RuggedServer RS416 Family Modular Serial Device Server with Integrated Managed Ethernet Switch Installation Guide December 18, 2012 www.ruggedcom.com RuggedCom Inc.
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Federal Communications Commission Radio Frequency Interference Statement This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Table of Contents Table of Contents Federal Communications Commission Radio Frequency Interference Statement ...........3 Table of Contents............................................................................................................4 Table of Figures ..............................................................................................................5 Table of Tables ...............................................................................................................
Table of Figures 8 9 7.3 IEC Environmental Type Tests ......................................................................42 Agency Approvals..................................................................................................43 Warranty................................................................................................................43 Table of Figures Figure 1: RS416 LED Display Panel..............................................................................
Table of Tables Table 10: RS416 Time Synchronization Sources ..........................................................31 Table 11: RS416 Time Synchronization Services..........................................................31 Table 12: IRIG-B Daughter Board LED..........................................................................32 Table 13: Main Power Supply Specifications.................................................................36 Table 14: PoE Power Supply Specifications....................
Product Overview 1 Product Overview 1.1 Functional Overview RuggedServer™ RS416 represents a family of industrially hardened serial device servers with integrated, fully managed, Ethernet switches. The RS416 is designed to operate reliably in electrically harsh and climatically demanding environments.
Product Overview 1.
Product Overview Terminal blocks for reliable maintenance free connections CSA/UL 60950 safety approved to +85°C Rugged Operating System (ROS®) Features Simple plug and play operation - automatic learning, negotiation, and crossover detection Integrated Cyber Security features RSTP (802.1w), Enhanced Rapid Spanning Tree (eRSTP™) network fault recovery (<5ms), and Multiple Spanning Tree (MSTP – 802.1s) Quality of Service (802.1p) for real-time traffic VLAN (802.
Product Overview 1.3 Display Panel Description The RS416 is equipped with a versatile display panel, shown in Figure 1, which is designed to provide quick status information for each port, as well as the entire device to allow for simple diagnostics and troubleshooting. It features: RS232 console port for ‘out of band’ console access and configuration Power supply and Alarm status indicators Convenient port status indicators conveying Link-Activity, Duplex, or Speed via push-button control.
Product Overview Mode Status Duplex Color Ethernet Port Status LEDs Green (Solid) Green (Blinking) Off Green (Solid) Orange (Solid) Off Green Blinking Green (Solid) Link Activity No link Full-Duplex Half-Duplex No link 100Mbps Orange (Solid) Off 10 Mbps No link Speed Serial Port Status LEDs Traffic No Traffic Full-Duplex Half-Duplex No link > 57600 bps > 19200 bps, ≤ 57600 bps ≤ 19200 bps No link Table 2: LED Display - Port LED behavior definition RuggedCom® 11 RuggedServer™ RS416 Family Insta
Installation 2 Installation 2.1 Mounting The RS416 has been designed with maximum mounting and display flexibility. Customers can order an RS416 that can be mounted in a standard 19” rack, 1” DIN Rail, or directly onto a panel. For rack mount installations, the RS416 can be ordered with connectors on the front of the unit, or located on the rear of the chassis to allow for all data and power cabling to be installed and connected at the rear of the rack. See Figure 2 for rack mount orientation examples.
Installation 2.1.1 Rack Mounting The RS416 can be rack mounted using the included rack mount adapter assemblies shown in Figure 3. Secure the one rack mount adapter to the front of each side of the chassis using the included black PAN head Phillips screws in the positions shown in Figure 4. The entire chassis can then be mounted to a standard 19” rack. An additional two rack mount adapters are included to optionally secure the rear of the chassis in highvibration, or seismically active locations.
Installation 2.1.2 Panel and DIN Rail Mounting The RS416 can be ordered as a Panel/DIN mount chassis. Both options involve the use of the panel/DIN adapters to be mounted on each side of the chassis enclosure. The adapter allows the chassis to be mounted on the standard 1” DIN rail using the grooves in the adapter, secured using the included Phillips screw. See Figure 5 for a PANEL/DIN mount diagram.
Installation 2.2 Power Supply Wiring and Grounding The RS416 supports dual redundant power supplies – “Power Supply 1 (PS1)” and “Power Supply 2 (PS2)”. RS416P features a universal high voltage range power supply as PS1, and a separate 48VDC supply, PS2, to provide Power over Ethernet. The connections for PS1, PS2 and the fail-safe relay are located on the terminal block as shown in Figure 6 and Figure 7.
