DATRAN XL4 RTU. Owners Manual

Transcription

1 DATRAN XL4 RTU Owners Manual

2

3 Copyright 2012 to QTech Data Systems Limited Christchurch, New Zealand All rights reserved The circuit details and know how disclosed in this document are proprietary to QTech Data Systems Limited and shall remain the intellectual property of QTech Data Systems Limited. DISCLAIMER The information in this document is subject to change without notice and does not represent a commitment on any part of QTech Data Systems Limited. While the information contained herein is assumed to be accurate, QTech Data Systems Limited assumes no responsibility for any errors or omissions. QTech Data Systems Limited 12 Midas Place, Middleton Christchurch 8024 New Zealand Phone: Fax: REVISION DETAILS 1.0 May 2012 Initial Issue 1.1 June 2012 Amended jumpers for Rev D & addition of upgrade section Page 3

4

5 TABLE OF CONTENTS Revision Details... 3 Table of Contents... 5 DATRAN XL4 Introduction... 7 Q04 Processor overview... 8 Q04 Processor Layout...8 Functional Description...9 Central Processor Core...9 Real Time Clock...9 System Reset...9 Module Address...9 Factory Default Jumper...9 Q04 Status LEDs...9 Connections...10 RS485 Port...10 USB Configuration Port...11 Ethernet Port...11 USB Port...12 Q04 Configuration Jumper Functions...12 Functionality Functional Descriptions...13 System Status LEDs...14 Error Codes...14 Digital Inputs...14 Digital Outputs...15 Analog I/O...17 Analog Inputs...19 Analog Outputs...21 Configuration Jumpers Configuration Jumper Functions...24 Configuration Jumper Locations...26 Upgrading to an XL4 RTU Upgrade Procedure...27 Power Supply Connections...29 Low Voltage Detection...30 Typical Power Supply Wiring...31 Warranty & Liability DISCLAIMER...32 WARRANTY SERVICE Page 5

6 OUT OF WARRANTY SERVICE...33 User Notes Page 6

7 DATRAN XL4 RTU Owners Manual v1.1 June 2012 DATRAN XL4 INTRODUCTION The DATRAN XL4 RTU The DATRAN XL4 RTU is a new state of the art RTU from QTech. It is powered by the new 32 bit Q04 ARM processor. Amongst the many new features are native Ethernet, 3MByte data logging memory and it delivers a massive increase in computational power and connectivity/integration options. The PC/laptop Configuration & Diagnostics application for the XL4 RTU is called QTech Workbench. This replaces Q90 from the previous Q03 powered excel RTU and provides a dramatically improved user interface and allows the XL4 RTU to be configured both online and offline. The XL4 RTU can be used with DATRAN VI software v6.66 Service Pack 2 and above. Due to the massive improvements in the data logging capability, DATRAN VI v6.68 is required to take advantage of this. Page 7

8 Q04 PROCESSOR OVERVIEW EW This section describes the functions and facilities of the Q04 ARM Processor Module. Q04 Processor Layout The diagrams below show a photo and generalised layout of the Q04 ARM Processor and can be used to locate and identify the various parts and functions detailed in this manual. Generalised layout of the Q04 Processor. Page 8

9 Central Processor Core Functional Description The Q04 ARM Processor Module is based around industry standard 32 bit ARM Micro-controller architecture. The ARM processor is an NXP LPC2468 microcontroller implemented on a four layer printed circuit board running at a clock frequency of 72MHz with fully implemented 32 bit address and data busses. The ARM processor has 96 kbytes of SRAM used exclusively by the integrated processor peripherals and core functions. Operating firmware is stored in the ARM processor s 512 kbytes of Flash. Memory The Q04 ARM Processor Module has the following memory: 16 MBytes of high speed volatile Dynamic Memory used for program data storage. 4 Mbytes of non-volatile NOR Flash Memory used for DLP and Data Logging Data storage. 8 Kbytes of Non-volatile RAM used for system configuration data storage. Real l Time Clock The real time clock chip provides system day of the week, day of month, month, year, time in 12 or 24 hours format and am:pm. The real time clock is battery backed up to maintain its operation during power down. An inbuilt software algorithm that provides accurate time keeping compensates for real time clock time drift. A jumper labelled BAT on the module is provided to disable the real time clock battery backup function. This allows the battery to be disconnected and preserved during long term storage of the module. This jumper is closed for normal operation, open for long term storage. System Reset The system reset circuitry ensures proper and reliable operation of the processor during power failure and power brown-outs. A system watchdog function provides protection and ensures re-starting of an out of step central processor. The Q04 ARM Processor does not include an externally accessible reset switch like the Q03 Processor. If the module needs to be manually reset, simply remove the power for a few seconds and then reconnect it. Module Address The Q04 ARM Processor Module Address is set by using QTech Workbench. The Q04 ARM Processor does not have a DIP Switch setting like the Q03 Processor. Factory Default Jumper During normal operation the Factory Default Jumper, labelled INIT should not be installed. Whenever the Factory Default Jumper is installed and the Q04 ARM Processor Module is repowered, then, a set of default configuration parameters is loaded into the Q04 ARM Processor. The jumper must be then removed for normal operation. Q04 Status LEDs The status of the Q04 is displayed on 5 LEDs. The function of these LEDs is detailed below: PWR OK MSG A1 B1 This is a blue LED that shows that power is applied to the Q04 Processor. This is a green LED that shows the status of the central processing unit. The LED blinks slowly when the CPU is functioning correctly. The LED blinks 6 times quickly whenever a system reset has occurred. Any other condition of this LED indicates a malfunction of the CPU. This orange LED is unused but may be used for diagnostics or other indicator purposes in future versions of the firmware. This orange LED is unused but may be used for diagnostics or other indicator purposes in future versions of the firmware. This orange LED is unused but may be used for diagnostics or other indicator purposes in future versions of the firmware. Page 9

