Scadapack 100 User Manual
Scadapack 100 User Manual
Overview .........................................................................................9
Installation ....................................................................................10
Field Wiring .......................................................................................................... 10
Power Supply ....................................................................................................... 11
System Grounding ............................................................................................... 12
Analog Inputs ....................................................................................................... 12
Digital Outputs ...................................................................................................... 14
Digital Inputs ........................................................................................................ 15
Digital I/O Connection Examples ......................................................................... 15
Counter Input ....................................................................................................... 16
Turbine Meter Counter Input ................................................................................ 16
Operation ......................................................................................27
Operating Modes.................................................................................................. 27
Led Power Control ............................................................................................... 29
Jumpers ............................................................................................................... 29
Status LED ........................................................................................................... 29
Firmware Loading ................................................................................................ 30
Maintenance .................................................................................32
Fuses ................................................................................................................... 32
Lithium Battery ..................................................................................................... 32
Troubleshooting ..........................................................................34
Specifications ..............................................................................35
General ................................................................................................................ 35
Controller .............................................................................................................. 35
Communications .................................................................................................. 36
Visual Indicators ................................................................................................... 36
Power Supply ....................................................................................................... 37
Analog Inputs ....................................................................................................... 37
Counter Inputs ...................................................................................................... 37
Digital Inputs/Outputs ........................................................................................... 38
Read these instructions carefully, and look at the equipment to become familiar
with the device before trying to install, operate, or maintain it. The following
special messages may appear throughout this documentation or on the
equipment to warn of potential hazards or to call attention to information that
clarifies or simplifies a procedure.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can
result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can
result in minor or moderate.
CAUTION
CAUTION used without the safety alert symbol, indicates a potentially hazardous
situation which, if not avoided, can result in equipment damage..
CAUTION
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.
Before operational tests are performed, remove all blocks or other temporary
holding means used for shipment from all component devices.
Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in injury or equipment
damage.
Follow all start-up tests recommended in the equipment documentation. Store all
equipment documentation for future references.
Software testing must be done in both simulated and real environments.
Verify that the completed system is free from all short circuits and grounds,
except those grounds installed according to local regulations (according to the
National Electrical Code in the U.S.A, for instance). If high-potential voltage
testing is necessary, follow recommendations in equipment documentation to
prevent accidental equipment damage.
Before energizing equipment:
Remove tools, meters, and debris from equipment.
Close the equipment enclosure door.
Remove ground from incoming power lines.
Perform all start-up tests recommended by the manufacturer.
OPERATION AND ADJUSTMENTS
The following precautions are from the NEMA Standards Publication ICS 7.1-
1995 (English version prevails):
At a Glance
Document Scope
This manual describes the SCADAPack 100 controller.
Validity Notes
This document is valid for all versions of the SCADAPack 100 controller.
WARNING
UNINTENDED EQUIPMENT OPERATION
The application of this product requires expertise in the design and
programming of control systems. Only persons with such expertise should be
allowed to program, install, alter and apply this product.
Follow all local and national safety codes and standards.
Failure to follow these instructions can result in death, serious injury or
equipment damage.
User Comments
We welcome your comments about this document. You can reach us by e-mail at
technicalsupport@controlmicrosystems.com.
Overview
The SCADAPack 100 is a small footprint controller that comes complete with an
integrated power supply, analog and digital I/O, serial communications and a
counter input. Application programs can be written in Telepace Relay Ladder
Logic, IEC 61131-3 and the C language.
As of October 2004 the SCADAPack 100 controller has been upgraded to
include more memory to run larger applications and, if needed, a single gas flow
computer. The versions of the SCADAPack 100 are identical in every way except
for the difference in memory size.
The controller type for the original version of the SCADAPack 100 is
SCADAPack 100:256K. This controller type has a total of 256K CMOS non-
volatile (battery backed) RAM and will have a controller ID of A182921 or less.
