SCADAPack LP Hardware Manual Scada Pack

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ScadaPack%20LP%20Manual

ScadaPack%20LP%20Manual

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SCADAPack LP
Hardware Manual
CONTROL
MICROSYSTEMS
SCADA products... for the distance
48 Steacie Drive Telephone: 613-591-1943
Kanata, Ontario Facsimile: 613-591-1022
K2K 2A9 Technical Support: 888-226-6876
Canada 888-2CONTROL
SCADAPack LP Hardware Manual
©2000 - 2006 Control Microsystems Inc.
All rights reserved.
Printed in Canada.
Trademarks
TeleSAFE, TelePACE, SmartWIRE, SCADAPack, TeleSAFE Micro16 and
TeleBUS are registered trademarks of Control Microsystems Inc.
All other product names are copyright and registered trademarks or trade names
of their respective owners.
Material used in the User and Reference manual section titled SCADAServer
OLE Automation Reference is distributed under license from the OPC
Foundation.
SCADAPack LP Hardware Manual
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Table of Contents
1 OVERVIEW.................................................................................................... 5
2 IMPORTANT SAFETY INFORMATION ........................................................ 6
3 INSTALLATION............................................................................................. 8
3.1 Field Wiring .................................................................................................... 8
4 POWER SUPPLY ........................................................................................ 10
4.1 System Grounding ....................................................................................... 10
4.2 Power Management Features...................................................................... 10
4.2.1 COM3 Serial Port Power Control ............................................................ 11
4.2.2 VLOOP Power Control............................................................................ 11
4.2.3 12V to 24V DC/DC Converter Control .................................................... 12
5 ANALOG INPUTS ....................................................................................... 13
5.1 Internal Analog Inputs .................................................................................. 13
5.2 I/O Analog Inputs ......................................................................................... 13
5.2.1 Analog Input Connections....................................................................... 14
5.2.2 Analog Input Wiring ................................................................................ 14
5.2.3 Analog Input Wiring Examples................................................................ 14
5.3 Analog Input Range Jumpers....................................................................... 15
5.4 Analog Inputs Data Format .......................................................................... 15
6 ANALOG OUTPUTS ................................................................................... 17
6.1 Current Outputs............................................................................................ 17
6.2 Voltage Outputs ........................................................................................... 17
6.3 Analog Outputs Data Format ....................................................................... 17
7 DIGITAL OUTPUTS..................................................................................... 19
8 DIGITAL INPUTS......................................................................................... 20
8.1 Digital I/O Connection Examples.................................................................. 21
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9 COUNTER INPUTS ..................................................................................... 22
9.1 Counter Input 0 ............................................................................................ 22
9.2 Turbine Meter Counter Inputs 1 and 2 ......................................................... 22
10 SERIAL COMMUNICATION........................................................................ 24
10.1 RS-232 Serial Communications Ports.......................................................... 24
10.1.1 COM2 RS-232 Serial Port....................................................................... 24
10.1.2 COM3 RS-232 Serial Port....................................................................... 26
10.2 RS-232 Wiring Examples ............................................................................. 27
10.2.1 DTE to DTE without Handshaking .......................................................... 27
10.2.2 DTE to DTE with Handshaking ............................................................... 28
10.2.3 DTE to DCE with Handshaking............................................................... 28
10.3 RS-232 Cables............................................................................................. 29
10.3.1 RJ-45 to DE-9S DTE .............................................................................. 29
10.3.2 RJ-45 to SCADAPack Vision .................................................................. 29
10.3.3 RJ-45 to DE-9P DCE .............................................................................. 30
10.4 COM1 RS-485 Serial Communication Port .................................................. 30
10.4.1 RS-485 Bias Resistors............................................................................ 31
10.4.2 RS-485 Termination Resistors................................................................ 31
10.5 RS-485 Wiring Examples ............................................................................. 31
11 OPERATION................................................................................................ 33
11.1 Operating Modes.......................................................................................... 33
11.1.1 Run Mode ............................................................................................... 33
11.1.2 Service Mode.......................................................................................... 33
11.1.3 Cold Boot Mode ...................................................................................... 33
11.1.4 Sleep Mode............................................................................................. 34
11.2 LED Indicators.............................................................................................. 34
11.3 LED Power Control ...................................................................................... 35
11.4 Jumpers ....................................................................................................... 35
11.5 Status LED................................................................................................... 36
11.5.1 I/O Module Error Indication..................................................................... 36
11.5.2 Register Assignment Checksum Error.................................................... 36
12 MAINTENANCE........................................................................................... 37
12.1 Fuses ........................................................................................................... 37
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12.2 Lithium Battery ............................................................................................. 37
12.2.1 Battery Replacement Procedure............................................................. 37
13 TROUBLESHOOTING................................................................................. 39
13.1 Analog Inputs ............................................................................................... 39
13.2 Analog Outputs ............................................................................................ 39
13.3 Digital Inputs ................................................................................................ 39
13.4 Digital Outputs.............................................................................................. 39
13.5 Counter Inputs.............................................................................................. 40
14 SPECIFICATIONS....................................................................................... 41
14.1 General ........................................................................................................ 41
14.2 Controller ..................................................................................................... 41
14.3 Communications .......................................................................................... 41
14.4 Visual Indicators........................................................................................... 42
14.5 Power Supply ............................................................................................... 42
14.6 I/O Capacity ................................................................................................. 43
14.7 Analog Inputs ............................................................................................... 43
14.8 Analog Outputs ............................................................................................ 44
14.9 Counter Inputs.............................................................................................. 44
14.10 Digital Inputs/Outputs................................................................................... 45
15 APPROVALS AND CERTIFICATIONS ....................................................... 46
Index of Figures
Figure 1: SCADAPack LP Controller ................................................................................... 7
Figure 2: SCADAPack LP Board Layout............................................................................. 9
Figure 3: Power Management........................................................................................... 11
Figure 4: Analog Input Wiring ........................................................................................... 15
Figure 5: Analog Output Wiring.......................................................................................... 17
Figure 6: Digital Input/Output Wiring.................................................................................. 21
Figure 7: Counter Input Wiring........................................................................................... 22
Figure 8: Counter Jumpers ................................................................................................ 23
Figure 9: RS-485 Wiring .................................................................................................... 32
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1 Overview
The SCADAPack LP is a low power controller complete with an integrated power supply, analog
and digital I/O, serial communications and turbine flow meter counter inputs. See
Figure 1: SCADAPack LP Controller. Application programs can be written in Relay Ladder Logic,
IEC 61131-3 and the C language.
Several power saving features are included in the SCADAPack LP. These power saving features
include Sleep Mode, 24V-power shutdown, communication port power control and SCADAPack
Vision power down.
The SCADAPack LP has six analog input channels. Five analog inputs are user configurable for
either 10V or 20mA operation and one is a 32V analog input. Two optional 20mA analog outputs are
available.
Eight digital I/O points, each capable of sinking 1A or monitoring a dry contact closure, provide
flexible digital input and output configurations.
Three counter inputs, two of which are designed for direct connection to the millivolt output of
turbine meter transducers, provide for a variety of connections to metering elements.
The I/O capacity of the SCADAPack LP can be expanded using 5000 Series I/O modules. A
maximum of forty 5000 Series I/O modules may be used for a total expansion capacity of 512 digital
inputs, 512 digital outputs, 128 analog inputs, 64 analog outputs and 64 counter inputs.
Three serial communication ports are provided. An RS-485 port is designed for use with
multivariable transmitters. One of the two RS-232 ports is designed for use with the SCADAPack
Vision operator interface. The SCADAPack LP supports direct wired, telephone and radio
communication.
The primary microcontroller memory is 512KBytes flash ROM, and 1MBytes RAM. The CMOS
RAM is non-volatile (battery backed). An EEPROM (1kBytes) stores configuration parameters. A
real time clock calendar provides for time of day operations and alarms. A hardware watchdog timer
protects against application program failures.
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2 Important Safety Information
Power, input and output (i/o) wiring must be in accordance with Class I, Division 2 wiring methods
Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as
specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in
accordance with the authority having jurisdiction.
WARNING !
EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY
IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2.
WARNING !
EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, TURN
OFF POWER BEFORE REPLACING OR WIRING MODULES.
WARNING !
EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT
UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS
KNOWN TO BE NONHAZARDOUS.
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Figure 1: SCADAPack LP Controller
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3 Installation
The installation of SCADAPack controllers requires mounting the controller on the 7.5mm by 35mm
DIN rail and connecting the SCADAPack controller to the system I/O Bus. Refer to the System
Configuration Guide, at the beginning of this manual, for complete information on system layout,
I/O Bus cable routing and SCADAPack controller installation.