10 The following connection ports available on the XL4: Connections RS485 Port The connector used for the RS485 port looks similar to the one used on the Q03. Care must be taken! The connectors are NOT the same. Forcing a plug intended for a Q03 into a Q04 can damage the socket. The RS485 port is used for inter-module long distance, high speed communications. The RS485 port features 2,500Volt galvanic isolation and both 2 and 4 wire operation. The RS485 port has inbuilt provision for line termination. In RS485 applications, especially over long lines, the RS485 transceivers at either end of the line should be terminated with a 120 ohm load. In multi-drop RS485 applications only the far end RS485 transceivers should be terminated. The RS485 serial can operate in a multidrop configuration allowing a maximum of 32 devices to be connected to the RS485 line. The RS485 port can be extended up to a maximum distance of approximately 1000 meters with appropriate cable and installation. It is generally recommended to install a 3 rd party surge protection devices on any exposed RS485 cable runs, or runs exceeding 200 meters in length. Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Function Not Used Not Used (Yellow) (Green) 485 (Red) Ground (Black) Not Used Note. RJ12 cable connector pin numbering RS232 Ports RS485 RJ12 Connections The XL4 RTU contains two RS232 serial ports used for specialised communication devices and peripherals. These include PLC Interfaces, Cellular modems, Data Radios, modems etc. The specific application and required settings are configured using the QTech Workbench configuration software. The RS232 serial port connectors are both 8 way RJ45 connectors. One is located on the Q04 processor board, labelled RS232-A, while the other is located on the Q22 I/O board, labelled RS232-B. The RS232-B port can be configured via J23 on the Q22 I/O board to provide an output voltage (+V sup ) on pin 8. This is of specific use for the Q71 external 1200bps modem. Please refer to the Q71 Quick Start Guide for further details. Standard 8 way RJ45 crimp plugs are used in making up serial port interconnection cables. These plugs are designed for use with stranded (24/26 AWG) 8 core flat data cable. An RJ45 crimping tool must be used to crimp the RJ45 plugs onto the data cable to ensure proper and reliable crimping. Improperly crimped connectors can damage the RJ45 socket and cause unreliability. Page 10

11 Note In electrically noisy environments it is necessary to use screened data cable and keep the cable length as short as possible. Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Function DTR RTS CTS Ground RXD TXD DCD RI Note. RJ45 cable connector pin numbering RS232 RJ45 Connections In general the RS232 serial port can be extended up to a maximum of 15 metres. communications will be unreliable. Beyond this distance USB Configuration Port The Configuration Port is used for on-line configuration, diagnostics and data/program exchange. The port is also used for I.C.P. (In circuit programming) of the system firmware. The port is labelled CNFG on the XL4 and uses a Type A to Type B USB cable. Maximum cable length is 5 meters. The configuration and software upgrade of the Q04 ARM Processor is detailed in a separate manual. Ethernet Port This is a 10/100 MBit Ethernet port labelled ETH on the XL4. This port can be used for Base Station or peripheral communications via such protocols as QComms, DNP3, Modbus Slave/Master, etc. The Ethernet socket has a green and an orange LED. The orange LED is the Link LED and turns on when a good link is established then flashes off for Ethernet traffic. The green LED is the Speed LED and turns on for 100 MBit connections and off for 10 MBit connections. Page 11

12 Function Pin 1 Tx + Pin 2 Tx - Pin 3 Rx + Pin 4 Unused Pin 5 Unused Pin 6 Rx - Pin 7 Unused Pin 8 Unused Note. RJ45 cable connector pin numbering Ethernet RJ45 Connections USB Port The labelled USB is a USB Host Port and provides a method of connecting standard and specialised USB Devices peripherals to the Q04 ARM Processor. These USB peripheral devices may include USB Pen Drives, USB Mass Storage devices; QTech supplied programming and configuration devices. The USB Host Port is not currently implemented, and is intended for future feature development. Q04 Configuration Jumper Functions This section describes how to configure the Q04 Processor in the XL4 RTU via the various on-board configuration jumpers. The power should be removed from the XL4 RTU by removing the power connector before carrying out any of the configurations detailed below. The XL4 RTU incorporates static discharge sensitive devices. Normal Anti Static Discharge precautions should be employed when setting up and making any adjustments to the XL4 RTU. An anti-static wristband should be worn and the earth connection of this wristband should be connected to the terminal marked EARTH on the Q04 Processor before any adjustments are made. The following list describes the function of each of the configuration jumpers on the Q04 Processor: INIT When closed, this jumper will cause the RTU to load the factory default settings on power-up. The jumper is normally open, and should be returned to the open position after performing a factory default operation. 485TERM Close jumper A to provide a 120 ohm termination to the RS485 lines. Jumper B should not be installed and is provided for future RS422 termination options. BAT ISP DEBUG Note: When open, this disables the real time clock battery backup function. This allows the battery to be disconnected and preserved during long term storage of the module. This jumper is closed for normal operation, open for long term storage. These jumpers are normally open in normal use. They must be closed when upgrading the firmware through the QTech Workshop software, if this feature is available. The jumpers must then be opened again once the firmware update is completed. This jumper is only used by QTech developers when developing software for the XL4. A jumper is closed when a jumper shorting link is installed on the jumper. A jumper is open when a jumper shorting link is removed/not installed. A two way jumper has three pins so that the jumper shorting link can be installed one of two ways. Page 12

