RuggedSwitch™

RS1600 Family
Installation Guide

RuggedCom Inc.
64 Jardin Dr. (Unit 3G)
Concord, Ontario Canada
L4K 3P3

Web: www.ruggedcom.com
Tel: (905) 760-7799
Fax: (905) 760-9909
Toll Free: (888) 264 – 0006
Federal Communications Commission Radio Frequency Interference
Statement
This equipment has been tested and found to comply with the limits for a Class A digital device
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which
case the user will be required to correct the interference on his own expense.

Warning: Changes or modifications not expressly approved by RuggedCom Inc. could void the
user’s authority to operate the equipment.

Trademarks:
Ethernet is a trademark of Xerox Corporation
RuggedSwitch is a registered trademark of RuggedCom Inc.

Important:
The RS1600 series contain no user serviceable parts. Attempted service by unauthorized
personnel shall render all warranties null and void.

The RS1600 family of products should be installed in a restricted access location where access
can only be gained by service personnel or users who have been instructed about the reasons for
the restrictions applied to the location and about any precautions that shall be taken; and access is
through the use of a tool or lock and key, or other means of security, and is controlled by the
authority responsible for the location.

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Table of Contents

1 Product Overview .................................................................................................................... 4

1.1 Functional Overview........................................................................................... 4
1.2 Feature Highlights............................................................................................... 4
1.3 RS1600 Front Panel Description ........................................................................ 5
1.4 RS1600T Front Panel Description ...................................................................... 6
1.5 RS1600F Front Panel Description ...................................................................... 7
1.6 RS1600 Family Rear Panel Description ............................................................. 8
2 Installation ............................................................................................................................... 9
2.1 Rack Mounting.................................................................................................... 9
2.2 Power Supply Wiring and Grounding............................................................... 10
2.2.1 Single Power Supply - AC Input ............................................................. 11
2.2.2 Dual Power Supplies – AC Inputs ............................................................ 11
2.2.3 Single Power Supply – DC Input.............................................................. 12
2.2.4 Dual Power Supplies – DC Inputs ............................................................ 12
2.2.5 Dual Power Supplies – DC and AC Inputs............................................... 13
2.3 HIPOT (Dielectric Strength) Testing................................................................ 14
2.4 Failsafe Output Wiring and Specifications ....................................................... 15
2.5 RS232 Port Wiring............................................................................................ 16
2.6 RJ45 Twisted-Pair Data Ports........................................................................... 17
3 Technical Specifications .........................................................................................................18
3.1 Power Supply Specifications ............................................................................ 18
3.2 Networking Standards Supported ..................................................................... 18
3.3 Data Port Specifications.................................................................................... 18
3.4 Fiber Optical Specifications.............................................................................. 19
3.5 Networking Performance Specifications .......................................................... 19
3.6 Type Test Specifications................................................................................... 20
3.7 Operating Environment..................................................................................... 21
3.8 Mechanical Specifications ................................................................................ 21
3.9 Agency Approvals ............................................................................................ 22
4 Warranty.................................................................................................................................22

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
1 Product Overview
1.1 Functional Overview
The RuggedSwitch™ RS1600 series are substation hardened fiber optical Ethernet switches
specifically designed to operate in harsh environments such as those found in electric utility
substations and harsh industrial environments.

Specifically tested to the same standards as mission critical protective relaying equipment, (i.e.
ANSI/IEEE C37.90 and IEC 60255) the RS1600 family is ideally suited to form the Ethernet
network in a UCA2 (Utility Communications Architecture 2.0) based substation automation
network. Because they were designed to meet the demands of the substation environment it is also
ideally suited for industrial automation networks based on Industrial Ethernet. The reliability of the
RS1600 family exceeds that of commercial Ethernet switches by having no rotating mechanical
parts such as cooling fans and by utilizing high-temperature solid-state components. The RS1600
series also offers dual redundant power supplies each of which can be specified to operate from
different voltage sources which allows for increased network availability and maximum network
design flexibility.

1.2 Feature Highlights

Utility Grade (i.e. substation hardened) per ANSI/IEEE C37.90, IEC 60255, IEC 61850-3, IEC
61000-6-5 standards
Operating temperature: -40° to 85°C (no fan)
Radiated RF Immunity: 35V/m per ANSI/IEEE C37.90.2
Dual, redundant power supply options: 24VDC, 48VDC, or HI (88-300VDC or 85-264VAC)
Failsafe output relay for critical failure or error alarming
RS1600:
12 –10BaseFL fiber optical ports
2 – 100BaseFX fiber optical uplink ports
2 – 10/100BaseTx RJ45 ports (optional)
RS1600T:
14 – 10/100BaseTx RJ45 ports
2 – 100BaseFX fiber optical uplink ports
RS1600F:
16 – 100BaseFX fiber optical ports
Advanced layer 2 switching functions: 802.1p Message Prioritization, 802.1Q VLAN
Full-duplex operation (no collisions)

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1.3 RS1600 Front Panel Description
22 –– 10/100BaseTX
10/100BaseTX Ports
Ports
RJ45
RJ45 Connectors
Connectors

12
12 -- 10BaseFL
10BaseFL Ports
Ports 22 -- 100BaseFX
100BaseFX Ports
Ports
820nm,
820nm, 2km,
2km, Multimode,
Multimode, 1300nm,
1300nm, 2km,2km, Multimode,
Multimode,
ST
ST Connectors
Connectors MTRJ
MTRJ Connector
Connector

10/100BaseTX
RJ45 Ports
Option

Rx = Receive Port
Tx = Transmit Port
100BaseFX Port PS1 = Power Supply #1
Link/Activity LED MTRJ Connector PS2 = Power Supply #2