3.1 Field Wiring
SCADAPack controllers use screw termination style connectors for termination of field wiring.
These connectors accommodate solid or stranded wires from 12 to 22 AWG. The connectors are
removable allowing replacement of the SCADAPack Controller without disturbing the field wiring.
Leave enough slack in the field wiring for the connector to be removed.
CAUTION: Remove power before servicing unit.
To remove the termination connector:
• Pull the connector upward from the board. Apply even pressure to both ends of the connector.
• To install the termination connector:
• Line up the pins on the module with the holes in the connector. Make sure all the pins line up
properly.
• Push the connector onto the pins. Apply even pressure to both ends on the connector.
There are six connectors for field wiring. Refer to Figure 2: SCADAPack LP Board Layout for
connector locations.
• The two RS-232 communication ports, COM 2 and COM 3, connect to 8 pin modular jacks.
Refer to section 10.1-RS-232 Serial Communications Ports for pinout details and wiring
diagrams for these modular jacks.
• All other field wiring terminates in removable terminal connectors. Connector pinouts and
wiring examples are described in each of the respective sections of this manual.
Optional Analog
Out
p
ut Module
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Figure 2: SCADAPack LP Board Layout
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4 Power Supply
The SCADAPack LP is powered from an 11VDC to 24VDC input power source.
• Input power is applied to the 11-24Vdc positive (+) and negative (-) terminals on connector P3.
Refer to section 14-Specifications of this manual for the minimum and maximum operating voltages
and input power requirements.
• When the input voltage is below the minimum recommended voltage the SCADAPack LP will
turn off.
• Exceeding the maximum input voltage or applying a reverse voltage will blow the input power
fuse.
Note: Unlike the other members of the SCADAPack family, the SCADAPack LP connects only to
DC power sources. Connections to power sources such as 16Vac transformers will blow the
fuse and may cause damage to the SCADAPack LP.
The DC power-input voltage is used to generate 5V for the SCADAPack LP circuitry. The output
capacity of the 5V supply is sufficient to power the SCADAPack LP and a SCADAPack Vision
operator interface with 100mA remaining capacity for a limited number of 5000 Series I/O modules.
For 12VDC power-input voltages a 12V to 24V DC/DC converter is used to power 20mA analog
input and output devices. The DC/DC converter is controlled by the user application program and
may turned on or off. Refer to section 4.2.3-12V to 24V DC/DC Converter Control for more
information on DC/DC converter control.
4.1 System Grounding
In most applications, it is desirable to ground the system by connecting the system power supply
common, to the chassis or panel ground. The negative (–ve) side of the DC power input terminal as
well as all I/O point terminals labeled GND are connected to chassis ground.
4.2 Power Management Features
The SCADAPack LP provides a number of special features to reduce power consumption. These
power management features are:
• COM3 serial port power control.
• VLoop power control.
• 12V to 24V DC/DC Converter Control.
The SCADAPack LP provides three internal digital outputs that can be operated by the user
application to manage the power saving features. Internal digital outputs 9, 10 and 11 and the power
management functions they control are described in the following sections.
Refer to Figure 3: Power Management for an overview of the power management features. Refer
to the appropriate software manual for information on using and controlling the internal Digital
Outputs. For TelePACE applications refer to the Register Assignment for SCADAPack LP I/O
module and for ISaGRAF applications refer to the I/O Complex Equipment for SCADAPack LP I/O.
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12V to 24V boost
ON/OFF
Dout 11
P10 - Vloop
P2
I/O Expansion
5V supply
P3 – Power In
Dout 10
Sleep = open
P5 – COM1
RS-485
P7 – COM2
RS-232
P8 – COM3
RS-232
Dout 9
J13
5305 Analog
Output Module
Figure 3: Power Management
4.2.1 COM3 Serial Port Power Control
The COM3 serial port is intended for use with the SCADAPack Vision or other Human Machine
Interface (HMI). Pin 1 of the RJ-45 connector provides switched 5-volt power for the SCADAPack
Vision or other HMI.
Refer to section 10.1.2-COM3 RS-232 Serial Port section for information on COM3 and section
10.3.2-RJ-45 to SCADAPack Vision section for wiring examples. HMI power is controlled in the
following ways.
• When internal Digital Output 9 is ON HMI power is turned on.
• When internal Digital Output 9 is OFF HMI power is turned off.
• HMI power is turned on for five minutes when a momentary contact is made between pin 2
(DCD) and pin 3 (DTR) on the COM3 RJ-45 connector. This permits the SCADAPack Vision or
an HMI pushbutton to control HMI power. At each momentary contact, the five-minute power
timer is reloaded. If the five-minute power timer is maintaining the HMI power on, a sustained
two-second or longer contact between DCD and DTR will turn off HMI power. Refer to section
10.3.2-RJ-45 to SCADAPack Vision for more information.
Internal Digital Input 9 indicates the status of COM3 serial port power. Digital Input 9 is set when
COM3 serial port power is on and is cleared when COM1 serial port power is off.
HMI power is turned on whenever the LED power is enabled. This feature is provided for service
and diagnostics. Refer to section 11.3-LED Power Control for further information on this feature.
4.2.2 VLOOP Power Control
The DC/DC converter output can be used to power analog input current loops or other
instrumentation. This output, VLOOP, is controlled for intermittent or continuous operation. Turning
the VLOOP output off when it is not required can save considerable electrical power.
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The switched VLOOP power source is the output of the DC-DC 12/24V converter if it is turned on.
See the section 4.2.3-12V to 24V DC/DC Converter Control for converter information. The VLOOP
power source is the applied input power if the DC-DC converter is turned off.
• Turn on Digital Output 10 to turn ON the VLOOP output.
• Turn off Digital Output 10 to turn OFF the VLOOP output.
Internal Digital Input 10 indicates the status of VLOOP power. Digital Input 10 is set when VLOOP
power is on and is cleared when VLOOP power is off.
Note: When VLOOP is first turned on, the user application program must wait some period of time
for input readings to stabilize. This time period is dependent on the field sensors and
transmitters connected. Documentation for these devices should be consulted.
The VLOOP output is turned on when the LED power is enabled. This feature is provided for service
and diagnostics. Refer to section 11.3-LED Power Control for further information on this feature.
4.2.2.1 VLOOP Over-Current Protection
When VLOOP output is turned on, it is monitored for excessive current consumption caused by field
wiring or instrumentation problems. If sustained over-current is detected (100 ms), VLOOP is turned
off even though internal Digital Outputs 10 is turned on. This protection prevents unnecessary fuse
blowing, circuitry damage and rapid battery depletion.
When VLOOP output is turned on, using internal Digital Output 10, and a short circuit is detected
VLOOP will turn off. VLOOP will turn on to try again 5 seconds after turning off. If the fault
condition still exits VLOOP will again turn off and retry after a 5 second delay. While the fault
condition exists internal Digital Input 12 will be ON.
4.2.3 12V to 24V DC/DC Converter Control
The 12V to 24V DC/DC converter is used to provide 24 Vdc for VLOOP power and for the 5305
Analog Output module. The converter should be turned on if the SCADAPack LP is equipped with
analog outputs for which 24V drive capability is required. Otherwise, the DC/DC converter can be
turned off to conserve power.
• Turn on Digital Output 11 to turn ON the 12V to 24V DC/DC converter. When the converter is
turned on 24Vdc is provided to the VLOOP power and to the 5305 Analog Output module.
• Turn off Digital Output 11 to turn OFF the 12V to 24V DC/DC converter. When the converter
is turned off VLOOP power and the 5305 Analog Output module use is the applied input power.
Internal Digital Input 11 indicates the status of the 12V to 24V DC/DC converter. Digital Input 11
is set when the 12V to 24V DC/DC converter is on and is cleared when the 12V to 24V DC/DC
converter is off.
The 12V to 24V DC/DC converter is turned on when the LED power is enabled. This feature is
provided for service and diagnostics. Refer to section 11.3-LED Power Control for further
information on this feature
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5 Analog Inputs
There are six single ended analog inputs available to the user. These inputs provide 15-bit resolution
over the range of the input. Five of these inputs are selectable for voltage or current inputs. One of
these inputs is a 0 to 32.768-volt input and can be used to monitor battery voltage.
In addition to these analog inputs there are internal analog inputs available to the user. These analog
inputs are used in application programs to monitor, RAM battery voltage, controller board ambient
temperature and DC\DC converter voltage used for VLOOP.
Input Type Description
0 to 4 external Jumper selectable for 0-10V or 0-40mA inputs.
5 external 0-32.768V for battery monitoring
6 internal DC/DC converter output voltage
7 internal Used internally by SCADAPack LP.
