Total Number of Inputs 8 AI ±20 mA (4-20 mA) (Option V318) 16 AI ±20 mA (4-20 mA) (Option V463) 8 AI ±5 V (0-5 V, 1-5 V) (Option V742) 16 AI ±5 V (0-5 V, 1-5 V) (Option V743) Input configuration Isolated (floating) analog inputs A to D Resolution 16 bit (including sign) Input Accuracy ±0.1% full scale @ -40ºC to +70ºC Input sampling time 10 mSec @ 50 Hz filtering 8.
MIXED I/O MODULE General Description The ACE3600 Mixed I/O modules include a mixture of Digital Inputs, Relay Outputs and Analog Inputs on the same module. The available Mixed I/O modules are: • 16 Digital Inputs + 4 EE DO Relay Outputs + 4 Analog Inputs ( ±20 mA) • 16 Digital Inputs + 4 ML DO Relay Outputs + 4 Analog Inputs ( ±20 mA) Figure 10-1 provides a general view of the ACE3600 Mixed I/O module.
Mixed I/O Module Figure 10-2 provides a detailed view of the Mixed I/O module front panel. ERR D I D O AI 1 UF OF 2 UF OF 3 UF OF 4 UF OF Figure 10-2 ACE3600 Mixed I/O Module – Front Panel The Digital Input (DIs) on the Mixed I/O modules are voltage (“wet”) inputs IEC 61131-2 Type II compliant. All DIs can function as fast counters. All DIs are optically isolated. Each DI can be an event trigger (by interrupt) to a high priority fast process.
Mixed I/O Module The Mixed I/O modules Analog-to-Digital conversion resolution is 16 Bit (including sign). Each input is fully isolated from the other inputs on the module and also optically isolated from the module internal circuits. The modules are fully calibrated. It is possible to test and recalibrate the module in the field. The measured values are digitally filtered to reduce the 50 or 60 Hz noise. The user can select the filtering frequency per module.
Mixed I/O Module Module Status and Diagnostics In the event of Mixed I/O Module failure, the ERR LED will be lit. This event is registered by the CPU in the Error Logger. DI Module failure status is also visible to the user application program. The Mixed I/O module can be diagnosed and monitored using the STS Hardware Test utility. For Hardware Test of the DIs, refer to the DI Module chapter. For Hardware Test of the DOs, refer to the DO/DI FET Module or DO Relay Module chapter.
Mixed I/O Module Module Block Diagram Mixed I/O 10-5
Mixed I/O Module Mixed I/O Module Specifications Total Number of Inputs / Outputs 16 Digital Inputs + 4 EE Relay Outputs + 4 Analog Inputs ( ±20 mA) (Option V245) 16 Digital Inputs + 4 ML Relay Outputs + 4 Analog Inputs ( ±20 mA) (Option V453) I/O Arrangement 1 group of 16 DIs with shared common 4 relay outputs - Form C 4 isolated analog inputs DI Counter Inputs All inputs can be configured as fast counter DI Frequency 0 - 1 KHz DI Fast Counter Frequency 0 - 5 KHz DI Max. DC Voltage Max.
Mixed I/O Module Diagnostics LEDs LED per each DO and DI. Overflow and Underflow LED per each AI. AI Overflow and Underflow levels can be configured to: Current inputs: ±20mA / 4-20 mA Voltage inputs: ±5 V / 0-5 V /1-5 V 24 V DC output Supports one isolated 24V / 0.35 A plug-in “wetting” power supply User Connection 4 Terminal Blocks (3.
RADIO TYPES AND INSTALLATION KITS ACE3600 Radio Types In order to prevent overheating of the radio and and degradation of radio performance, the radio should not exceed operating duty factors of 30% transmission and 70% receive mode. The ACE3600 RTU supports conventional, analog trunked radios and digital trunked radios. It also supports data radios and various wireless modems. Conventional and analog trunked radios are connected to a plug-in radio modem port.