13 FUNCTIONALITY This section describes the functions and facilities of the Q22 I/O board. Functional Descriptions The photograph and diagram below shows the generalised layout of the Q22 DATRAN I/O board and can be used to locate and identify the various parts and functions detailed in this section. Q22 DATRAN XL4 I/O Board (revision D) Many of the XL4 RTU functions inter-relate with the application software. Workbench, the Configuration & Diagnostic tool. Reference should be made to Page 13

14 System Status LEDs There are 8 System Status LED s on the front panel of the DATRAN XL4 RTU. The LEDs indicate the following status information: ON OK IP MU Rx KY TX ER This blue LED indicates that power is applied to the XL4 RTU. If power is connected and the LED is not on this could indicate that the supply voltage is low or that the Q22 fuse has blown This green LED flashes at a slow regular interval to indicate that the Q04 Processor is running. The LED will flash 6 times rapidly whenever a system reset occurs. System resets occur at system power up or if the watch dog timer times out. This yellow LED flashes on for approximately 0.5 seconds every time a valid communications packet is received for this module address from another module on the RS485 bus. This yellow LED turns on when the mute gate in the radio connected to the RS232-B port opens showing the radio channel is busy. The module will not transmit data when MU (mute) LED is on. This yellow LED turns on whenever a valid data carrier is detected from the RS232-B port. This yellow LED turns on whenever the modem attached radio s transmitter on the RS232-B port is requested to be turned on. This yellow LED turns on whenever the RTU is transmitting data from the RS232-B port. This red LED is used to indicate if any of the seven error conditions are present. The LED will blink a certain number of times corresponding to that error condition. The LED pulses are separated by a 2 second period allowing multiple error codes to be indicated. Error Codes The following is a list of the number of error light flashes for each of the error/fault codes: 1. Main battery failure 2. Clock battery low 3. Communications with Base Station has failed. 4. RS485 Bus communications failure 5. One or more real digital outputs have failed. 6. One or more analog input is out of range 7. The DLP is not loaded or is corrupted. Digital Inputs The DATRAN XL4 has 8 digital input channels labelled 1 through 8 and a ground connection labelled G. The state of each digital input is indicated with a corresponding green status LED. To turn ON a digital input channel, the external device must ground the appropriate terminal. To turn OFF a digital input channel, the external device must open circuit the appropriate terminal or hold it at the supply voltage. Note. The input voltage on any digital input channel should not be allowed to go above the power supply voltage. The digital input channels can be connected to a range of devices including relays, mechanical switches, solidstate switches, or transistors. The digital input channels are sampled by the Q04 Processor each 100ms. This implies that the state of a given digital input channel must be constant for at least 100ms for the state to be detected. However, digital input Page 14

15 channel 8 can be configured as a high speed pulse counter, allowing pulses with duration less than 20 ms to be detected. Please contact QTech for application specific details. Note that the digital input status LEDs are controlled by the Q04 Processor and are not connected electrically in any way with the input circuitry. The diagram below shows the electronic circuitry of an individual digital input channel. Note that the digital input channels are each individually opto-isolated. The intention of this design is to prevent noise and voltage spikes from propagating further into the DATRAN XL4, and has proven to be an effective design. Circuit details of a Digital Input Channel. The 4K7 resistor limits the current through the opto-isolator while the 10nF capacitor filters noise from the input line. The BAV99 prevents input voltage spikes from exceeding the reverse breakdown voltage of the opto-isolator LED. With a supply voltage of 12V, each digital input channel ON state current to ground is approximately 2.5mA. With a supply voltage of 24V the current will be approximately 5mA. The current transfer ratio of the H11A817D opto-isolator is greater than 100%. Therefore a minimum of 1mA must flow through the opto-isolator LED to ensure reliable switching (assuming a 50% safety margin). This implies that the maximum allowable ON state resistance of the external switching device is 5k for a 12V supply voltage, and 10k for a 24V supply voltage. Digital Outputs The DATRAN XL4 has 8 digital output channels physically separated into two banks. The first bank contains digital output channels 1 to 4, and is located on the front of the DATRAN XL4. The second bank contains digital output channels 5 to 8, and is located on the bottom of the DATRAN XL4. The first bank of the digital outputs has 4 yellow status LEDs to indicate the state of the corresponding digital output channel. The second bank does not have status LEDs, but in all other respects, operates the same as the first bank. In the ON state, the DATRAN XL4 connects the specific digital output channel to ground. In the OFF state a digital output channel becomes open circuited. The digital outputs also contains two voltage supply terminals labelled + on each bank. These make the internal switched positive voltage rail available externally. The voltages can be used to deactivate any connected devices if the DATRAN XL4 goes into low voltage shut down mode. Note. Relays and other control devices should always be wired to be failsafe. Always ensure that any equipment attached to relays goes into a safe state when the relay or controlling device is removed or not powered. The diagram below shows some of the details of the digital output circuit electronics. Page 15