Refer to the appropriate software manual for information on using the SCADAPack LP Analog
Inputs in application programs. For TelePACE applications refer to the Register Assignment for
SCADAPack LP I/O module and for ISaGRAF applications refer to the I/O Complex Equipment for
SCADAPack LP I/O.
5.1 Internal Analog Inputs
SCADAPack LP Controllers have two internal analog inputs. These internal analog inputs are
accessed from the user application program.
The ambient temperature input measures the temperature at the controller circuit board. It is useful
for measuring the operating environment of the controller and returns an integer value in the range –
40 to 75 deg C or –40 to 167 deg F. The temperature reading represents temperatures in the range -
40°C to 75°C or -40°F to 167°F. Temperatures outside this range cannot be measured.
• For TelePACE applications use the AIN Controller Temperature register assignment to read the
ambient temperature in degrees C and degrees F.
• For ISaGRAF applications use the aintemp I/O connection to read the ambient temperature in
degrees C and degrees F.
The lithium battery input measures the voltage of the battery that maintains the non-volatile RAM in
the controller. The reading returned from this input is in the range from 0 – 5000 representing the
battery voltage in mV. It is useful in determining if the battery needs replacement. The 3.6V lithium
battery will return a typical value of 3600 or 3700. A reading less than 3000 (3.0V) indicates that the
lithium battery requires replacement.
• For TelePACE applications use the AIN Controller RAM Battery V register assignment to read
the lithium battery voltage.
• For ISaGRAF applications use the ainbatt I/O connection to read the lithium battery voltage.
5.2 I/O Analog Inputs
There are six single ended analog inputs available to the user. These analog inputs provide 15-bit
resolution over the entire range of the input. The analog inputs are transient protected and share a
common return (GND) that is connected to the chassis. Refer to Figure 2: SCADAPack LP Board
Layout for the location of P9.
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5.2.1 Analog Input Connections
The six external analog inputs connect to connector P10. The analog inputs are identified as Channel
0 through Channel 5. The first five, identified as Channels 0 through 4, use range jumpers to select
either voltage inputs or current inputs. These analog inputs are single ended and measure voltages up
to 10V. When configured as current inputs, the 250Ω current sense resistor will produce at 5V input
at 20mA. See section 5.3-Analog Input Range Jumpers for information on setting the range. See
Figure 2: SCADAPack LP Board Layout section for the location of the range jumpers.
The sixth input, identified as Channel 5, is a 32.768V voltage input. This input is typically used to
monitor the input power or battery voltage.
5.2.2 Analog Input Wiring
The analog inputs support loop powered and self powered transmitters. Loop powered transmitters
are two terminal devices that connect between a power supply and the analog input. The loop current
continues from the power supply, through the transmitter and to ground through a 250Ω resistor built
into the 20mA input circuit. Self-powered transmitters have three terminals called power in, signal
out and common. Self-powered transmitters can have a current or voltage output. The signal out
connects to the Analog Input Channel, the common connects to GND and the power in connects to a
power supply.
There are three options for the user when selecting the power source. In all cases it is important for
the user to ensure that the transmitter has enough voltage for proper operation. The transmitter
manufacturer supplies the minimum operating voltage specification of the transmitter. The analog
input requires a minimum of 5V.
The first option is to use the SCADAPack LP VLOOP Supply that steps up the input voltage to 24V.
The stepped up voltage is available on the Analog Connector P10 and is labeled VLOOP. There is
sufficient power available here for the five analog inputs and two analog outputs all operating at
20mA. Significant power saving is possible by switching the Loop Supply off.
The second option is similar to the first except that the power supply is not stepped up to 24V. This
can be used with low voltage transmitters or when then the input voltage is sufficiently high that
further stepping up is not necessary. It is still possible to switch the supply off under program
control. When the step up is turned off, VLOOP is approximately 0.5V less that the power input
voltage.
The third option is to power the transmitter from a power supply supplied by the user.
5.2.3 Analog Input Wiring Examples
Figure 4: Analog Input Wiring shows example wiring of several transmitters.
• Channel 0 has a loop powered current transmitter connected to VLOOP.
• Channel 1 has a loop powered current transmitter connected to an external 24V power supply.
• Channel 2 is unused.
• Channel 3 has a self-powered voltage transmitter connected to an external 24V-power supply.
• Channel 4 has a self-powered current transmitter connected to an external 24V-power supply.
• Channel 5 is used to monitor the external 24V-power supply.
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+
External 24Vdc
Power Supply
_
Voltage
8
+
_
Vloop
7 6 5 4 3 2 1
GND012345
12304
Current
P10 - Analog Inputs
+
_
PWR
Voltage O/P
COM
PWR
Current O/P
COM
J1 J2 J3 J4 J5
Figure 4: Analog Input Wiring
5.3 Analog Input Range Jumpers
Channels 0 through 4 can be user configured for either voltage or current operation with jumper
links. Refer to Figure 4: Analog Input Wiring for examples of the how a jumper link is installed on
J1 through J5. A jumper link installed in the Current position of the header results in a 250Ω resistor
across the appropriate analog input. A jumper link installed in the Voltage position of the header
results in high impedance analog input.
5.4 Analog Inputs Data Format
The I/O analog inputs have a 16-bit, unipolar, analog to digital (A/D) converter that measures input
voltages from 0 to 10V. The analog inputs are factory calibrated to scale the data and represent it
with a 15 bit unsigned number.
When an analog input is configured for voltage, 10V input is represented with 15 bits of data. The
input resolution is 0.305mV/count.
When an analog input is configured for current, 20mA input is represented with 14 bits of data.
There is 100% over range. The input resolution is 1.22µA/count.
The channel 5 analog input is configured for voltage. 32.768V is represented with 15 bits of data.
The input resolution is 0.001V/count.
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The following table shows the A/D output value for several input signals.
Current
Channel 0-4
Voltage
Channel 0-4
Voltage
Channel 5
A/D Output
0mA 0V 0V 0
1.22µA 0.305mV 0.001V 1
4mA 1.0V 3.277V 3277
10mA 2.5V 8.192V 8192
20mA 5.0V 16.384V 16384
39.999mA 9.9997V 32.767V 32767
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6 Analog Outputs
The SCADAPack LP may include two channels of analog output if this option was requested at time
of purchase.
Refer to the appropriate software manual for information on using the SCADAPack LP Analog
Outputs in application programs. For TelePACE applications refer to the Register Assignment for
SCADAPack LP I/O module and for ISaGRAF applications refer to the I/O Complex Equipment for
SCADAPack LP I/O.
6.1 Current Outputs
The optional analog output module provides two 20mA analog outputs.
The internal power supply powers the analog output circuits. The user can, under program control,
boost the DC Input Power to 24V. This is required when generating current outputs into high
resistance loads. Refer to section 4.2.3-12V to 24V DC/DC Converter Control for further
information.
Figure 5: Analog Output Wiring shows example wiring of the analog outputs.
6.2 Voltage Outputs
To obtain voltage outputs, connect a load resistor in the current output. Connect the voltage device
across the load resistor. The table below list resistance values and output range settings for two
common voltage ranges. The resistance value listed is the parallel resistance of the device and the
load resistor.
Voltage Range Resistance Output Range
0 to 5V 250Ω 0-20mA
0 to 10V 500Ω 0-20mA
32 1
GND 0 1
P10 - Analog Outputs
–
L
O
A
D
+
–
L
O
A
D
+
Figure 5: Analog Output Wiring
6.3 Analog Outputs Data Format
The optional analog output module has a 12-bit, unipolar, digital to analog converter. There are 4096
counts in the output signal range. The 0-20mA output range resolution is 4.88µA/count. The table
below shows the output current for several D/A values.
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D/A Value Current
0 0mA
8 4.88µA
6552 4mA
16384 10mA
24576 15mA
32760 19.995mA
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7 Digital Outputs
The SCADAPack LP I/O Module provides eight universal digital inputs or outputs. Outputs are
open-collector/open drain type for use with sustained DC loads up to 1 ampere. Higher peak loads
can be tolerated.
The negative side of the load is connected to the desired terminal on the controller terminal block P3.
The positive side of the load connects to a power supply. When the load is on the load current is
switched through the controller to terminal labeled GND. GND must be connected to the negative
side of the power supply.
Inductive load transient suppression is built into each digital output point. It is not necessary to add
additional inductive load transient suppression unless highly inductive loads (greater than 1H) are
operated continuously at greater than 0.5Hz.
The SCADAPack LP also provides three internal digital outputs that can be controlled by the user
application to manage power saving features unique to the SCADAPack LP.