Radio Types and Installation Kits Trunked VHF Radio ACE3600 with XTL5000 136-174 MHz Analog F7523A ACE3600 with XTL5000 136-174 MHz Digital F7513A Trunked UHF Radio ACE3600 with XTL5000 380-520 MHz Analog F7524A ACE3600 with XTL5000 380-520 MHz Digital F7514A Trunked 800MHz Radio ACE3600 with XTL5000 800MHz Analog F7585A ACE3600 with XTL5000 800MHz Digital F7586A For a list of the radio models and regional options for the CM/EM/GM radios, see CM/EM/GM Radio Models and Regional Options for AC
Radio Types and Installation Kits XTL5000 Radio Installation Kit The XTL5000 radio installation kit (ACE3600 option V681AT or V157AB) enables the user to install the XTL5000 radio in ACE3600 Remote Terminal Units (RTU). The ACE3600 can use the XTL5000 in two operation modes, depending on the system used. • Digital mode (ACE3600 option V681AT) - suitable for Astro 6.x system trunked ASTRO IV&D only • Analog mode (ACE3600 option V157AB) - suitable for SmartNet 3.x system or Astro 4.
Radio Types and Installation Kits analog mode only the plug-in ports may be used. See RTU Port Configuration for the Astro IV&D Digital Radio and RTU Port Configuration for the Astro IV&D Analog Trunked Radio below. 4. Connect the DC power cable (FKN8436A) to the Power connector on the radio and the free red wire to the ignition pin on the FKN8432A/FKN8438A cable. Connect the opposite side of the power cable to the AUX2A or AUX2B connector on the ACE3600 power supply unit.
Radio Types and Installation Kits Radio Antenna Radio Power Connector Connector Radio Accessory Connector Antenna Cable (FKN8437A) Power Cable (FKN8436A) Signal Cable (FKN8432A/ FKN8438A) Figure 11-2 XTL5000 Radio Cable Connections- Rear View 5. Mount the bracket on the RTU chassis above the CPU and I/O modules, using the four built-in screws. (See Figure 11-4.) The wider side of the bracket is attached to the chassis. 6. Connect the antenna cable (FKN8437A) to the Antenna connector on the XTL5000.
Radio Types and Installation Kits Radio Radio Bracket (#0789422V41) Radio Mounting Screws (#0310906A67) Power Cable (FKN8436A) Radio Antenna Cable (FKN8437A) Signal Cable (FKN8432A/ FKN8438A) Power Supply CPU Antenna Cable N-Type Connector Figure 11-4 XTL5000 Radio Installed on ACE3600 Chassis RTU Port Configuration for the Astro IV&D Digital Radio To enable MDLC communication using Astro XTL5000 radios, use the ACE3600 STS site configuration utility to configure the ACE3600 RTU plug-in port con
Radio Types and Installation Kits Port Type (for Astro IV&D Digital Radio) Procedure 11-2 How to Configure the ACE3600 Port for the Astro IV&D Digital Radio 1. In the ACE3600 STS click on the desired site, and open the site view. 2. In the Port Tab, click on the on-board or plug-in port through which the RTU will communicate with the XTL5000 radio. 3. Confirm that the port parameters and data speed are as shown in the screen below. 4. Define desired links. 5.
Radio Types and Installation Kits Generally no other changes are required to Advanced Physical or Link Layer parameters. For information on these parameters, see the MDLC over IP chapter of the ACE3600 STS Advanced Features manual. Procedure 11-3 How to Configure the Advanced Parameters of the ACE3600 Port for the Astro IV&D Digital Radio 1. (ASTRO System 6.3-6.5 only) Make sure that the Advanced Link parameter Registration life time to 28800 seconds (default) in order to restart the radio periodically.
Radio Types and Installation Kits Radio Connections To program the XTL5000 radio with Customer Programming Software (CPS), the radio must be connected to a PC. Procedure 11-4 How to Connect the XTL5000 Radio to the CPS 1. Connect one side of the programming cable (HKN6155) to the microphone connector on the front of the radio. This cable is not supplied and must be ordered separately. 2. Connect the other side to the serial port of a PC on which the ASTRO CPS software (RVN4185) is installed.