16 Circuit details of a Digital Output Channel. The digital output MOSFET transistors have an ON resistance of typically 1 ohm and are capable of switching 3 amps at 5.5 to 26.5 volts. The output voltage is clamped at 65 volts to help reduce the effects of voltage spikes when switching inductive loads. It is still recommended good practice that such loads be fitted with their own fly back or free-wheeling diode. Note. The total digital switching current is limited to approximately 1.5 amps by the DATRAN XL4 internal 2 amp fuse. Output Protection tion Each digital output channel is protected against over-current and over-temperature conditions. The over-current protection will activate if the current being sourced through a given channel exceeds nominally 4 A. The default behaviour is that if an over-current fault is detected on a given channel, then that channel will be turned OFF and remain OFF until the over-current fault clears. By removing jumper J28 the behaviour can be changed to be if an over-current fault is detected on a given channel, then that channel will be put into current-limit mode. While in current-limit mode, the output current on that channel will be limited to 500mA until such time as the over-current fault clears (provided thermal shut down has not occurred also). Jumper J28 is located at the centre lower right hand side of the Q22 as viewed with the front display panel to the right and the Q04 Processor removed. Page 16

17 Location of Digital Outputs Over-Current Jumper J28. Open Circuit Detection The DATRAN XL4 can detect if there is a load connected to each digital output channel. It achieves this by sourcing a 50uA sensing current through each digital output channel when they are in the OFF state. Fault Status Reporting The DATRAN XL4 can be configured to display Output Protection and Open Circuit Detection status information on the status LEDs. This feature only applies to bank 1 of the digital outputs. If the DATRAN XL4 has been configured to display digital output status information, and one of the above mentioned faults occurs on a given channel, the corresponding status LED will flash. This feature can be selectively enabled for each channel, which is useful if not all digital output channels are intended to be connected to an external device. Analog I/O The XL4 RTU has six analog I/O channels and can be reconfigured to suit a wide range of analog input or output requirements. The analog I/O uses a 9 way connector labelled ANALOG I/O located on the front panel of the DATRAN XL4. The analog I/O channels are numbered 1 to 6. The configuration each analog I/O channel is achieved by a combination of range setting and mode setting. Analog I/O Ranges Each channel can be individually configured to use the following voltage or current ranges. 0 to 5V 0 to 10V 0 to 20mA 4 to 20mA. By default the factory settings for all Analog I/O are set to 4-20 ma inputs. Page 17

18 Analog I/O Modes The table shows that channel pairs 1 & 2 and 3 & 4 can be configured as differential inputs, and that only channels 5 and 6 can be configured as outputs. Analogue I/O port mode settings Channel No Single Ended Input Differential Input Single Ended Output Note. The voltage applied to an analog input channel should never be greater than 15V or less than 0V. Note. Note. Analog output channels configured as voltage output have low output impedance. Therefore, assuming a 100mA maximum output current, the minimum allowable load impedance of the attached device is 50 Ohms for 0 to 5V operation, and 100 Ohms for 0 to 10V operation. When an Analog channel is to be configured for 4 to 20mA input, configure the jumpers for 0 to 20mA input. Then use QTech Workbench to configure the channel as 4 to 20mA. The 6 Analog channels can each be individually configured as single ended voltage or current inputs. Channels 1 & 2 and/or 3 & 4 can be configured together to form 2 differential voltage or current input channels. Note. For Single Ended Input channels, the input signal is referenced to ground (the G terminal on the Analog I/O port). Status LEDs Each analog channel has a yellow status LED to indicate the state of the channel. Each yellow status LED shows the following channel status: OFF ON FLASHING Indicates that the analog input is at 0V, 0mA, or less than 4mA, depending on the mode configured. Indicates that the analog input is within the specified voltage or current range, depending on the mode configured. Indicates that the analog input is at full scale or higher dependent upon the mode configured. The terminal labelled G is a system ground connection. The terminals labelled + are connected to the internal switched positive supply rail. As with any analog measurement system, care must be taken to correctly earth the equipment to prevent earth loops. Use the G connector on the ANALOG I/O port for all analog ground signal return paths. Analog I/O Signal Resolution and Accuracy The analog input channels are sampled by a 10 bit analog to digital converter (ADC) on the Q04 Processor. The DATRAN XL4 software compensates the gain and offset of each analog channel to reduce measurement errors introduced by component tolerance variations. The analog output channels are driven from an 8 bit pulse width modulation (PWM) output from the Q04 Processor. Page 18