Refer to the appropriate software manual for information on using the SCADAPack LP Digital
Inputs and Outputs in application programs. For TelePACE applications refer to the Register
Assignment for SCADAPack LP I/O module and for ISaGRAF applications refer to the I/O Complex
Equipment for SCADAPack LP I/O.
The following table describes the SCADAPack LP digital outputs.
Output Type Description
0 to 7 external Open drain outputs. These outputs are located on terminal
P3.
0 = output transistor off
1 = output transistor on
8 internal Not used for applications, internal use only.
9 internal com3 (HMI) power control
0 = off
1 = on
See section 4.2.1-COM3 Serial Port Power Control for
details.
10 internal VLOOP power control
0 = off
1 = on
See section 4.2.2- VLOOP Power Control for details.
11 internal DC/DC converter control
0 = off
1 = on
See section 4.2.3-12V to 24V DC/DC Converter Control for
details.
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19
8 Digital Inputs
The SCADAPack LP I/O Module provides eight universal digital inputs and outputs. The inputs are
for use with dry contacts such as switches and relay contacts. The SCADAPack LP provides the
wetting current for the contacts.
If LED power is enabled, the SCADAPack LP continuously sources approximately 5mA wetting
current into each dry contact input. Indicator LEDs will be at their maximum brilliance if on. This
facilitates field service and diagnostics.
If LED power is disabled then the wetting current is turned on only when the digital inputs are
scanned by the SCADAPack LP. Power consumption is reduced as the inputs are scanned only once
every millisecond. Indicator LEDs are dim in this condition. This is normal.
Refer to the appropriate software manual for information on using the SCADAPack LP Digital
Inputs and Outputs in application programs. For TelePACE applications refer to the Register
Assignment for SCADAPack LP I/O module and for ISaGRAF applications refer to the I/O Complex
Equipment for SCADAPack LP I/O.
The SCADAPack LP I/O Module provides the following digital inputs.
Input Type Description
0 to 7 external Dry contact inputs. These inputs are located on terminal P3.
0 = contact open (associated is LED off)
1 = contact closed (associated is LED on)
8 internal Not for use in applications. Internal use only.
9 internal Com3 (HMI) power output status
0 = off
1 = on
See section 4.2.1-COM3 Serial Port Power Control for
details.
10 internal VLOOP output status
0 = off
1 = on
See section 4.2.2- VLOOP Power Control for details.
11 internal DC/DC converter status
This bit reports the true status of the DC/DC converter. If
over-current causes the converter to be turned off, this bit
will clear.
0 = off
1 = on
See section 4.2.3-12V to 24V DC/DC Converter Control for
details.
12 internal VLOOP over-current status
Indicates VLOOP over-current has been detected. This input
clears when VLOOP output is off, or the over-current
condition clears.
0 = off
1 = on
See section 4.2.2.1-VLOOP Over-Current Protection
section for details.
13 internal Digital output mismatch
Known out
p
uts are com
p
ared to the corres
p
ondin
g
in
p
uts to
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May 26, 2006
20
Input Type Description
detect incorrect outputs. A point is compared if it has been
turned on at any time since controller reset. This input
indicates if one or more outputs mismatch. The source of the
mismatch can be determined by comparing each digital input
against the corresponding digital output.
0 = off
1 = on
14 internal If the SCADAPack Vision power key is pressed while DO 9
is off, digital input bit 14 will be set. DI 14 is cleared 5
minutes after the power key is pressed or immediately upon
DO 9 turning on.
See section 4.2.1-COM3 Serial Port Power Control for
details.
15 internal reserved for future use
8.1 Digital I/O Connection Examples
Various I/O point wiring examples are shown in Figure 6: Digital Input/Output Wiring. Digital I/O
point 0 is shown connected to a 12V load that uses the same 12V power supply that powers the
SCADAPack LP. Digital I/O point 4 is shown connected to a 24V load and external 24V-power
supply. Digital I/O point 2 is shown monitoring a dry contact. Digital I/O point 5 is shown
monitoring an open collector contact. Transient voltage suppression is included on each I/O point.
109876543
GND0123 45
P3 – DC Power In and Digital I/O
+ 24V Load –
1 2
+–
11 12
67GND
+
12Vdc Power
Supply
_
+
24Vdc Power
Supply
_
+ 12V Load –
Figure 6: Digital Input/Output Wiring
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21
9 Counter Inputs
The SCADAPack LP has three counter inputs, identified as Counter 0, 1 and 2. Two of the counter
inputs, Counter 1 and 2, are designed for millivolt level turbine meters. The third, Counter 0, is a
high level digital input for use with open collector/drain output amplifiers.
Refer to the appropriate software manual for information on using the SCADAPack LP Counter
Inputs in application programs.
• For TelePACE applications refer to the Register Assignment for SCADAPack LP I/O module
and
• For ISaGRAF applications refer to the I/O Complex Equipment for SCADAPack LP I/O.
• For C applications use the readCounter function.
9.1 Counter Input 0
Counter Input 0 is used to count contact closures. The input circuitry includes a 1000-ohm resistor
from the counter input to the 5V power supply. Refer to Figure 7: Counter Input Wiring for an
example of wiring to an open collector output.
5 4 3 2 1
0 1 2
P5 – Counters
GND
Turbine
Meter
Sensor
GND
Turbine
Meter
Amplifier
Consult manufacturer of
amplifier for wiring details.
J9 J10 J11 J12
1 2 1 2
Counter 1 input through
internal amplifier
Counter 2 input
bypassing internal amplifier.
Figure 7: Counter Input Wiring
9.2 Turbine Meter Counter Inputs 1 and 2
The SCADAPack LP allows for the direct connection of two turbine meter sensors. These sensors
produce millivolt outputs and do not require an external pre-amplifier when used with the
SCADAPack LP. The turbine meter inputs should be used in low noise environments with shielded
cabling.
There are four jumper links associated with configuring the inputs for either millivolt signals (direct
to sensor) or high level signals such as external amplifiers, dry contacts or open collector outputs.
Refer to Figure 7: Counter Input Wiring for examples of how to configure the jumper links and
wire the inputs. Counter 1 is shown as a millivolt input with a direct connection to a turbine meter
SCADAPack LP Hardware Manual
May 26, 2006
22
sensor. Note the use of shielded wiring and that the shield is connected at one end only. Counter 2 is
shown connected to an external turbine meter pre-amplifier.
When connecting to a turbine meter amplifier the manufacturer may have a specific current
requirement to power the pre-amplifier. The SCADAPack LP includes a 1000-ohm resistor from the
counter input to the DC input power source. This is the recommended wiring for a Halliburton Low
Power Pre-Amp when the SCADAPack LP is powered from 12V. If this resistor is not suitable for
your external amplifier then do not connect the jumper in either position. On Counter 1, the J11
jumper would be removed. On Counter 2, the J12 jumper would be removed. Wire the amplifier as
per the manufacturers recommendations.
Counter Inputs 1 and 2 can be used with conventional sources such as open collector transistors and
contacts. The SCADAPack LP includes a 1000-ohm resistor from the counter input to the DC input
power source. This resistor can be used when the SCADAPack LP is powered from 12V. On
Counter 1, J11 would be in the External Amplifier or bottom position. On Counter 2, J12 would be
in the External Amplifier or bottom position. If a higher voltage is used or a pullup current other than
12V at 1000-ohms is required then the user must wire an external resistor to an appropriate power
source. On Counter 1, the J11 jumper would be removed. On Counter 2, the J12 jumper would be
removed.
J9 J11
Internal
amplifier
To counter 1
Counter 1 input
Internal 1000
ohms connected
to Input Voltage
J10 J12
Internal
amplifier
To counter 2 Counter 2 input
Internal 1000
ohms connected
to Input Voltage
12VDC PWR IN
12VDC PWR
IN
Figure 8: Counter Jumpers
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23
10 Serial Communication
The SCADAPack LP controller is equipped with three serial communication ports. Two of the serial
communication ports support RS-232 serial communication and one port supports RS-485 serial
communication.
Serial ports on the SCADAPack LP controller are designated COM1, COM2 and COM3. Refer to
Figure 2: SCADAPack LP Board Layout for the location of the serial ports.
10.1 RS-232 Serial Communications Ports
The two RS-232 serial ports are designated COM2 and COM3.
All RS-232 wiring must use shielded cable. The shield should be connected to chassis ground at one
point. Failure to properly shield the cable may result in the installation not complying with FCC or
DOC radio interference regulations.
10.1.1 COM2 RS-232 Serial Port
The following table shows the serial and protocol communication parameters supported by COM2.