Installation compression plate allowing either bare wire connections or crimped terminal lugs. We recommend the use of #6 size ring lugs to ensure secure, reliable connections under severe shock or vibration. Both terminal blocks have a safety cover which must be removed via two Phillips screws before connecting any wires. The safety cover must be re-attached after wiring to ensure personnel safety. Refer to Table 3 and Table 4 below for a description of each terminal as well as sections 2.2.1 through 2.2.
Installation 2.2.1 AC Power Supply Wiring Examples Figure 9: AC Single Power Supply Wiring Example Figure 10: AC Dual Redundant Power Supply Wiring Example NOTES: 1. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be installed. 2. Equipment must be installed according to the applicable country wiring codes. 3. When equipped with two HI voltage power supplies, independent AC sources can be used to power the product for greater redundancy.
Installation 2.2.2 DC Power Supply Wiring Examples Figure 11: DC Power Supply Wiring Examples NOTES: 1. 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker must be installed. 2. A circuit breaker is not required for 12, 24 or 48 VDC rated power supplies. 3. Equipment must be installed according to the applicable country wiring codes. 4. When equipped with two HI voltage power supplies, independent AC sources can be used to power the product for greater redundancy.
Installation 2.2.3 Dual Power Supplies – DC and AC Inputs Figure 12: DC and AC Power Supply Wiring Examples NOTES: 1. 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker must be installed. 2. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be installed. 3. A circuit breaker is not required for 12, 24 or 48 VDC rated power supplies. 4. Separate circuit breakers must be installed and separately identified. 5.
Installation 2.2.4 Dual Power Supplies – AC Input and 48VDC for PoE Figure 13: AC Input to PS1 and 48VDC Input to PS2 for PoE NOTES: 1. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be installed. 2. A circuit breaker is not required for 48VDC rated power supplies. 3. Equipment must be installed according to the applicable country wiring codes.
Installation 2.3 Dielectric Strength (HIPOT) Testing For dielectric strength (HIPOT) testing in the field, users must remove the metal jumper located on terminal 2, 4, and 6 of the power supply terminal block. This metal jumper connects transient suppression circuitry to chassis ground and must be removed in order to avoid damage to transient suppression circuitry during HIPOT testing. Figure 14 shows the proper HIPOT test connections and should be followed to avoid damage to the device.
Installation 2.4 Failsafe Alarm Relay Wiring The “Failsafe” output relay is provided to signal critical error conditions that may occur on the RS416. The contacts are energized upon power up of the unit and remain energized until a critical error occurs. The proper relay connections are shown in Figure 15. A common application for this output is to signal an alarm if a power failure or removal of control power occurs. The failsafe relay current and power handling capabilities are specified in section 6.
Installation 2.5 Console Port Wiring An RS232 console port for configuration and management of the device is located on the LED display module shown in Figure 16. This port is intended to be a temporary connection during initial configuration or troubleshooting and allows for direct access to the serial-based management console. The connection is made using the DB9-Female to RJ45 console cable included in the device packaging shown below.
Serial Ports 3 Serial Ports The RS416 can be equipped with a Fiber Serial Interface, RS232/RS485/RS422 DB9 serial ports or RS232/RS485/RS422 RJ45 serial ports. DB9 and RJ45 ports may optionally be ordered with support for IRIG B time code. RS416 serial ports are designed with a high degree of isolation. DB9 and RJ45 ports feature isolation of all external signals. Serial port common ground terminals are connected to chassis ground via transient voltage protection circuitry. 3.
Serial Ports 3.2 RS232/RS485/RS422 via DB9 Each port is individually selectable via software to be RS232, RS485 or RS422. The DB9 port pin-out diagram and listing are shown below. Figure 19: DB9 female port pin-out Pin 1 2 3 4 5 6 7 8 9 Shield RS232 DCE Mode RS485 Mode RS422 Mode 2 DCD 4 TX TX/RX+ TX+ 4 RX RX+ 2 DTR Common (Isolated) Ground 2 DSR RX2 RTS TX/RXTX2 CTS 3 RI Chassis Ground Table 6: DB9 Female DCE Port pin-out NOTES: 1. No internal termination is provided. 2.