Radio Types and Installation Kits 3) Change TX Power Level High for Freq. Range B from 38.5 to 15. 3. b. In the General tab, set the Out of Range Indicator and Imbalanced Coverage Indicator to Alert & Display. c. (Recommended) In the Data tab, enable SNMP Traps. (You can disable it, but the RTU will only detect a loss of context activation the next time it polls the radio (every 10 seconds by default). d. (Optional) Specify the Mobile Computer IP address.
Radio Types and Installation Kits 6. b. In the 700/800 Failsoft tab, data only subscribers should set Failsoft Type to disabled. (There is no data service unless the subscriber is affiliated to a widearea trunking site.) c. In the Talkgroup tab, set the radio talkgroup value in hexadecimal. Consult your radio system administrator for the talkgroup information. d. (Recommended) In the Preferred Sites tab, set the status of the first record to None.
Radio Types and Installation Kits 2. In the Port Tab, click on the plug-in port through which the RTU will communicate with the XTL5000 radio. 3. Set the port parameters as shown in the screen below. The Trunk system parameter should reflect the type of trunking system (e.g. SmartNet, SmartZone.) 4. Save the changes.
Radio Types and Installation Kits a. Click on Control Head. b. Make sure that the control head is W4. c. Click on Radio VIP. 1) Set VIP In for VIP 1, VIP 2, and VIP 3 to Blank. 2) Set VIP Out for VIP 1 to MOSCAD CG. 3) Set VIP Out for VIP 2 to MOSCAD TXE/CM. 4) Set VIP Out for VIP 3 to NULL. 4. 5. 6. Double-click on Conventional ->Conventional Personality -> Conventional Personality 1. a. In the Rx Options tab, set Unmute/Mute Type to UnMute, Or Mute. b. Set Rx Voice/Signal Type to Non-Astro.
Radio Types and Installation Kits Time Out Timer is set to 3 (for 60 sec). Check that the Type II Individual ID is set to the value obtained from the radio system administrator for the site. b. In the Talkgroup tab, set the radio talkgroup value in hexadecimal. Consult your radio system administrator for the talkgroup information. (Note: Talkgroup for voice in analog trunking is the same for voice and data on analog trunk. 7. From the File Menu, select Save to save changes to the radio. 8.
Radio Types and Installation Kits CDM750 Radio Installation Kit The CDM750 radio installation kit (ACE3600 option V143AH/kit FLN3638A) enables the user to install the CDM750 radio series in ACE3600 Remote Terminal Units (RTU). The FLN3638A installation kit includes a bracket, adapter, and cables. Installation The CDM750 radio can be mounted on the ACE3600 RTU as follows: Procedure 11-9 How to Install the CDM750 Radio on the Metal Chassis 1.
Radio Types and Installation Kits 4. Connect the antenna cable (FKN8437A) to the Antenna connector on the radio and to the opening on the bottom of the ACE3600 RTU housing, using the four supplied screws. See Figure 11-8 and Figure 11-10.) 5. Attach the radio to the bracket (0789422V45 from FHN6898A) by using screws and washers from kit FHN6898A. See Figure 11-9 below. Radio Bracket, Screws and Washers (FHN6898A) CDM750 Radio Figure 11-9 CDM750 Radio and Metal Bracket 6.
Radio Types and Installation Kits Communicatio n Cable (FKN8427A) Radio Adapter (FLN3639A) Radio Mounting Screws (#0387839V89) and Washers Radio Bracket (FHN6898A) Power Cable (FKN8436A) Power Supply Radio CPU Antenna Cable N-Type Connector Antenna Cable (FKN8437A) Figure 11-10 CDM750 Radio Installed on ACE3600 Chassis 11-17
Radio Types and Installation Kits RTU Port Configuration for the CDM750 Radio To enable MDLC communication using CDM750 radios, use the ACE3600 STS site configuration utility to configure the ACE3600 RTU plug-in port connected to the radio. The following figures show the port configuration and advanced parameter configuration. Although these show Port PI1, the same values can be applied to port PI2 as well, where relevant.