These parameters are set from TelePACE, ISaGRAF Workbench or from an application program
running in the SCADAPack LP controller. Default values are set when a Cold Boot or Service Boot
is performed on the SCADAPack LP controller.
Parameter Supported Values
Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200 and 38400
Default: 9600
Duplex Full or Half
Default: Full
Parity Odd, None or Even
Default: None
Data Bits 7 or 8 Bits
Default: 8 Bits
Stop Bits 1 or 2 Bits
Default: 1 Bit
Receive Flow Control ModbusRTU or None
Default: ModbusRTU
Transmit Flow Control Ignore CTS or None
Default: None
Station 1 to 65534
Default: 1
Protocol None, Modbus RTU or Modbus ASCII
Default: Modbus RTU
Addressing Mode Standard or Extended
Default: Standard
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24
Connections to COM2 are made through a RJ-45 modular connector. COM2 supports six signals
plus Ground and 5V power. The following diagram shows the pin connections for the RS-232 (RJ-
45) port connector for COM2.
RJ-45 Modular Jack
1. +5V
2. DCD
3. DTR
4. GND
5. RxD
6. TxD
7. CTS
8. RTS
2
18
7
6
5
4
3
NOTES:
• +5V is only available on Pin 1 when a jumper is installed on J13. Refer to the Figure 2:
SCADAPack LP Board Layout for the location of J13.
• The low power transmitters used in COM2 generate 0 to 5V levels. This is less than the RS-232
specification but still compatible with all RS-232 receivers. Cables should be limited to a
maximum of 10 ft (3m).
The following table provides a description of the function of each pin of the RJ-45 connector. In this
table a MARK level is a voltage of +3V or greater and a SPACE level is a voltage of 0V.
Pin Function Description
1 5V
(Output)
This pin can be connected to the 5V power supply by installing
a jumper at J13 on the SCADAPack LP.
2 DCD
(Input)
The DCD led is on for a MARK level.
3 DTR
(Output)
This pin is normally at a MARK level.
This pin is at a SPACE level when DTR is de-asserted.
4 GND This pin is connected to the system ground.
5 RxD
(Input)
The level is SPACE on standby and MARK for received data.
The LED is lit for a MARK level.
6 TxD
(Output)
The level is SPACE on standby and MARK for transmitted
data.
The LED is lit for a MARK level.
7 CTS
(Input)
This level must be a MARK for the communication port to
transmit data. When the attached device does not provide this
signal, the controller keeps the line at a MARK.
When the attached device does provide this signal, it must set
CTS to MARK to allow the controller to transmit data.
8 RTS
(Output)
This pin is a MARK if full-duplex operation is selected for the
port.
This pin is set to a MARK just before and during transmission
of data if half-duplex operation is selected.
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25
Pin Function Description
This pin is set to a SPACE when no data is being transmitted.
The LED is ON for a MARK level.
10.1.2 COM3 RS-232 Serial Port
The following table shows the serial and protocol communication parameters supported by COM3.
These parameters are set from TelePACE, ISaGRAF Workbench or from an application program
running in the SCADAPack LP controller. Default values are set when a Cold Boot or Service Boot
is performed on the SCADAPack LP controller.
Parameter Supported Values
Baud Rate 1200, 2400, 4800, 9600, 19200, 38400, 57600 and
115200
Default: 9600
Duplex Half
Default: Half
Parity Odd, None or Even
Default: None
Data Bits 7 or 8 Bits
Default: 8 Bits
Stop Bits 1 or 2 Bits
Default: 1 Bit
Receive Flow Control ModbusRTU or None
Default: ModbusRTU
Transmit Flow Control Ignore CTS or None
Default: None
Station 1 to 65534
Default: 1
Protocol None, Modbus RTU or Modbus ASCII
Default: Modbus RTU
Addressing Mode Standard or Extended
Default: Standard
Connections to COM3 are made through a RJ-45 modular connector. COM3 supports RxD and TxD
plus Ground and 5V power. The following diagram shows the pin connections for the RS-232 (RJ-
45) port connector for COM3.
The SCADAPack LP COM3 is designed to operate with the SCADAPack Vision operator interface
and has several special features noted below.
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26
RJ-45 Modular Jack
1. +5V
2. Test1
3. Test2
4. GND
5. RxD
6. TxD
7. NC
8. NC
2
18
7
6
5
4
3
NOTES:
• +5V is available on Pin 1 when turned on by the user under program control, when the
SCADAPack LP detects the contact closure of the ON switch of the SCADAPack Vision or
when the LED Power is ON.
• The SCADAPack Vision ON switch is wired to Pins 2 and 3. It is important that when a
SCADAPack Vision is not used that only the TxD, RxD and GND pins are used.
• The low power transmitters used in COM3 generate 0 to 5V levels. This is less than the RS-232
specification but still compatible with all RS-232 receivers. Cables should be limited to a
maximum of 10 ft (3m).
The following table provides a description of the function of each pin of the RJ-45 connector. In this
table a MARK level is a voltage of +3V or greater and a SPACE level is a voltage of 0V.
Pin Function Description
1 5V
(Output)
+5V power for the SCADAPack Vision.
2 Test1
(Input)
Used to detect SCADAPack Vision ON switch closure.
3 Test2
(Output)
Used to detect SCADAPack Vision ON switch closure.
4 GND This pin is connected to the system ground.
5 RxD
(Input)
The level is SPACE on standby and MARK for received data.
The LED is lit for a MARK level.
6 TxD
(Output)
The level is SPACE on standby and MARK for transmitted data.
The LED is lit for a MARK level.
7 NC No connection.
8 NC No connection.
10.2 RS-232 Wiring Examples
10.2.1 DTE to DTE without Handshaking
There are several methods for wiring the RS-232 COM port to DTE (Data Terminal Equipment) and
DCE (Data Communications Equipment) devices. The simplest connection requires only 3 wires:
RxD, TxD and signal ground. The following diagram shows a common RS-232 COM port to DTE
device.
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27
RS-232 COM port (DTE)
8 Pin connector DTE
5
6
3
4
8
7
1
2
DCD
RxD
TxD
DT
R
GND
RT
S
CT
+5V
DCD
RxD
TxD
DTR
GND
RTS
CTS
See devi ce
specification
s
for pin number
s
10.2.2 DTE to DTE with Handshaking
Some DTE devices may require hardware handshaking lines. The most common are the CTS and
RTS lines. Less common are the DTR and DCD lines. The controller does not require these lines.
Refer to the specifications of the external device for exact requirements. The following diagram
shows a common connection of an RS-232 COM port with a DTE device requiring handshaking
lines.
RS-232 COM port (DTE)
8 Pin connector DTE
5
6
3
4
8
7
1
2
DCD
RxD
TxD
DT
R
GND
RT
S
CT
+5V
DCD
RxD
TxD
DTR
GND
RTS
CTS
Se e d ev i c
e
specification
s
for pin number
s
10.2.3 DTE to DCE with Handshaking
DCE devices require different wiring. The handshaking lines must be connected in most cases. Note
that many DCE devices are half-duplex. Select half-duplex operation with these devices. The
diagram below shows common connection of a SCADAPack with a DCE device requiring
handshaking lines.
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May 26, 2006
28
RS-232 COM port (DTE)
8 Pin connector DCE
5
6
3
4
8
7
1
2
DCD
RxD
TxD
DT
R
GND
RT
S
CT
+5V
DCD
RxD
TxD
DTR
GND
RTS
CTS
See devi ce
specification
s
for pin number
s
10.3 RS-232 Cables
10.3.1 RJ-45 to DE-9S DTE
This cable is used to connect from an RJ-45 based RS-232 port on the SCADAPack controller to
DE-9P connector on a DTE such as a PC. A 10 ft. long cable is available from Control Microsystems
as part number 297217.
RJ-45
8 Pins SCADAPack
DTE Function DE9S DTE
Function DE9S
Shield connects to shell
6 TxD RxD 2
5 RxD TxD 3
4 GND GND 5
1, 2, 3, 7 and 8
are not connected
at this end.
Wires not connected at
this end.
10.3.2 RJ-45 to SCADAPack Vision
This cable is used to connect from an RJ-45 based RS-232 port on the SCADAPack LP controller to
DE-9P connector on a SCADAPack Vision. A 5-ft. long cable is available from Control
Microsystems as part number 297237.
RJ-45
8 Pins SCADAPack
LP Function SCADAPack
Vision Function DE9S
Shield connects to
shell
6 TxD RxD 2
5 RxD TxD 3
4 GND GND 5
3 Test 2 ON switch 1
2 Test 1 ON switch 4
1 +5V Out +5V In 9
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29
RJ-45
8 Pins SCADAPack
LP Function SCADAPack
Vision Function DE9S
7 and 8 are not
connected at this
end.