The controller type for the current version of SCADAPack 100 is SCADAPack
100: 1024K. This controller type has a total of 1024K CMOS non-volatile (battery
backed) RAM and will have a controller ID of A182922 or newer.
Installation
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.
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.
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 1: SCADAPack 100
Board Layout for connector locations.
The two RS-232 communication ports, COM1 and COM2, connect to 8 pin
modular jacks. Refer to section RS-232 Serial Communications Ports for
pinout details and wiring diagrams for these modular jacks.
Field wiring terminates in removable terminal connectors. Connector pinouts
and wiring examples are described in each of the respective sections of this
manual.
Power Supply
The SCADAPack 100 is powered from an 11VDC to 24VDC power source. Refer
to section Specifications of this manual for the minimum and maximum
operating voltages and actual power requirements.
The SCADAPack 100 will shutdown when operating below the minimum
recommended voltage.
Exceeding the maximum input voltage or applying a reverse voltage will blow
the input power fuse.
Unlike the other members of the SCADAPack family, the SCADAPack 100
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 100.
The DC power input voltage generates 5V for the SCADAPack 100 circuitry and
a limited amount of expansion. Refer to the SCADAPack 100 power supply
specifications and the specifications of the expansion components to determine if
the power supply has sufficient capacity for your application. The capacity of the
5V supply is sufficient to power the SCADAPack 100, one 5000 modem and a
SCADAPack Vision operator interface.
System Grounding
In 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 I/O point terminals labeled GND are
connected to chassis ground.
Analog Inputs
The controller has two internal analog inputs, used by application programs to
monitor RAM voltage and controller board ambient temperature. There are four
single ended analog inputs available to the user.
Refer to the appropriate software manual for information on using the
SCADAPack 100 Analog Inputs in application programs. For Telepace
applications refer to the Register Assignment for SCADAPack 100 I/O module
and for IEC 61131-1 applications refer to the I/O Complex Equipment for
SCADAPack 100.
PWR PWR
5 4 3 2 1
GND 0 1 2 3
P9 - Analog Inputs
0 1 2
Current
Voltage
J1 J2 J3
Digital Outputs
The SCADAPack 100 provides six universal digital inputs or outputs. Outputs are
open-collector/open drain type for use with sustained DC loads up to 1 ampere.
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 is to 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.
Refer to the appropriate software manual for information on using the
SCADAPack 100 Digital Inputs and Outputs in application programs. For
Telepace applications refer to the Register Assignment for SCADAPack 100 I/O
module and for IEC 61131-1 applications refer to the I/O Complex Equipment for
SCADAPack 100 I/O.
Digital Inputs
The SCADAPack 100 provides six universal digital inputs and outputs. The
inputs are for use with dry contacts such as switches and relay contacts. The
SCADAPack 100 provides the wetting current for the contacts.
If LED power is enabled, the SCADAPack 100 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 100. 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 100 Digital Inputs and Outputs in application programs. For
Telepace applications refer to the Register Assignment for SCADAPack 100 I/O
module and for IEC 61131-1 applications refer to the I/O Complex Equipment for
SCADAPack 100 I/O.
Internal turbine
meter amplifier.
J9 J11
1 2 3 4 5 6 7 8 9 10 11 12
+
24Vdc Power + 24V Load
Supply
_
Counter Input
The Counter described in this manual applies to the SCADAPack 100 version 4
PCB. If you require a description of earlier versions please contact Control
Microsystems Technical Support.
The SCADAPack 100 has one counter input identified as CTR. This counter can
be configured for use with open collector/drain output amplifiers, dry contacts or
a direct connection to a turbine meter sensor.
The maximum number of counts is 4,294,967,295. The counter rolls over to 0
when the maximum count is exceeded. The count value is stored in two user-
defined registers.
Refer to the appropriate software manual for information on using the
SCADAPack 100 Counter Inputs in application programs. For Telepace
applications refer to the Register Assignment for SCADAPack 100 I/O module
and for IEC 61131-1 applications refer to the I/O Complex Equipment for
SCADAPack 100 I/O.