19 Single Ended or Differential Configuration Analog Inputs Analog input channel pairs 1 & 2 and 3 & 4 can be individually configured to become differential inputs. In this configuration channel 1 and 3 are the positive inputs, and channel 2 and 4 are the negative inputs. Note. Note. Differential analog inputs provide for non ground referenced negative inputs and provide up to 10 volts common mode rejection on analog input signals. Differential inputs can be used as part of a multi-drop current loop arrangement. Single Ended Input Details The diagram below shows the single ended analog input circuit. The circuit includes an analog preconditioning network and unity gain buffer to produce a scaled 0 to 5 volts output to the Q04. The Q04 then converts that to a 0 to 2.5V value. Circuit details of Single Ended Analog Input Channel. The following paragraphs describe the various single ended Analog input configurations: 0 to 5V In this configuration jumper J5 has pins 2 & 3 closed and jumper J6 is left open. The analog input voltage is fed via a 100k resistor to the non-inverting input of the op-amp. In this configuration the input impedance is high and negligible current is drawn from the analog source. 0 to 10V In this configuration J5 has pins 1 & 2 closed and jumper J6 pins 2 & 3 closed. Resistors R1 and R3 form a voltage divider that divides the analog input voltage by 2 to produce a 0 to 5 volts input to the non-inverting input of the op-amp. In this configuration the input impedance is 20k and the input current at 10V input is 500uA. 0 to 20mA In this configuration jumper J5 has pins 2 & 3 closed and jumper J6 pins 1 & 2 closed. The analog input current flows through the 250 ohms resistor so that 0 to 20mA produces a voltage of 0 to 5 volts to the non-inverting input of the op-amp. In this configuration a voltage drop of 5 volts at 20mA is created in the 20mA loop by the Q22. 4 to 20mA The 4 to 20mA loop configuration is the same as the 0 to 20mA loop described above, except the central processor scales the output to 4 to 20mA range. This reduces the ADC resolution to 80% of the 1024 counts for full scale to 1 part in 800 counts. Note. Each of the single ended analog inputs are clamped with BAV99 high speed switching diodes to both ground and +15 volts to keep the input voltage to the op-amp in the range 0 to +15 volts. Analog input voltages outside 0 to +15 volts will cause the clamping diodes to conduct and draw current from the analog input source. The BAV99 diodes are rated at 200mA forward current. Therefore care must be taken to ensure that over-voltage/under-voltage analog input currents do not exceed 200mA. Differential Input Details Analog input channels 1 & 2 and/or 3 & 4 can be configured together to form two separate differential input channels. When configured as differential inputs analog input channels 1 and/or 3 are the positive inputs and analog input channels 2 and/or 4 are the negative inputs. The diagram below shows the differential analog input circuit. The circuit includes an analog preconditioning network and a unity gain differential op-amp to produce a scaled 0 to 5 volts output to the Q04 Processor. Page 19

20 Circuit details of Differential Analog Input Channel. It can be seen from the above diagram that the analog preconditioning networks are identical to those in the single ended input circuit. Therefore the various analog input mode configurations and jumper settings are the same as for the single ended analog input circuit. The op-amp is configured as a unity gain differential amplifier. Jumper J21 selects the input mode as follows: Note. When J21 is open the circuit is configured for differential input mode. That is the negative analog input line is above ground therefore allowing for common mode input voltages up to 10 volts. When jumper J21 is closed the circuit is configured for single ended input mode. Each of the inputs to the differential analog inputs are clamped with BAV99 high speed switching diodes to both ground and +15 volts to keep the input voltage to op-amp in the range 0 to +15 volts. Differential and common mode analog input voltages outside 0 to +15 volts will cause the clamping diodes to conduct and draw current from the analog input source. The BAV99 diodes are rated at 200mA forward current. Therefore care must be taken to ensure that over-voltage/under-voltage analog input currents do not exceed 200mA. Page 20

21 Single Ended Output Details Analog Outputs The diagram below shows the single ended analog output circuit. The circuit includes PWM input preconditioning, low impedance 5V/10V voltage output circuit and a voltage to current converter. Circuit details of Single Ended Analog Output Channel. The following paragraphs describe the various single ended Analog output configurations: 0 to 5V In this configuration jumper J1 is left open and jumper J3 has pins 2 & 3 closed. The op-amp U3A operates as a unity gain amplifier. Q2 provides low impedance output drive. 0 to 10V J1 is closed and jumper J3 has pins 2 & 3 closed. The op-amp U3A operates as a 2 x gain amplifier. Q2 provides low impedance output drive. 0 to 20mA In this configuration jumper J1 is left open and jumper J3 has pins 1 & 2 closed. The op-amp U3A operates as a unity gain amplifier. Op-amps U1A & U1B form a voltage to current converter. 4 to 20mA The 4 to 20mA loop configuration is the same as the 0 to 20mA loop described above, except the central processor scales the output to 4 to 20mA range. This reduces the DAC resolution to 80% of the 256 counts for full scale to 1 part in 205 counts. Page 21