Serial Ports 3.3 RS232/RS485/RS422 plus IRIG-B via DB9 Each port is individually selectable via software to be RS232, RS485 or RS422. IRIG-B signal and ground are available on pins 4 and 6, respectively, for every mode. The DB9 port pin-out diagram and listing are shown below. NOTE: The RS232 pin configuration of the IRIG-B ports is DTE rather than DCE, meaning that the port transmits on pin 3 and receives on pin 2. Connection to DTE ports requires null-modem cabling (pin 2 to 3; pin 3 to 2).
Serial Ports 3.4 RS232/RS485/RS422 via RJ45 Each port is individually selectable via software to be RS232 (EIA-561 DTE), RS485 or RS422. The RJ45 port and pin-out is shown below. Figure 21: RJ45 port pin-out Pin 1 2 3 4 5 6 7 8 Shield RS232 Mode RS485 Mode RS422 Mode 2 DSR RX2 DCD 2 DTR Common (Isolated) Ground 3 RXD RX+ 3 TXD TX/RX + TX + 2 CTS 2 RTS TX/RX TX Chassis Ground Table 8: RJ45 Port pin-out NOTES: 1. No internal termination is provided. 2. Pins 1, 2, and 3 are connected internally.
Serial Ports 3.5 RS232/RS485/RS422 plus IRIG-B via RJ45 Each port is individually selectable via software to be RS232, RS485 or RS422. IRIG-B signal and ground are available on pins 2 and 3, respectively, for every mode. The RJ45 port and pin-out is shown below.
Serial Ports 3.6 RS485 Wiring Each RS485 port can communicate to multiple RS485 devices by daisy chaining devices over a single twisted pair with transmit and receive signals on the same two wires (half duplex). The following guidelines should be followed to ensure reliable continuous communication: 1. To minimize the effects of ambient electrical noise, shielded cabling is recommended. 2. The correct polarity must be observed throughout a single daisy chain. 3.
Serial Ports 3.7 Serial Port Transient Protection RuggedCom does not recommend the use of copper cabling of any length for critical real-time substation automation applications. However, transient suppression circuitry is present on all copper ports to protect against damage from electrical transients and to ensure IEC 61850-3 and IEEE 1613 Class 1 conformance. This means that during the transient event communications errors or interruptions may occur but recovery is automatic.
Time Synchronization 4 Time Synchronization The RS416 is able to derive and provide time synchronization via Ethernet using the Precision Time Protocol (PTP - IEEE1588v2) and NTP (Network Time Protocol). With the IRIG-B module is installed, the RS416 is also able to synchronize to received IRIG-B time signal and to distribute it via BNC and via serial ports equipped with IRIG-B signals. Please refer to the data sheet for ordering options.
Ethernet Ports Figure 24 shows layout of the BNC connectors on the IRIG-B I/O board. The LED in the center of the board, indicated by the mark, reflects the status of the received IRIG-B signal, and is described in Table 12. Figure 24: IRIG-B daughter board BNC connections LED Color Meaning Off No IRIG-B signal detected Red Errors detected in received IRIG-B signal Green Received IRIG-B signal is good Table 12: IRIG-B Daughter Board LED 4.
Ethernet Ports negotiating, auto-polarity, and auto-crossover functions. On the RS416P, these ports support PoE, providing up to 15.4W per port at a nominal 48VDC, auto-sensing and auto-power off when cables are disconnected. The RJ45 receptacles can also accept and take advantage of screened (commonly known as “shielded”) cabling. Figure 26 shows the RJ45 port pins configuration.
Ethernet Ports 5.2 Fiber Optic Ports Depending on the order code of the product, the RS416 can be equipped with several different types of fiber optic ports. The Transmit (TX) and Receive (RX) connections of each port must be properly connected and matched for proper link and operation. Modules populated on the top row of the device typically have locking mechanisms or tabs towards the top of the unit.
Ethernet Ports 5.3 Ethernet Panel Description Each Ethernet module is equipped with two LEDs that indicate link/activity status information. The LED will be solid for ports with link, and will blink for activity. The diagram in Figure 32 highlights the port and the associated link/activity LED.