Internal turbine
meter amplifier.
J9 J11
CTR GND
1 2 3 4 5 6 7 8 9 10 11 12
Turbine
Meter
Sensor
J9.
Turbine meter sensor uses internal
amplifier.
J11.
Turbine meter sensor uses internal
amplifier.
J9.
Open collector, dry contact or turbine
meter with external amplifier.
J11.
Open collector or dry contact. Internal
pullup resistor is used.
J11.
Open collector, dry contact or turbine
meter with external amplifier. User must
supply external resistor from input to
suitable power source.
Serial Communication
The SCADAPack 100 controller is equipped with two serial communication ports.
One serial communication port support RS-232 serial communication and the
other serial port supports either RS-232 or RS-485 serial communication.
Serial ports on the SCADAPack 100 controller are designated COM1 and COM2.
Refer to Figure 1: SCADAPack 100 Board Layout for the location of the serial
ports.
1 2 3 4 5 6 7 8 1. +5V
2. NC
3. NC
4. GND
5. RxD
6. TxD
7. NC
8. NC
NOTES:
+5V is only available on Pin 1 when a jumper is installed on J5. Refer to the
Figure 1: SCADAPack 100 Board Layout for the location of J5.
The low power transmitters used in COM1 transmit 0 to 5V levels. This is
less than the RS-232 specification but still compatible with 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.
1 2 3 4 5 6 7 8 1. +5V
2. DCD
3. DTR
4. GND
5. RxD
6. TxD
7. CTS
8. RTS
NOTES:
+5V is only available on Pin 1 when a jumper is installed on J6. Refer to the
Figure 1: SCADAPack 100 Board Layout for the location of J6.
The low power transmitters used in COM2 transmit 0 to 5V levels. This is
less than the RS-232 specification but still compatible with 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.
DCD 2 DCD
RxD 5 RxD
TxD 6 TxD
DTR 3 DTR
GND 4 GND
RTS 8
CTS 7 RTS
+ 5V 1 CTS
See device
specifications
for pin numbers
DCD 2 DCD
RxD 5 RxD
TxD 6 TxD
DTR 3 DTR
GND 4 GND
RTS 8
CTS 7 RTS
+ 5V 1 CTS
See device
specifications
for pin numbers
DCD 2 DCD
RxD 5 RxD
TxD 6 TxD
DTR 3 DTR
GND 4 GND
RTS 8 RTS
CTS 7 CTS
+ 5V 1
See device
specifications
for pin numbers
RS-232 Cables
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 TBUM297217.
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
suggested value of the bias resistors is 470 ohms. One bias resistor is installed
from P3 terminal 12 (B) to P3 terminal 2 or 10 (COM). The second bias resistor is
installed from P3 terminal 11 (A) to +5V. +5V is available on P7 pin 1 when J8 is
installed. Consult Control Microsystems Tech Support for application assistance.
1 2 3 4 5 6 7 8 9 10 11 12
+ PWR
+ A
24Vdc Power
Supply
_ B
PWR
Operation
Operating Modes
SCADAPack 100 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 application
programs.
Run Mode
The RUN mode is the normal operating mode of the SCADAPack 100 Controller.
No action is required to select RUN mode. When power is applied to the
controller board:
The user defined serial communication parameters for COM ports are used.
If a Telepace Ladder Logic application program is loaded in RAM, it is
executed.
If a Telepace 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.
Service Mode
SERVICE mode is used during application programming and maintenance work.
When the SCADAPack 100 controller starts in SERVICE mode:
The default serial communication parameters are used (see the Telepace
Ladder Logic User Manual or the Telepace C Tools User Manual for a
description of the default parameters).
The Ladder Logic program is stopped.
The C program is stopped.
Application 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:
Remove power from the SCADAPack 100 controller.