Radio Types and Installation Kits Radio Disassembly If the CDM750 radio is to be programmed outside of the ACE3600 housing, disassemble the radio as follows: Procedure 11-12 How to Disassemble the CDM750 Radio from the ACE3600 Metal Chassis 1. Disconnect the antenna cable (FKN8437A) to the radio Antenna connector. 2. Remove the radio/bracket unit from the RTU chassis by unscrewing the four built-in screws. 3. Disconnect the DC power cable (FKN8436A) from the radio Power connector. 4.
Radio Types and Installation Kits Figure 11-12 Radio Configuration- Basic Settings Figure 11-16 Radio Configuration- Tx Power 11-20
Radio Types and Installation Kits Figure 11-13 Radio Configuration - Accessory Connector Configuration Figure 11-14 Radio Configuration - Accessory Pins Definition 11-21
Radio Types and Installation Kits Figure 11-15 Conventional Buttons Configuration – Mobile Key Buttons Figure 11-16 Conventional Buttons Configuration – Programmable Buttons 11-22
Radio Types and Installation Kits Figure 11-17 Conventional Personality Configuration – Basic Settings Figure 11-18 Conventional Personality Configuration – Options 11-23
Radio Types and Installation Kits Figure 11-19 Conventional Personality Configuration – Advanced Settings Figure 11-20 Radio Channel Assignment - Personality Assignment to Zone 11-24
Radio Types and Installation Kits GP/HT/PRO Radio Installation Kit The GP/HT/PRO Radio Installation Kit for ACE3600 (V154AE, FLN3637A) enables the user to install the GP320/GP328/HT750/PRO5150 portable radios in ACE3600 Remote Terminal Units (RTU). Each kit includes a bracket, radio interface, adapters, and cables. Volume Knob Retainer The volume knob retainer sets a fixed position for the volume knob on the GP/HT/PRO radios, for optimal operation in an ACE3600 RTU installation.
Radio Types and Installation Kits Metal Volume Rod GP/HT/PRO Radio Body Volume Knob Retainer (Motorola P/N 0787502V66) Figure 11-23 Attach Retainer to Radio Installation The GP/HT/PRO radio can be mounted on the ACE3600 RTU as follows: 1. Attach the radio plug-in port from the installation kit (FLN3696A) to the desired opening on the ACE3600 CPU module. For instructions on attaching plug-in ports, see Connecting Plug-In Ports to the CPU Module in the CPU Module chapter above. 2.
Radio Types and Installation Kits 3 Fit radio into adapter base and press radio to adapter. 2 4 1 5 Figure 11-24 GP/HT/PRO Radio Installation 7. Using the two screws, attach the radio assembly to the radio bracket (FHN6899A). 8. Using the three screws on the bracket, attach the bracket with the radio to the chassis of the ACE3600. (See Figure 11-25.) 9.
Radio Types and Installation Kits Power Cable (FKN8433A) Radio Radio Bracket (FHN6899A) Signal Cable (FKN8431) Antenna Cable (FKN8434A) Power Supply CPU Antenna Cable N-Type Connector Figure 11-25 GP/HT/PRO Radio Installed on ACE3600 Chassis RTU Port Configuration for the GP320/GP328/HT750/PRO5150 Radio To enable MDLC communication using GP320/GP328/HT750/PRO5150 radios, use the ACE3600 STS site configuration utility to configure the ACE3600 RTU plug-in port connected to the radio.
Radio Types and Installation Kits 4. Define desired radio links and zones if necessary. 5. Save the changes. Generally no other changes are required to Advanced Physical or Link Layer parameters.
Radio Types and Installation Kits CM/EM/GM Radio Installation Kit The CM/EM/GM Installation Kit for ACE3600 (V148AC/FLN3635A) enables the user to install the CM/EM/GM mobile radio (CM200, CM140, EM200, GM3188) in ACE3600 Remote Terminal Units (RTU). Each kit includes a bracket, adapter, and cables. Installation The CM/EM/GM can be mounted on the ACE3600 RTU as follows: Procedure 11-16 How to Install the CM/EM/GM Radio on the Metal Chassis 1.