22 Analog I/O Configuration Jumpers The analog input configuration jumpers are located at the top right region of the Q22 when viewed with the Q24 on the right and the Q04 Processor board removed. The square pad on each jumper header is indicates pin 1. The pins are numbered 1, 2, and 3 away from pin 1. Analog input configuration jumpers. The following tables show the jumper configurations of analog channel when configured as Single Ended Inputs. Channel No 1 Single Ended Input J7 J8 J V 2-3 OPEN INSTALL 0..10V INSTALL 0..20mA INSTALL Channel No 2 Single Ended Input J5 J6 J V 2-3 OPEN V mA Channel No 3 Single Ended Input J9 J10 J V 2-3 OPEN INSTALL 0..10V INSTALL 0..20mA INSTALL Channel No 4 Single Ended Input J11 J12 J V 2-3 OPEN V mA Channel No 5 Single Ended Input J13 J14 J V 2-3 OPEN V mA Channel No 6 Single Ended Input J15 J16 J V 2-3 OPEN V mA The following tables show the jumper settings for configuring analog input channels 1 & 2 and/or 3 & 4 as Differential Input channels: - Page 22

23 Channel No 1 & 2 Differential Input J7 J8 J17 J V 2-3 OPEN 1-2 OPEN 0..10V OPEN 0..20mA OPEN Channel No 3 & 4 Differential Input J9 J10 J18 J V 2-3 OPEN 1-2 OPEN 0..10V OPEN 0..20mA OPEN The analog output configuration jumpers are located at the centre upper right hand side of the Q22 as viewed with the front display panel to the right and the Q04 Processor board removed. Analog output configuration jumpers. The diagram above shows the location of the jumpers used to configure the analog output channels. The square pad on each jumper header is pin No 1. The pins are numbered 1, 2, and 3 away from pin No 1. The following two tables show the jumper configurations for analog channels 5 and 6 when configured as single ended output channels. Note. Single ended output means that the output voltage or current is referenced to ground. That is, the negative side of the output is at ground potential (the G terminal on the ANALOG I/O port). Channel No 5 Single Ended Output J2 J4 J V OPEN V INSTALL mA OPEN Channel No 6 Single Ended Output J1 J3 J V OPEN V INSTALL mA OPEN Note. When an analog output channel is to be configured for 4 to 20mA output, configure the channel s jumpers for 0 to 20mA output. Then use Workbench to configure the analog output channel as 4 to 20mA. Page 23

24 CONFIGURATION JUMPERS This section describes how to configure the Q22 I/O board via the various on-board configuration jumpers. The power should be removed from the module by removing the power connector before carrying out any of the configurations detailed below. The Q22 Module incorporates static discharge sensitive devices. Normal Anti Static Discharge precautions should be employed when setting up and making any adjustments to the module. An anti-static wristband should be worn and the earth connection of this wristband should be connected to the terminal marked EARTH on the Q22 I/O board before any adjustments are made. Configuration Jumper Functions The following list describes the function of each of the configuration jumpers on the Q22 I/O board: J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 This jumper selects the output voltage range for Analog output channel No. 6. Close is 0 to 5V/0 to 20mA output range whilst open is 0 to 10V output range. This jumper selects the output voltage range for Analog output channel No 5. Close is 0 to 5V/0 to 20mA output range whilst open is 0 to 10V output range. This 2 way jumper selects the output mode of Analog output channel No 6. Pins 1 & 2 closed is current output mode whilst 2 & 3 closed is voltage output mode. This 2 way jumper selects the output mode of Analog output channel No 5. Pins 1 & 2 closed is current output mode whilst 2 & 3 closed is the voltage output mode. This 2 way jumper selects the single ended input range of Analog input channel No. 2. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 2. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the single ended input range of Analog input channel No. 1. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 1. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the single ended input range of Analog input channel No. 3. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 3. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the single ended input range of Analog input channel No. 4. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 4. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the single ended input range of Analog input channel No. 5. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 5. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the single ended input range of Analog input channel No. 6. Pins 1 & 2 closed is 0 to 10V input range, whilst 2 & 3 closed is 0 to 5V/0 to 20mA input range. This 2 way jumper selects the single ended input mode of Analog input channel No. 6. Pins 1 & 2 closed is 0 to 20mA input mode, 2 & 3 closed is 0 to 10V input mode, whilst jumper open is 0 to 5V input mode. This 2 way jumper selects the input mode of Analog input channels No s 1 & 2. Pins 1 & 2 closed is one differential input channel. Pins 2 & 3 closed is two single ended input channels. This 2 way jumper selects the input mode of Analog input channels No s 3 & 4. Pins 1 & 2 closed is one differential input channel. Pins 2 & 3 closed is two single ended input channels. Page 24