Technical Specifications 6 Technical Specifications 6.1 Power Supply Specifications Input Range Power Supply Type4 12 – 24 VDC 48 VDC HI (125/250 VDC) 1 HI (110/230 VAC) 1 Min Max 10 VDC 36 VDC 88 VDC 85 VAC 36 VDC 59 VDC 300 VDC 264 VAC Internal Fuse Rating 6.3A(F) 2 3.15A(T) 2 Max.
Technical Specifications 6.3 Data Port Specifications 6.3.1 Serial Ports 6.3.1.1 Copper Ports Parameter Specifications Connector 300 bps – 230 kbps DB9 or RJ45 Isolation 2.5 kV Baud Rate Notes RMS 1-minute Table 16: Copper Port Specification 6.3.1.2 Fiber Optic Ports Parameter Specifications Mode Multimode Connector ST Typical Dist. (km) Optical Wavelength (nm) Cable Size Core/Cladding (um) 5 820 50/125 62.5/125 Table 17: Fiber Optic Port Specification NOTES: 1.
Technical Specifications 6.3.3 Ethernet Ports 6.3.3.1 Copper Ports Parameter Speed Duplex Cable-Type Wiring Standard Max Distance Connector Isolation PoE Voltage PoE Current Specification Notes 10/100 Mbps FDX / HDX > Category 5 TIA/EIA T568A/B 100 m RJ45 1.5 kV 44-57 V 350 mA Auto-negotiating Auto-negotiating Shielded/Unshielded Auto-Crossover, Auto-polarity RMS 1-minute Table 20: Ethernet Ports - Copper Specifications 6.3.3.
Technical Specifications 12-11-0006 100FX SM/ST 1310 9/125 -15 -7 -34 -3 20 19 12-11-0005 100FX SM/SC 1300 9/125 -15 -8 -31 -7 20 16 12-11-0004 100FX SM/LC 1300 9/125 -15 -8 -38 -3 20 23 12-11-0031 100FX SM/SC 1310 9/125 -5 0 -34 -3 50 29 12-11-0032 100FX SM/LC 1310 9/125 -5 0 -35 -3 50 30 12-11-0033 100FX SM/SC 1310 9/125 0 5 -37 0 90 42 12-11-0034 100FX SM/LC 1310 9/125 0 5 -37 0 90 37 Table 21: Ethernet Ports – Fiber Optic Speci
Technical Specifications 6.5 Mechanical Specifications Parameter Dimensions Weight Enclosure Value 18.29 x 10.17 x 1.74 inches (464,57) x (258,32) x (44,20) mm Comments (Length x Width x Height) with mounting brackets installed 10 lb (4.
Type Tests 7 Type Tests 7.1 IEC 61850-3 Type Tests Test Description IEC 61000-4-2 ESD IEC 61000-4-3 Radiated RFI IEC 61000-4-4 Burst (Fast Transient) Enclosure Contact Enclosure Air Enclosure ports Signal ports D.C. Power ports A.C. Power ports Earth ground ports Surge Signal ports D.C. Power ports 30V Continuous, 300V for 1s 4 D.C. Power ports 10% 3 Signal ports D.C. Power ports A.C. Power ports Signal ports D.C. Power ports A.C. Power ports 2kV AC (Fail-Safe Relay output) 1.
Type Tests 7.2 IEEE 1613 Type Tests IEEE Test IEEE 1613 Clause C37.90.3 9 ESD C37.90.2 8 Radiated RFI C37.90.1 7 Fast Transient C37.90.1 7 Oscillatory C37.90 6 H.V. Impulse C37.90 6 Dielectric Strength Description Test Levels Enclosure Contact Enclosure Air Enclosure ports Signal ports D.C. Power ports A.C. Power ports Earth ground ports Signal ports D.C. Power ports A.C. Power ports Signal ports D.C. Power ports A.C. Power ports Signal ports D.C. Power ports A.C.
Agency Approvals 8 Agency Approvals Agency CSA CE FCC CISPR FDA/CDRH IEC/EN Standards CSA C22.2 No. 60950, UL 60950 EN 60950, EN 61000-6-2 FCC Part 15, Class A EN55022, Class A 21 CFR Chapter 1, Subchapter J EN60825-1:1994 + A11:1996 + A2:2001 Comments Approved Approved Approved Approved Compliant Compliant Table 27: Agency Approvals 9 Warranty RuggedCom warrants this product for a period of five (5) years from date of purchase. For warranty details, visit http://www.ruggedcom.