Radio Types and Installation Kits Radio Adapter Communication Cable (FKN8427A) Power Connector Power Cable (FKN8428A) Radio Antenna Connector Antenna Cable (FKN8429A/ * FKN8430A ) Figure 11-28 CM/EM/GM Radio Cable Connections 4. Connect the communication cable (FKN8427A) to the back of the radio adapter (FLN3636A) connector (10-pin RJ45 connector). (See Figure 11-28.
Radio Types and Installation Kits Communication Cable (FKN8427A) Radio Adapter (FLN3636A) Radio Mounting Screws (#0387839V89) Metal Bracket (FHN6894A) CM/EM/GM Radio Power Cable (FKN8428A) Power Supply CPU Antenna Cable (FKN8429A/FKN8430A) Figure 11-29 CM/EM/GM Radio Installed on ACE3600 Chassis RTU Port Configuration for the CM/EM/GM Radio To enable MDLC communication using CM/EM/GM radios, use the ACE3600 STS site configuration utility to configure the ACE3600 RTU plug-in port connected to the
Radio Types and Installation Kits Radio Information The picture below shows the radio model information screen in the CPS. Figure 11-30 CM/EM/GM CPS Radio Information Screen Radio Power Settings The picture below shows the TX power setting (1-25 W) in CPS.
Radio Types and Installation Kits Radio Accessory Connector Pins Definition The picture below shows the setting of the radio’s accessories pins required for interfacing with the ACE3600.
Radio Types and Installation Kits Frequency and Bandwidth Settings The picture below shows the setting of the radio’s frequency, bandwidth and power level. Figure 11-33 CM/EM/GM CPS Radio Personality Tx/Rx Screen Note: The Power Level should be set according to the power output.
Radio Types and Installation Kits CM/EM/GM Radio Models and Regional Options for ACE3600 The CM/EM/GM models of the ACE3600 RTU, F7573A (VHF) and F7574A (UHF) include the following regional options: Option Region Radio V851 North America (NA) CM200, 1-25W V852 EMEA* CM140, 1-25W V853 Asia* GM3188, 1-25W V854 Latin America (LA) EM200, 1-25W V148AC CM/EM/GM INSTALL KIT FLN3635A CM/EM/GM INSTALL KIT Note: 1. When ordering an ACE3600 model with a CM/EM/GM radio, a V95x option must be added.
Radio Types and Installation Kits Mounting the ACE3600 Radios on a Wall ACE3600 radios can be mounted on a wall near the ACE3600 frame/housing, using a special metal bracket. 223 145 80 182.5 75 75 179.8 80 P/N:0789422V45 REV:A CM/EM/GM/CDM750 Bracket P/N:0789422V41B XTL5000 Bracket 74 GP/HT/PRO Bracket Figure 11-34 Radio Wall Mount Brackets Procedure 11-17 How to Mount a Radio on a Wall The following installation procedure should be followed to install radios on a wall near the ACE36000 frame.
Radio Types and Installation Kits 3) Insert four M3 Phillips 10mm screws (not supplied) into the holes and tighten with a screwdriver to secure the bracket firmly against the wall. 4) Attach the radio to the bracket using the supplied screws.
PLASTIC BOX INTERFACES Plastic Box Interfaces Cards such as RS485 interface card can be attached to the ACE3600 RTU using a plastic box. The plastic box can be attached to the 19" accessories metal chassis, small/large metal chassis, or small/large NEMA housing. Procedure 12-1 How to Install the Plastic Box Interface on the Metal Chassis 1) To connect the plastic box interface to the metal plate, place the box on the metal plate and click into holes. See Figure 12-1.
CONFIGURATION General For information on setting the 12V DO dipswitch in the DO relay module board, see the Digital Output Relay chapter above.
OPTIMIZATION General No optimization is required for the ACE3600 units.
OPERATION General The operational functions of the ACE3600 unit are performed using the ACE3600 System Tools Suite (STS). These are administrative and diagnostic tasks, generally performed by technicians and administrators. The functions available depend on the specific software applications installed in the unit. See the ACE3600 STS User Guide for details.