25 J19 J20 J21 J22 This 2 way jumper selects the input/output mode of Analog channel 5. Pins 1 & 2 closed is output mode, whilst 2 & 3 closed is input mode. This 2 way jumper selects the input/output mode of Analog channel 6. Pins 1 & 2 closed is output mode, whilst 2 & 3 closed is input mode. This jumper selects the single ended/differential input mode for Analog input channels 1 & 2. Closed is single ended input for channel 1, whilst open is differential input for channels 1 & 2. This jumper selects the single ended/differential input mode for Analog input channels 3 & 4. Closed is single ended input for channel 3, whilst open is differential input for channels 3 & 4. J23 This jumper selects the function of pin 8 on the RS232 B port. Pins 1 & 2 closed pin 8 is +V supply. Pins 2 & 3 closed pin 8 of the RS232 B port is Ring Indicate (RI). J27 J28 Note: This jumper selects the module s low battery/power supply detect voltage range. Closed is 10.5V low battery detection, whilst open is 21V low battery detection. This jumper selects the digital output channels over-current mode. Closed is channel turns OFF in overcurrent mode, whilst open is channels goes into current limit in over-current mode. A jumper is closed when a jumper shorting link is installed on the jumper. A jumper is open when a jumper shorting link is removed/not installed. A two way jumper has three pins so that the jumper shorting link can be installed one of two ways. J24, J25 & J26 are only installed on earlier revision C Q22 boards, hence they are missing from this list. Page 25

26 Configuration Jumper Locations The diagram below shows the general location of each of the configuration jumpers on the Q22 I/O board. The precise location, orientation and identification of jumper pin numbers is best done by referring to the diagrams in this manual and referring to an actual Q22 I/O board. Location of Configuration Jumpers on Q22 I/O board. In the diagrams shown the square pad on each jumper header is pin No 1. The pins are numbered 1, 2, and 3 away from pin No 1. Orientation of pin No 1 of the jumpers on the actual Q22 I/O board can vary. TIP A pair of fine pointed nosed pliers or tweezers can be used to remove and install the jumper shorting links. The jumper shorting links will only fit onto the jumper pins one way. Always check that they are seated properly. Unused or open jumper shorting links may be installed on only one pin of the jumper Page 26

27 UPGRADING TO AN XL4 RTU This section describes the process required to upgrade the configuration of an existing DATRAN II excel RTU site to use the XL4 RTU, and shows how the original configuration can be reused. Upgrade Procedure What s Required In order to perform an upgrade from an excel RTU to an XL4 RTU, the following equipment and software is required; Laptop with Q90 and QTech Workbench software installed USB cable Type A to Type B (QTech P/N CB-USB-AB) Q90 Serial Diagnostics cable D9 Female to RJ45 (QTech P/N PD6502) DATRAN VI v6.68 software installed at the Base Station Upgrade Procedure Saving the Existing Configuration Using the existing Q90 serial diagnostics cable, connect the Laptop to the DIAG port on the excel RTU. Run Q90 software and click Load from RTU button. Once the excel RTU s configuration is successfully loaded save it by clicking File menu then Save Configuration giving an appropriate filename. Please note down what RTU address number is being used. This will be needed later to check the configuration has been restored correctly. The excel RTU with a Q03 uses DIP switches, the XL4 uses Workbench to set this address, Load from RTU Save Configuration Page 27

28 Configuring the XL4 RTU Using the USB cable, connect the Laptop to the XL4 RTU s CNFG port. Run the QTech Workbench software and choose XL4 RTU device type before clicking connect button. Ensure that comms status is reported as Online before continuing. Load the previously saved configuration into the XL4 RTU by first selecting Open from the File menu then navigate to the.q22 configuration file and then pressing the Open button. Then upload the file to the RTU. Open Configuration Checking the Correct Configuration is Retained 1) Click the Disconnect button in QTech Workbench. 2) Cycle the power to the XL4 RTU. 3) Click the Connect button in QTech Workbench. 4) Download the configuration from the device, by clicking the Read from Device button. 5) Ensure the RTU Address and other configuration items are correctly presented. DATRAN VI Base Station Software The minimum recommended version of DATRAN VI base station SCADA software is v6.66 Service Pack 2. However, significant improvements have been made to the RTU Data Logging functionality. To achieve RTU data logging with an XL4 RTU, the minimum version of DATRAN VI is v Page 28

29 POWER SUPPLY This section describes the power supply and connection of the XL4 RTU. Connections The XL4 RTU is designed to operate with DC power supply voltages of nominally 12 or 24V but can operate on any DC voltage within the range 11 to 28 volts. The XL4 RTU draws approximately 200mA at 12V and 100mA at 24V. The power connector is located on the bottom panel of the XL4 RTU and is labelled PWR. The connections to the power connector are: -V Ground. The negative lead of the power supply +V Positive. The positive lead of the power supply O/P The switched positive output to auxiliary equipment Note The XL4 RTU has a 2 amp fuse on the Q22 I/O board to protect the unit under fault conditions or when reversed polarity or over-voltage power supplies are connected to the module. This 2 amp fuse limits the available switched positive output on the + connectors to approximately 1.5 amps. The QTech part number for replacement fuses is FS-2AMPTES The DC power supply to the XL4 RTU must be adequately smoothed and be free from noise and voltage transients. Where the DC supply is derived from the AC mains, or batteries with an associated AC mains battery charger these devices must comply with the relevant electrical regulations. In many applications the XL4 RTU is operated from power supply systems with a 12V or 24V standby battery. In the event of the main power supply failing and the standby battery becoming discharged the XL4 RTU has a low battery detection circuit. This circuit turns off the internal power supply of the XL4 RTU to prevent erratic operation of the Q22 Module and to prevent the battery from being totally discharged The low battery detection modes voltages are: 12V 24V Module OFF at 10.5 volts and back on at 11.5 volts. Module OFF at 21.0 volts and back on at 23.0 volts. The XL4 RTU also has an optional software controlled low battery alarm. This alarm turns on when the battery falls below 11.5/23.0 volts and turns off again when the battery rises above 12.5/25 volts for 12/24 volts power supplies respectively. These thresholds can be configured in the Battery tab of QTech Workbench. The DC power supply to the module must be adequately smoothed and free from noise and voltage transients. Where the DC supply is derived from the AC mains, or batteries with an associated AC mains battery charger these devices must comply with the relevant electrical regulations. Circuit details of Power Supply Front End. In the above circuit diagram the 30 volt transient suppression diode ZD1 and the 2 amp fuse protect the Q22 Module against reversed supply connection, over voltage supply and transient voltages. The fuse is a plug-in 2 Page 29