Wires not
connected at this
end.
10.3.3 RJ-45 to DE-9P DCE
This cable is used to connect from an RJ-45 based RS-232 port on the SCADAPack controller to
DE-9S connector on a DCE such as a modem. A 15-inch long cable is available from Control
Microsystems as part number 297218.
RJ45 SCADAPack DTE
Function DE-9P DCE
Function DE-9P
Shield connects to shell
3 DTR DTR 4
6 TxD TxD 3
5 RxD RxD 2
2 DCD DCD 1
4 GND GND 5
7 CTS CTS 8
8 RTS RTS 7
1 +5V +5V 9
10.4 COM1 RS-485 Serial Communication Port
Serial port COM1 on the SCADAPack LP controller is configured as a two-wire RS-485 serial
communication port.
The following table shows the serial and protocol communication parameters supported by COM1.
These parameters are set from TelePACE, ISaGRAF Workbench or from an application program
running in the SCADAPack LP controller. Default values are set when a Cold Boot or Service Boot
is performed on the SCADAPack LP controller.
Parameter Supported Values
Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200 and 38400
Default: 9600
Duplex Half
Default: Half
Parity Odd, None or Even
Default: None
Data Bits 7 or 8 Bits
Default: 8 Bits
Stop Bits 1 or 2 Bits
Default: 1 Bit
Receive Flow Control None or Xon/Xoff
Default: None
Transmit Flow Control None or Xon/Xoff
Default: None
Station 1 to 65534
Default: 1
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30
Parameter Supported Values
Protocol None, Modbus RTU or Modbus ASCII, DF1 or DNP.
Default: Modbus RTU
Addressing Mode Standard or Extended
Default: Standard
COM1 transmits and receives differential voltages to other RS-485 devices on a network. The RS-
485 specification allows a maximum of 32 devices connected on a single RS-485 network. The
specification for RS-485 recommends that the cable length should not exceed a maximum of 4000
feet or 1200 meters. Termination resistors are required when using long cable lengths and high baud
rates. Refer to section 10.4.2-RS-485 Termination Resistors for information on termination resistors.
The signal grounds of the RS-485 devices in the network are not connected together but instead are
referenced to their respective incoming electrical grounds. The grounds of the RS-485 devices on the
network must be within several volts of each other. The SCADAPack LP ground is connected to the
chassis.
10.4.1 RS-485 Bias Resistors
The RS-485 receiver inputs on the SCADAPack LP controller are biased to ensure that that received
data is driven to a valid state (space) when there are no active drivers on the network. The value of
these bias resistors is 5100 ohms from Ground to the B input and 5100 ohms from +5V to the A
input.
10.4.2 RS-485 Termination Resistors
Termination resistors are required in long networks operating at the highest baud rates. Shorter
networks in high noise environments may also benefit from terminations. Networks as long 1000 ft.
operating at 9600 baud will function without termination resistors. Terminations should be
considered if the baud rate is higher and the network is longer.
When termination resistors are required, they are installed on the first and last station on the RS-485
wire pair. All other stations should not have termination resistors.
RS-485 networks are generally terminated with 120-ohm resistors on each end. The required 120-
ohm resistor must be supplied and installed by the user. When using termination resistors it is
necessary to increase the line biasing by adding lower value bias resistors in order to generate at least
0.2V across RS-485 line. The suggested value of the bias resistors is 470 ohms. One bias resistor is
installed from P5 terminal 7 (B) to P5 terminal 8 (COM). The second bias resistor is installed from
P5 terminal 6 (A) to +5V. +5V is available on P7 pin 1 when J13 is installed.
10.5 RS-485 Wiring Examples
A typical RS-485 wiring example is shown below. COM1 is shown connected to a multivariable
transmitter such as the Rosemount 3095. The power for the transmitter can come from the
SCADAPack LP power input source or can be obtained from the 24V Vloop output for possible
power savings.
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31
76
AB
P6 – RS-485
1 2
P3 – DC Power In
+–
+
12Vdc Power
Supply
_
A
B
– PWR
+ PWR
SCADAPack LP
Rosemount 3095 MVT
Figure 9: RS-485 Wiring
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32
11 Operation
11.1 Operating Modes
SCADAPack LP Controllers may start up in RUN, SERVICE or COLD BOOT mode. Start up in the
RUN mode automatically executes TelePACE Ladder Logic and TelePACE C programs in the
controller memory. Start up in the SERVICE mode stops the programs to allow reprogramming and
controller initialization. Start up in the COLD BOOT mode initializes the controller and erases all
programs.
11.1.1 Run Mode
The RUN mode is the normal operating mode of the SCADAPack LP Controller. No action is
required to select RUN mode. When power is applied to the controller board:
• The user defined serial communication parameters, for all COM ports are used.
• If a TelePACE Ladder Logic or ISaGRAF application program is loaded in RAM, it is executed.
• If a TelePACE or ISaGRAF C application program is loaded in RAM and the program checksum
is correct, it is executed.
• If there is no application program in RAM and there is an application program in flash ROM
then the flash ROM program will be executed.
• The controller lock settings and password are used.
11.1.2 Service Mode
SERVICE mode is used during application programming and maintenance work. When the
SCADAPack LP controller starts in SERVICE mode:
• The default serial communication parameters are used (see section 10-Serial Communication for
a description of the default parameters).
• The TelePACE Ladder Logic or ISaGRAF program is stopped.
• The C program is stopped.
• All programs are retained in non-volatile memory.
• The controller lock settings and password are used.
SERVICE mode is selected by performing a SERVICE BOOT using the following procedure:
1. Remove power from the controller.
2. Hold down the LED POWER button.
3. Apply power to the controller.
4. Continue holding the LED POWER button until the STAT LED turns on.
5. Release the LED POWER button.
Note: If the LED POWER button is released before the STAT LED turns on, the SCADAPack
controller will start in RUN mode.
11.1.3 Cold Boot Mode
COLD BOOT mode is used after installing new controller firmware. When the SCADAPack LP
controller starts in COLD BOOT mode:
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33
• The default serial communication parameters are used (see section 10-Serial Communication for
a description of the default parameters).
• The TelePACE Ladder Logic or ISaGRAF and C Tools programs are erased.
• The C program is erased.
• The registers in the I/O database or I/O Connection are initialized to their default values.
• The Register Assignment is erased.
• The controller is unlocked.
COLD BOOT mode is selected by performing a COLD BOOT using the following procedure:
1. Remove power from the SCADAPack controller.
2. Hold down the LED POWER button.
3. Apply power to the SCADAPack controller.
4. Continue holding the LED POWER button for 25 seconds until the STAT LED begins to flash
on and off continuously.
5. Release the LED POWER button.
Note: If the LED POWER button is released before the STAT LED begins to flash, the
SCADAPack controller will start in SERVICE mode.
11.1.4 Sleep Mode
All SCADAPack LP Controllers are capable of extremely low power operation when in sleep mode.
The user’s TelePACE or ISaGRAF application program can enable and disable sleep mode by using
the SLP or SLEEP functions respectively. During sleep mode the following happen:
• All programs stop executing.
• The 5V power to most of the circuit of the controller is switched off.
• The 5V power to the I/O bus is switched off.
• The three counter inputs on the controller board continue to function.
• The real-time clock and alarm continue to function.
• 24V DC power is not affected.
The SCADAPack LP Controller wakes up from sleep mode under the following conditions:
1. Hardware RESET caused by power removed and applied to the controller.
2. The LED POWER push-button is pressed.
3. A real time clock alarm, defined by application program, occurs.
4. Any of the controller board counters roll over. This occurs every 65536 pulses on each input.
5. A change in state of any of the Digital Inputs.
6. The COM3 Test1 to Test2 pins are connected together indicating the SCADAPack Vision is to
be turned on.
11.2 LED Indicators
There are 23 LEDs on SCADAPack LP. All LEDs can be disabled to conserve power. The table
below describes the LEDs.
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34
LED Function
Power
Mode On when operating and the LEDs are enabled.
Blinks once per second when the LEDs are disabled.
Blinks once every two seconds when in Sleep Mode.
RUN On when the ladder logic program is executing.
STAT Blinking when an error exists.
FORCE On when I/O points are forced.
RX On when receiving data on the corresponding serial port.
TX On when transmitting data on the corresponding serial port.
CTS On when the CTS input is asserted COM2.
DCD On when the DCD input is asserted COM2.
Digital I/O On when the corresponding I/O point is on. LEDs are dim in Sleep
Mode when the corresponding I/O point is on.
Counter 0 On when the counter input is present and low.