MAINTENANCE General The following maintenance procedures are recommended for the ACE3600 RTU. Lead Acid Battery Maintenance It is recommended to perform the following maintenance procedures for the lead acid battery using the ACE STS Hardware Test utility or the user application program: • Once per month - run a full battery test (battery capacity) of the lead acid battery. • Once per day - run the short battery test (charge level) of the lead acid battery.
TROUBLESHOOTING Symptom The PWR LED on the CPU module front panel is not lit. The Power LED on the CPU module front panel is red. The ERR LED on the CPU module front panel is red. The ERR LED on the CPU module front panel is orange. The ERR LED on the CPU module front panel is green. The APPL LED on the CPU module front panel is red. The CONF LED on the CPU module front panel is red. The PWR LED on the CPU module front panel is flashing red. The PWR LED on the CPU module front panel is flashing red.
BREAK-FIX PROCEDURES General This chapter refers only to replacement of removable modules and plug-ins, not of other components of the unit. If any other components in the unit require replacement, contact your local service center Before replacing modules or plug-ins, see safety issues/warnings in the Installation chapter above. For information on installation of the frame/housing on the wall, see the Installation chapter above.
Break/Fix Procedures Press Down on Module Release Tab Press Up on Module Release Tab Figure 18-1 ACE3600 Module Release Tabs 5. Remove any SRAM plug-in memory from the old CPU module and plug in to the new CPU module. 6. Slide the new module all the way into the slot until the tabs click into place. 7. Reconnect the cables and press the cable holder back up into place. Replacing a Power Supply Module METAL PARTS OF THE POWER SUPPLY MAY BE VERY HOT.
Break/Fix Procedures Procedure 18-2 How to Replace a Power Supply Module 1. To replace the second power supply module in a site with redundant power supplies, 2. Open the door of the power supply module and press the cable holder downward. 3. Disconnect the cables from the connectors. 4. Simultaneously press on the tabs on the top and bottom of the plastic front of the old module, and pull the module from its slot. 5. Slide the new module all the way into the slot until the tabs click into place. 6.
Break/Fix Procedures 2. Unscrew the two supporting pins on the other side of the CPU board. Save the screws. 3. Unscrew the two supporting pins on the plug-in port. Save the screws. 4. Connect the two supporting pins with screws to the new plug-in port. 5. Replace the plug-in board with the RJ-45 connector facing the panel. Carefully insert the plug-in board connector into the appropriate connector on the CPU board. For Ethernet 10/100 MB, use the J14 connector on the CPU (Plug-in 1 only.
Break/Fix Procedures Figure 18-2 ACE3600 Motherboard on Metal Chassis 4. From inside the cage, push out the small cover on the side of the RTU rack/cage. Save the cover. 5. Slide the damaged motherboard out of the cage, through the opening on the side of the RTU rack/cage. 6. Slide the new motherboard into the rack, through the opening on the side of the RTU rack/cage. 7. Secure the motherboard to the rack/cage and metal chassis using the M5 screws saved in step 3. 8. Replace the cover on the cage. 9.
Break/Fix Procedures 4. Using narrow pliers, remove the faulty fuse from its groove on the board. 5. Press the new fuse into the groove on the board. 6. Slide the power supply module all the way into the slot until the tabs click into place. 7. Reconnect cables as in installation… Replacing the Backup Battery on the RTU For instructions on replacing the backup battery on the RTU, see Replacing the Backup Battery in the Power Supply and Backup Battery chapter above.
Break/Fix Procedures Figure 18-4 Electrical Interconnection (RTUs with no I/O slots) 18-7
APPENDIX A: GENERAL SPECIFICATIONS Specifications The specifications below are for the RTU as a whole. For the individual technical and performance specifications of each module in the RTU, see the specific module chapter. Table A-1 ACE3600 Specifications General Frames No I/O slots - PS and CPU modules only, wall mount, Dimensions (WxHxD): 117 x 244 x 198* mm (4.61" x 8.23" x 7.80"*), Weight: 0.95 Kg (2.1 lb) 3 I/O slots - PS, CPU and 3 I/O modules, wall mount, Dimensions (WxHxD): 234 x 244 x 198* mm (9.