30 amp TE5 fuse located on the Q22 Motherboard. The fuse is located at the lower right side of the Q22 Motherboard as viewed with the front display panel to the right and the Q04 Processor board removed. Location of Q22 2A Fuse Low Voltage Detection The DATRAN XL4 incorporates a Low Voltage Detection circuit that automatically shuts down the XL4 and associated peripherals if the supply voltage drops below a specified value. This feature is used to prevent the power supply backup battery from becoming totally discharged and to protect against erratic system operation that could occur if the supply voltage was low. In many applications the XL4 is operated from power supply systems with either a 12V or 24V power supply. To accommodate this, the voltage at which the Low Voltage Detection circuit activates can be configured for either supply voltage scenario. 12V 24V Module OFF at 10.5 volts and back on at 11.5 volts. Module OFF at 21.0 volts and back on at 23.0 volts. Location of the Low Voltage Detection Voltage Level Selection jumper When jumper J27 is installed the trip voltage is 10.5V and when jumper J27 is open the trip voltage is 21V. Jumper J27 is located at the lower middle side of the Q22 as viewed with the front display panel to the right and the Q04 Processor removed. Additionally, the XL4 has a software derived low voltage alarm. This alarm turns on when the battery voltage is less than 11.5/23.0 volts and turns off when the battery voltage is greater than 12.5/25 volts for 12/24 volts power supplies respectively. The alarm status is available to the DLP and at the DATRAN Base Station (via a Variable Status Poll). Page 30

31 Typical Power Supply Wiring The following is a typical DC power connection for a DATRAN XL4 including expansion modules and radio power supply. Page 31

32 WARRANTY & LIABILITY ITY Subject to the under mentioned exemptions QTech Data Systems Limited undertakes to repair any manufacturing defects and replace or repair any faulty materials within (12) twelve months from the date of sale to the original purchaser. The exemptions referred to are: 1) Fair wear and tear 2 Faulty installation, misuse, neglect, accident and similar causes. 3) Equipment that does not bear the original Serial Number label or the label has been defaced or altered. 4) Unsuitable operating conditions, including improper installation and other influences beyond QTech control. 5) Alterations carried out by the Purchaser or any unauthorised third party. 7) Power supply protection parts, including fuses and other circuitry provided to protect the unit from electrical damage. 8) Output drivers, transistors, relays and other parts of the circuitry that are directly connected to third party equipment. 9) Damage resulting from lightening strikes and other static discharges. Liability for replacements supplied or repairs carried out is limited to the original (12) twelve month warranty period. QTech will not accept responsibility for warranty work carried out by the purchaser or any unauthorised third party. QTech does not assume or authorise any person to assume for QTech any other liability regarding its products. QTech s liability is limited to the extent set out above and does not extend to any consequential damages or losses. DISCLAIMER In no event shall QTech nor it respective agents be liable for special, direct, indirect, or consequential damages losses, costs, charges, claims, demands, claims for loss of profit, fees, or expenses of any nature or kind. While QTech warrants it s products it does not imply a warranty for its use for a particular purpose. QTech shall not be liable for any infringement or violation of copyright with respect to the material reproduced or displayed on its products.. WARRANTY SERVICE Where the conditions of liability as set out above are met QTech will carry out warranty service as detailed below: 1) Goods returned for servicing shall be adequately packaged to prevent damage in transit and shall be forwarded freight pre-paid. 2) A description of the fault/s together with any other relevant information relating to the fault, together with the return address to which the equipment is to be returned, must be included with any equipment returned to QTech for repair. 3) QTech may elect at its sole discretion to repair or replace equipment returned for repair. 4) Where repairs to the equipment are undertaken, the repairs will be undertaken during normal business hours. 5) Once repairs or replacements are complete, the equipment will be returned by a suitable carrier to the Purchaser unless otherwise instructed by the Purchaser. Page 32

33 OUT OF WARRANTY SERVICE Where the equipment is outside the (12) twelve month warranty period or is not otherwise covered by the warranty, then the service work will be carried out as detailed above with the exception that all labour, materials and freight will be charged at QTech s rates applicable at the time of service. Page 33

34 USER NOTES Page 34

35 Page 35