Counters
1,2 When the input is configured to use an external amplifier, the LED
is on when the counter input is present and low.
When the input is configured to use the internal amplifier, the LED
is on when input pulses are present.
11.3 LED Power Control
The SCADAPack LP controller board can disable the LEDs on the controller board and the 5000
Series I/O modules to conserve power. This is particularly useful in solar powered or unattended
installations.
The Power Mode LED on the controller board indicates the LED power state. It is on when the
controller board enables LED power.
The LED POWER push-button toggles the LED power signal. Press the LED POWER push-button
to toggle LED power from off to on, or from on to off.
The application program sets the default state of the LED power. The LED power returns to the
default state 5 minutes after the LED POWER push-button is last pressed. The application program
may change the default time and state.
When the LED power state is ON all power saving modes are disabled. The 24V power supply boost
is on and Vloop power is turned ON. The SCADAPack Vision operator interface is powered on as a
result of 5V being available on COM3.
11.4 Jumpers
Most headers on the SCADAPack LP are user configurable and are described in the appropriate
sections of this manual. Some headers and jumpers on the SCADAPack LP are reserved for
manufacturing and test functions. Refer to Figure 2: SCADAPack LP Board Layout for the
location of all jumpers.
The following table lists the jumpers and the relevant section of this manual.
Jumper Function
J1 Analog Input 0 Range Figure 4: Analog Input Wiring
J2 Analog Input 1 Range Figure 4: Analog Input Wiring
J3 Analog Input 2 Range Figure 4: Analog Input Wiring
J4 Analog Input 3 Range Figure 4: Analog Input Wiring
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J5 Analog Input 4 Range Figure 4: Analog Input Wiring
J8
J9 Counter Input 1 Type Figure 7: Counter Input Wiring
J10 Counter Input 2 Type Figure 7: Counter Input Wiring
J11 Counter Input 1 Type Figure 7: Counter Input Wiring
J12 Counter Input 2 Type Figure 7: Counter Input Wiring
J13 COM2 5 Volts on Pin 1 10.1.1-
COM2 RS-232 Serial Port
11.5 Status LED
The STAT LED indicates an alarm condition. The STAT LED blinks when an alarm occurs. The
STAT LED turns off when all alarms clear.
The STAT LED blinks a binary sequence indicating alarm codes. The sequences consist of long and
short flashes, followed by an off delay of 1 second. The sequence then repeats. The sequence may be
read as the Controller Status Code. A short flash indicates a binary zero. A long flash indicates a
binary one. The least significant bit is output first. As few bits as possible are displayed, all leading
zeros are ignored. The application program defines the values of the alarm codes.
The table below shows the meaning of the sequences.
Sequence CONTROLLER STATUS CODE
Off 0 = Normal
1 Long I/O Module Error Indication
1 Short, 1 Long Register Assignment Checksum
Error
11.5.1 I/O Module Error Indication
When the Status LED flashes the controller status code 1 (i.e. a long flash, once every second), there
is a communication failure with one or more I/O module. To correct the problem, do one of the
following:
1. Ensure that every module contained in the Register Assignment Table is connected to the
controller. Check that the module address selected for each module agrees with the selection
made in the Register Assignment Table.
2. If a module is still suspect of having failed, confirm the failure by removing the module from the
Register Assignment Table. Download the changes to the controller. The Status LED should stop
flashing.
3. If a module is currently not connected to the controller, delete it from the Register Assignment
Table. Download the changes to the controller. The Status LED should stop flashing.
4. If unused modules must be intentionally left in the Register Assignment Table, the I/O error
indication may be disabled from a selection box on the Register Assignment dialog.
11.5.2 Register Assignment Checksum Error
When the status LED flashes the controller status code 2 (i.e. a short flash then a long flash followed
by a 1 second of delay), this indicates the register assignment is not valid. To correct this problem,
initialize the register assignment from the TelePACE software, or alternatively, perform a COLD
BOOT as described in section 11.1.3-Cold Boot Mode of this manual. The status LED should stop
flashing.
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12 Maintenance
The SCADAPack LP controller requires little maintenance. The Power Mode LED indicates the
status of the 5V supply. If the LED is off, the on board fuse F1 may require replacing. If the program
is lost during power outages, the lithium battery may require replacement.
The analog input and output circuitry is calibrated at the factory and does not require periodic
calibration. Calibration may be necessary if the module has been repaired as a result of damage.
If the SCADAPack LP Controller is not functioning correctly, contact Control Microsystems
Technical Support for information on returning the SCADAPack Controller for repair.
WARNING: Do not connect or disconnect any field wiring, including the wiring to the RS-232
ports, unless the power is off or the area is know to be non-hazardous.
12.1 Fuses
A single 1.0 Amp fast-blow fuses protects the power supply. The fuse is mounted under the cover.
Refer to Figure 2: SCADAPack LP Board Layout for the location.
CAUTION: Remove power before servicing unit.
Always replace a defective fuse with a fuse of the same rating. Under no circumstances should a fuse
be bypassed or replaced with a fuse of a higher rating.
The fuse is a Littelfuse Nano-SMF. Littelfuse part number LF R451 001. This fuse is available from
Control Microsystems.
In all cases investigate and correct the cause of the fuse failure before replacement. Common causes
of fuse failure are short circuits and excessive input voltages.
12.2 Lithium Battery
A small lithium battery powers the CMOS memory and real-time clock when input power is
removed. The voltage of a functioning battery should be greater than 3.0V. An application program
can monitor this voltage. Refer to the programming manual for details.
The battery should not require replacement under normal conditions. The shelf life of the battery is
10 years. The battery is rated to maintain the real-time clock and RAM data for two years with the
power off. Accidental shorting or extreme temperatures may damage the battery.
12.2.1 Battery Replacement Procedure
The battery is plugged into the circuit board and secured with a tie-wrap. If necessary it can be
replaced with an identical battery available from Control Microsystems.
1. Save the existing program running in the SCADAPack, if applicable.
2. Remove power from the SCADAPack.
3. Remove the SCADAPack top cover and locate the battery. It is found at the far right side of the
circuit board.
4. The battery tie wrapped in place at the factory. This is to ensure the battery does not become
disconnected during shipment. Cut the tie wrap using wire cutters.
5. Remove the battery by gently lifting it straight up from the circuit board. The battery has two
pins that mate with two sockets on the circuit board.
6. Replace the battery. A replacement tie wrap is not necessary.
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7. Cold boot the controller. (Refer to section 11.1.3-Cold Boot Mode in of this manual for the Cold
Boot procedure.)
Warning: If a cold boot is not done the behavior of the controller is unpredictable.
8. The controller may now be programmed.
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13 Troubleshooting
13.1 Analog Inputs
Problem Action
20mA inputs always read 0. Check transmitter power.
Reading is at or near 0 for
all input signals.
Check if the input transient suppressers are
damaged.
20mA readings are not
accurate.
Check for a damaged 250Ω current sense
resistor.
Inputs are 0-20mA, not 4-20mA.
Reading is constant. Check that the analog input is not forced.
13.2 Analog Outputs
Problem Action
Outputs are always 0mA Check the 24V power.
The full-scale output is less
than 20mA.
Check the 24V power.
Check that the load resistance is within
specification.
Output is constant and
should be changing.
Check that the analog outputs are not forced.
13.3 Digital Inputs
Problem Action
Input LED does not come
on when input signal is
applied.
Check the input signal at the termination block. It
should be at least 50% of the digital input range.
If this is a DC input, check the polarity of the
signal.
Input is on when no signal is
applied. The LED is off.
Check that the digital inputs are not forced on.
Input is off when a signal is
applied. The LED is on.
Check that the digital inputs are not forced off.
Input is on when no signal is
applied. The LED is on.
Check that the digital output at that point is off.
The LED is dim. This normal operation when the controller is in low
power mode or sleep mode.
13.4 Digital Outputs
Problem Action
Output LED comes on and
output is on, but the field
device is not activated.
Check the field wiring.
Check the external device.
Output LED and output are
on when they should be off.
Check that the output is not forced on.
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Problem Action
Output LED and output are
off when they should be on.
Check that the output is not forced off.
The LED is dim. This normal operation when the controller is in
sleep mode.
13.5 Counter Inputs
Problem Action
Input LED does not come
on when input signal is
applied.
Check the input signal at the termination block. It
should be at least 50% of the counter input range.
The LED is dim. This normal operation when the controller is in low
power mode or sleep mode.
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14 Specifications
Disclaimer: Control Microsystems reserves the right to change product specifications without
notice. For more information visit www.controlmicrosystems.com .
14.1 General
I/O Terminations 8 and 10 pole, removable terminal blocks.