Appendix A: Specifications Enclosures Large Nema 4X / IP65 painted metal - up to 7 I/O slot frame, two radios and 6.5 or 10 Ah, backup battery, Dimensions (WxHxD): 500 x 500 x 210 mm (19.7" x19.7" x 8.26" ) Small Nema 4X / IP65 painted metal - up to 3 I/O slot frame one radio and 6.5 Ah backup battery, Dimensions (WxHxD): 380 x380 x 210 mm (15" x 15" x 8.26") Power Supply 10.
Appendix A: Specifications Motorola Radio Support Mobile two-way radios – CM 200 , CM 340, GM 3188, EM 200, CDM750 Portable two-way radios – HT750, GP320, GP328, PRO5150 Astro radios – XTL 5000 (digital and analog trunked) , XTS 2500 (digital trunked) Dimetra radios – MTM 800 (PD) Third Party Radio Support Two-way radios, Data radios, TETRA radios (PD) Modem Support Dial-up modems, Cellular modems (dial mode and PD) Protocols MDLC, TCP, UDP, IP, PPP, NTP, DHCP Third Party Protocols Modbus RTU (Mas
APPENDIX B: ENVIRONMENTAL PROTECTION Disposal of Components All components of the ACE3600 should be properly disposed of, in accordance with local regulatory standards and laws. All ACE3600 models comply with RoHS European Directive no. 2002/95/EC (Restriction of the use of Hazardous Substances) and WEEE Directive no.
APPENDIX C: RS232/RS485 ADAPTOR CABLES General Note: On all of the Motorola RJ45 connector heads, the numbering of the pins is different than the standard, as shown in the figure below. Pin 1-8 are left to right rather than right to left, as shown below. Therefore, only original Motorola cables should be used.
Appendix C: RS232/RS485 Adaptor Cables RS232 Function 8-pin Connector (on RTU) 25-pin Female 9-pin Female Direction RTS 5← 4 7 from DTE CTS 8→ 5 8 to DTE DSR 7→ 6 6 to DTE GND 4 7 5 - DTR 3← 20 4 from DTE DCD (Rec line) 6→ 8 1 to DTE To extend the cable, you may use any extension cable with male and female D-type connectors (connected pin-to-pin, not crossed).
Appendix C: RS232/RS485 Adaptor Cables To extend the cable, you may use any extension cable with male and female D-type connectors (connected pin-to-pin, not crossed). Before transmitting, the RTU sends RTS=ON to the modem, and waits for CTS=ON from the modem as a condition for transmitting. The RTU will receive data from the modem only when DCD=ON.
Appendix C: RS232/RS485 Adaptor Cables Connecting a User Port to an External Unit To connect one of the RTU RS232 ports defined as a User port to an external unit (which supports RS232), you may use one of the two adaptors (FLN6457B or FLN6458B) according to the port definition in the site configuration. If the FLN6457B adaptor is used, refer to the pin assignment given in Connection to a Computer or Terminal in this chapter.
Appendix C: RS232/RS485 Adaptor Cables RS232 Function 8-pin Connector(on RTU) 9-pin Male Direction GND 4 5 - CD (Rec line) 5← 1 to RTU RTS 6→ 4 from RTU 7 Not used 8→ 7 DTR from RTU RTU-to-RTU Connection Using MDLC Protocol through RS232 To establish a link between two RTUs using MDLC protocol, the ports of both RTUs should be defined as RS232 RTU-to-RTU (RS-Link). The ports of the two RTUs should be connected by the FLN6457B and FLN6458B adaptors, when the adaptors are connected.
Appendix C: RS232/RS485 Adaptor Cables ACE3600 RTU-to-MOSCAD RTU Connection Using MDLC Protocol through RS485 To establish a link between an ACE3600 unit and a MOSCAD RTU using MDLC protocol, the ports of both RTUs should be defined as RS485 RTU multidrop. The ports of the two RTUs should be connected using the 3089004V58 cable. Do not connect between RTUs without the adaptor cables. A direct connection will cause a short circuit between the pins that have the same function.