LED Indicators
There are 17 LEDs on SCADAPack 100. LEDs can be disabled to conserve
power. The table below describes the LEDs.
LED Function
Power On when operating and the LEDs are enabled.
Mode Blinks once per second when the LEDs are disabled.
RUN On when the ladder logic program is executing.
STAT The LED will blink when an unwanted controller condition exists.
LED Function
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 when
LEDs are disabled when the corresponding I/O point is on.
CTR On when the counter input is present and low.
Jumpers
Headers on the SCADAPack 100 are user configurable and are described in the
appropriate sections of this manual. Some headers and jumpers on the
SCADAPack 100 are reserved for manufacturing and test functions. Refer to
Figure 1: SCADAPack 100 Board Layout for the location of jumpers.
The following table lists the jumpers and the relevant section of this manual.
Jumper Function
J1 Analog Input 0 Range Figure 2: Analog Input Wiring
J2 Analog Input 1 Range Figure 2: Analog Input Wiring
J3 Analog Input 2 Range Figure 2: Analog Input Wiring
J5 COM1 5 Volts on Pin 1 COM1 RS-232 Serial Port
J6 COM2 5 Volts on Pin 1 COM2 RS-232 Serial Port
Status LED
The status LED labeled STAT on the controller board indicates a controller
condition that needs to be addressed. The STAT LED blinks and the STATUS
output opens when such a condition occurs. The STATUS output remains open
continuously when a controller condition is present. The STAT LED turns off and
the STATUS output closes when the condition clears.
Firmware Loading
Periodically the firmware for a controller is updated to add new features or
provide bug fixes. As they become available new firmware versions may be
downloaded from www.controlmicrosystems.com.
Allowed connections for firmware loading for a SCADAPack 100 controller are
Com1 or com2 serial ports.
Maintenance
The SCADAPack 100 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 100 Controller is not functioning correctly, contact Control
Microsystems Technical Support for information on returning the SCADAPack
Controller for repair.
WARNING
Remove power or confirm the area is known to be non-hazardous before
changing field wiring, including the wiring to the RS-232 ports.
Failure to follow these instructions can result in death, serious injury or
equipment damage.
Fuses
A single 0.375 Amp fast-blow fuse protects the power supply. The fuse is
mounted under the cover. Refer to Figure 1: SCADAPack 100 Board Layout
for the location.
Remove power before servicing unit.
Replace a blown 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 R451.375. These
fuses are available from Control Microsystems.
Investigate and correct the cause of the blown fuse before replacement.
Common causes of blown fuses are wiring and excessive input voltages.
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.
Troubleshooting
Analog Inputs
Condition Action
20mA inputs constantly Check transmitter power.
read 0.
Reading is at or near 0 for Check if the input transient suppressers are
input signals. damaged.
20mA readings are not Check for a damaged 250 current sense
accurate. resistor.
Reading is constant. Check that the analog input is not forced.
Digital Inputs
Condition Action
Input is on when no signal is Check that the digital inputs are not forced on.
applied. The LED is off.
Input is off when a signal is Check that the digital inputs are not forced off.
applied. The LED is on.
Input is on when no signal is Check that the digital output at that point is off.
applied. The LED is on.
LED is dim. This is normal when the input is on and the
LED Power is disabled.
Digital Outputs
Condition Action
Output LED comes on and Check the field wiring.
output is on, but the field Check the external device.
device is not activated.
Output LED and output are Check that the output is not forced on.
on when they should be off.
Output LED and output are Check that the output is not forced off.
off when they should be on.
LED is dim. This is normal when the output is on and the
LED Power is disabled.
Specifications
General
I/O Terminations 5 and 12 pole, removable terminal blocks.