12 to 22 AWG
15A contacts
Dimensions 8.40 inch (213mm) wide
5.00 inch (127 mm) high
1.80 inch (45mm) deep
Packaging Corrosion resistant zinc plated steel with black enamel paint
Environment 5% RH to 95% RH, non-condensing
–40oC to 70oC
–40oF to 158oF
14.2 Controller
Processors 16-bit CMOS microcontroller, 14.74MHz clock
integrated watchdog timer
microcontroller co-processor, 14.74MHz clock
Memory 1MBytes CMOS RAM
512kBytes flash ROM
1kBytes EEPROM
Non-volatile
RAM CMOS RAM with lithium battery retains contents for 2 years
with no power
Clock calendar ±1 minute/month at 25°C
+1/–3 minutes/month 0 to 50°C
Internal
temperature Measurement range -40°C to 75°C. Accuracy ±5°C.
Measurement range -40°F to 167°F. Accuracy ±9°F.
Lithium battery
monitor
Accuracy ±0.2V.
14.3 Communications
Communication
Port COM1 RS-485 serial port
removable terminal block
2 wire half duplex
Bias resistors installed.
Communication
Port COM2 RS-232 compatible serial port (CMOS)
Data Terminal Equipment (DTE)
8 pin modular jack
Full or half duplex with RTS/CTS control
Implemented Td, Rd, CTS, RTS, DCD, DTR, 5V power with
jumper link.
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Communication
Port COM3 RS-232 compatible serial port (CMOS)
Data Terminal Equipment (DTE)
8 pin modular jack
Half duplex
Implemented Td, Rd, and 5V power under program control.
Intended for use with SCADAPack Vision operator
interface.
Baud Rates
(COM1, COM2) 300, 600, 1200, 2400, 4800, 9600, 19200, 38400
Baud Rate
(COM3)
1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
Parity none, even, or odd
Word Length 7 or 8 bits
Stop Bits 1 or 2 bits
Transient
Protection COM1, COM2: 2.5kV surge withstand capability as per
ANSI/IEEE C37.90.1-1989
Isolation Common ground return connected to Chassis Ground.
Cable Length RS-232 –maximum 10 ft (3 m)
RS-485 –maximum 4000 ft (1200 m)
Protocol TeleBUS (compatible with Modbus RTU and Modbus
ASCII)
Protocol Modes Slave, master, master/slave, store and forward
14.4 Visual Indicators
COM1 received data (Rx) LED
transmitted data (Tx) LED
COM2 received data (Rx) LED
transmitted data (Tx) LED
clear to send (CTS) LED
data carrier detect (DCD) LED
COM3 received data (Rx) LED
transmitted data (Tx) LED
Status Power Mode LED
Run LED
Status LED (shows functional status)
Forced I/O LED
Digital Inputs / Outputs 8 LEDs
Counters 3 LEDs
Push-button LED power toggle
14.5 Power Supply
DC power Input 30V maximum
10.0 to 11.5V turn on
9.5V typical turn off
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Typically 125mW (at 12V) during sleep mode.
Typically 360mW (at 12V) during normal operation. LEDs
off, no expansion.
6.5W maximum.
Output capacity
5V at 0.4A capacity
5V at 55mA required by 5207 controller
5V at 0.35A (current limited) on COM2 and the I/O
expansion
5V at 0.25A (current limited) on COM3
Vloop: 24V at 0.14A available for the 5 analog inputs and 2
optional analog outputs
Efficiency 85%, 12Vdc input, full load
14.6 I/O Capacity
5000 Series I/O
Expansion
Capacity
Maximum 40 I/O modules with a further limitation of 16
modules of any one type.
512 digital outputs using 32 point digital output modules
512 digital inputs using 32 point digital input modules
128 analog inputs using 8 point analog input modules
64 analog outputs using 4 point analog output modules
32 counter inputs using 4 point counter input modules
Example: 16 of the 32 point digital output modules + 16 of
the 32 point digital input modules + 8 of the 8 point analog
input modules would yield an expansion of 1088 I/O points.
14.7 Analog Inputs
Input Points 5 at 10V/20mA: 250Ω resistance user
configurable with jumper link.
1 at 32.768V
Resolution 15 bits over the 10V and 32.768V measurement
range.
14 bits over the 20mA measurement range.
Input Resistance 20kΩ for 10V inputs
60kΩ for 32.768V inputs
250Ω for 20mA inputs
Converter type 16 bit successive approximation
Accuracy ±0.1% of full scale at 25oC (77ºF)
±0.2% over temperature range
Type single ended
Calibration Calibration constants stored in on board
microcontroller EEPROM.
Normal mode rejection 27 dB at 60 Hz.
Over-scale Input Capacity
(without damage) 10V/20mA inputs clamped at 12V.
Transient: 2.5kV surge withstand capability as
per ANSI/IEEE C37.90.1-1989
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Isolation
Analog common side connected to Chassis
Ground.
Response Time 100ms typical for 10% to 90% signal change
14.8 Analog Outputs
Output Points 2 (when optional 5305 analog outputs installed)
Output Signal
Range 0-20mA
Maximum Load
Resistance 925Ω with 24Vdcinput voltage or when internal 24V power
supply is on.
375Ω with 12Vdc input voltage
250Ω with input voltage at power supply turnoff
Output Type Single ended regulation on positive side with common
negative return
Isolation Analog common side connected to Chassis Ground.
Resolution 12 bits
Accuracy Specified from 0.5-20mA
±0.15% of full scale at 25oC (77oF)
±0.25% of full scale over temperature range
Noise and
Ripple 0.04% maximum
Transient
Protection Transient: 2.5kV surge withstand capability as per
ANSI/IEEE C37.90.1-1989
Response Time 0.5ms to 2ms for 10% to 90% signal change
Power
Requirements 24V boost power supply off: Vin X output current.
24V boost power supply on: 27 X output current.
14.9 Counter Inputs
Counter Inputs Counter 0 Digital Input Counter
Counter 1 Turbine Meter inputs
Counter 2 Turbine Meter inputs
Digital Input
Counter 0 Maximum frequency 10Hz.
Dry contact input.
Wetting current typically 5mA.
Contact closure to ground is ON.
Open input is OFF.
Counter 1 and 2 Designed for use with low voltage, turbine meter outputs.
Jumper link selectable for use with turbine meter amplifiers
or dry contact closure.
Counter 1 and 2
Turbine Meter
Sensitivity
Minimum input 30mVp-p at 5-50Hz.
Minimum input 150mVp-p at 150Hz.
Minimum input 650mVp-p at 5kHz.
Minimum input 750mVp-p at 10kHz.
Maximum input 4Vp-p using internal amplifier.
Counter 1 and 2
Dry Contact Maximum input 10Vp-p without internal amplifier.
Maximum frequency 10KHz.
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Transient
Protection 2.5kV surge withstand capability as per ANSI/IEEE
C37.90.1-1989
Isolation Common ground return connected to Chassis Ground.
14.10 Digital Inputs/Outputs
I/O points 8 points
Each point is an input and an output
Output Rating 1.0A maximum
0.35V maximum drop at 1.0A
0.05V maximum drop at 0.1A
Open drain sinking when ON.
28V maximum when OFF.
Input Rating Dry contact input.
Wetting current typically 5mA, pulsed.
Contact closure to ground is ON.
Open input is OFF.
Digital Input
Thresholds 0.9V typical turn on input voltage.
Less than 0.4V guaranteed turn on input voltage.
1.5V typical turn off input voltage.
Greater than 2.2V guaranteed turn off input voltage.
Contact
Resistance ON input requires less than 100Ω contact resistance.
OFF input requires greater than 50kΩ contact resistance.
Cable contact capacitance not to exceed 0.033uF,
typically 1600ft (500m).
Transient
Protection 2.5kV surge withstand capability as per ANSI/IEEE
C37.90.1-1989
Isolation Common ground return connected to Chassis Ground.
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15 Approvals and Certifications
Safety Non-Incendive Electrical Equipment for Use in Class I,
Division 2 Groups A, B, C and D Hazardous Locations.
Digital
Emissions FCC Part 15, Subpart B, Class A Verification
EN50081-2: 1993 Electromagnetic Compatibility Generic
Emission Standard Part2: Industrial Environment
Immunity EN61000-6-2: 1999 Electromagnetic Compatibility Generic
Standards Immunity for Industrial Environments
Declaration This product conforms to the above Emissions and Immunity
Standards and therefore conforms with the requirements of
Council Directive 89/336/EEC (as amended) relating to
electromagnetic compatibility and is eligible to bear the CE
mark.
The Low Voltage Directive is not applicable to this product.
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