12 to 22 AWG
15A contacts
Screw termination - 6 lb.-in. (0.68 Nm) torque
Dimensions 5.65 inch (144mm) 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
o o
40 C to 70 C
o o
40 F to 158 F
Controller
Processors 16-bit CMOS microcontroller, 14.74MHz clock, integrated
watchdog timer
microcontroller co-processor, 14.74MHz clock
Memory 256KBytes CMOS RAM (controller ID number A182921 or
less)
1024KBytes CMOS RAM (controller ID number A182922
or greater)
512kBytes flash ROM
1kBytes EEPROM
Non-volatile CMOS RAM with lithium battery retains contents for 2
RAM years with no power
Clock calendar 1 minute/month at 25C
+1/3 minutes/month 0 to 50C
Internal Measurement range -40C to 75C. Accuracy 5C.
temperature Measurement range -40F to 167F. Accuracy 9F.
Lithium battery Accuracy 0.2V.
monitor
Communications
Communication RS-485 serial port
Port COM1 2 pole removable terminal block
2 wire half duplex
Bias resistors installed.
Communication RS-232 compatible serial port (CMOS)
Port COM1 Data Terminal Equipment (DTE)
8 pin modular jack
Full or half duplex
Implemented Td, Rd, +5V
Communication RS-232 compatible serial port (CMOS)
Port COM2 Data Terminal Equipment (DTE)
8 pin modular jack
Full or half duplex with RTS/CTS control
Implemented Td, Rd, CTS, RTS, DCD, DTR, +5V
Baud Rates 300, 600, 1200, 2400, 4800, 9600, 19200, 38400
(COM1, COM2)
Parity none, even, or odd
Word Length 7 or 8 bits
Stop Bits 1 or 2 bits
Transient COM1, COM2: 2.5kV surge withstand capability as per
Protection 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
Visual Indicators
COM1 received data (RxD) LED
transmitted data (TxD) LED
COM2 received data (RxD) LED
transmitted data (TxD) LED
clear to send (CTS) LED
data carrier detect (DCD) LED
Status Status LED (shows functional status)
Power Mode LED
Run LED
Forced I/O LED
Digital Inputs / Outputs 6 LEDs
Counters 1 LED
Push-button LED power toggle
Power Supply
DC power Input 30V maximum
10.0 to 11.5V turn on
9.5V typical turn off
UL508 rated 13.75-28Vdc. Class 2.
Less than 500mW (at 12V) LEDs off.
2.9W maximum.
Output capacity 5V at 0.425A capacity
5V at 0.060A required by 5208 controller
5V at 0.365A available on COM1 and COM2
Efficiency 75%, 12Vdc input, full load
Analog Inputs
Input Points 3 at 5V/20mA: 250 resistance user
configurable with jumper link.
1 at 32.768V
Resolution 12 bits over the 5V and 32.768V
measurement range.
Input Resistance 100k for 5V inputs
66k for 32.768V inputs
250 for 20mA inputs
Converter type 12 bit successive approximation
o
Accuracy 0.1% of full scale at 25 C (77F)
0.2% over temperature range
Type single ended
Normal mode rejection 27dB at 60 Hz.
Over-scale Input Capacity 5V/20mA inputs clamped at 17V.
(without damage) Transient: 2.5kV surge withstand capability as
per ANSI/IEEE C37.90.1-1989
Isolation Analog common side connected to Chassis
Ground.
Response Time 100ms typical for 10% to 90% signal change
Counter Inputs
Digital Input Maximum frequency 5kHz.
Counter Dry contact input.
Wetting current typically 5mA with 24V input power.
Digital Inputs/Outputs
I/O points 6 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 0.9V typical turn on input voltage.
Thresholds Less than 0.4V turn on input voltage.
1.5V typical turn off input voltage.
Greater than 2.2V turn off input voltage.
Contact Resistance ON input requires less than 100 contact resistance.
OFF input requires greater than 50k contact
resistance.
Cable contact capacitance not to exceed 0.033uF,
typically 1600ft (500m).
Transient 2.5kV surge withstand capability as per ANSI/IEEE
Protection C37.90.1-1989