10BaseFL Ports 100BaseFX Ports Power Supply LEDs

Fig. 1.3.1 RS1600 Front Panel Detail

ITEM Activity Comments

Port(1-14) Solid Link Established
Link/Activity LED Blinking – Once per second Tx, Rx Activity
Active Right LED Link Established
Optional RJ45 Ports (15-16)
Active Left LED 100BaseT Link
Link/Activity LEDs
Inactive Left LED 10BaseT Link
PS1 LED Solid Power Supply 1 ON
PS2 LED Solid Power Supply 2 ON

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1.4 RS1600T Front Panel Description

14 – 10/100BaseTx Ports 2 – 100BaseFX Ports

100m Category 5 Cabling, 1300nm, 2km, Multimode
RJ45 Connectors MTRJ Connector

Speed Link / 100FX MTRJ

Indicator Activity Connector
RJ45 Port
Link /Activity

10/100BaseTx Ports 100BaseFX Ports Power Supply LEDs

Fig 1.4.1 RS1600T Front Panel Detail

ITEM Activity Comments
Active Left LED 100BaseTx Link
Ports 1 - 14 Inactive Left LED 10BaseT Link
Link/Activity LEDs Active Right LED Link Established
Flashing Right LED Activity
Ports 15 – 16 Solid Link Established
Link/Activity LEDs Flashing Activity
PS1 LED Solid Power Supply 1 ON
PS2 LED Solid Power Supply 2 ON

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1.5 RS1600F Front Panel Description

Fig 1.5.1 RS1600F Front Panel Detail

ITEM ACTIVITY COMMENTS

Ports 1-16 Flashing Activity
Link / Activity LEDs Solid Link Established
PS1 LED Solid Power Supply 1 On
PS2 LED Solid Power Supply 2 On

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1.6 RS1600 Family Rear Panel Description

Primary
Primary Power
Power Supply
Supply Failsafe
Failsafe RS232
RS232 Secondary
Secondary Power
Power Supply
Supply
24/48VDC
24/48VDC Output
Output Port
Port 24/48VDC
24/48VDC
120-300VDC
120-300VDC (120/230VAC)
(120/230VAC) Relay
Relay 120-300VDC
120-300VDC (120/230VAC)
(120/230VAC)
Fig 1.6.1 RS1600 Family Rear Panel Description

RS1600 / RS1600T Rear Panel Detail

PIN5 PIN 1
PIN SIGNAL
1 n.c.
2 TXD
3 RXD
4 n.c.
5 GND
RS232 Port 6 n.c.
7 n.c.
8 n.c.
9 n.c.
PIN9 PIN 6

AC (Line) or DC (+) AC (Line) or DC (+)

AC (Neutral) or DC ( -) AC (Neutral) or DC ( -)
Surge Ground Surge Ground
Chassis Ground Chassis Ground
Power Supply #1 Power Supply #2

Normally Closed
Common
Normally Open

Failsafe Output Relay

Fig. 1.6.2 RS1600 Family Rear Panel Detail

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
2 Installation
2.1 Rack Mounting

19” Rack Mounting

Step 1: Attach 19”

mounting brackets Mounting
using # 6 - 32 screws. Bracket

Step 2: Mount to
19” Rack using # 10 - 32
screws.

Fig. 2.1.1 RS1600 Family 19” Rack Mounting

Note: Since heat within RS1600 products is channeled to the enclosure, it is recommended that 1
rack unit of space (1.75”) be kept unpopulated and free of equipment above each RS1600 series
product to allow for a small amount of convectional airflow. Although forced airflow is not
necessary, any increase in airflow will result in a reduction of ambient temperature that will improve
long-term reliability of all equipment mounted within the rack space.

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2.2 Power Supply Wiring and Grounding

RS1600 / RS1600T Power Supply Inputs

AC (Line) or DC (+) AC (Line) or DC (+)

AC (Neutral) or DC (-) AC (Neutral) or DC (-)
Surge Ground Surge Ground
Chassis Ground Chassis Ground

Fig. 2.2.1 RS1600 Family Power Supply Inputs

The RS1600 family supports dual redundant power supplies – “Power Supply 1” and “Power
Supply 2” (see Fig. 2.2.1). Each power supply as a set of identical inputs that perform the following:
1. +/H is connected to the positive (+) terminal if the power source is DC or to the (Hot)
terminal if the power source is AC.
2. -/N is connected to the negative (-) terminal if the power source is DC or to the (Neutral)
terminal if the power source is AC.
3. Surge Ground is connected to the Chassis Ground via a braided cable or other
appropriate grounding wire. Surge Ground is used as the ground conductor for all surge
and transient suppression circuitry internal to the RS1600. NOTE: Surge Ground must be
disconnected from Chassis Ground during HIPOT (dielectric strength) testing.
4. Chassis Ground is connected to the Safety Ground terminal for AC inputs or the
equipment ground bus for DC inputs.

Sections 2.2.1 to 2.2.5 describe connections for single, dual and mixed AC and DC power supply
inputs.

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2.2.1 Single Power Supply - AC Input

Fig. 2.2.2 Single Power Supply – AC Input

2.2.2 Dual Power Supplies – AC Inputs

Fig. 2.2.3 Dual Power Supplies – AC Inputs

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2.2.3 Single Power Supply – DC Input

Fig. 2.2.4 Single Power Supply – DC Input

2.2.4 Dual Power Supplies – DC Inputs

Fig. 2.2.5 Dual Power Supplies – DC Inputs

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2.2.5 Dual Power Supplies – DC and AC Inputs

Fig. 2.2.6 Dual Power Supplies – DC and AC Inputs

Notes:

1. 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker must be

installed within 3m of unit.
2. 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker must be
installed within 3m of unit.
3. A circuit breaker is not required for 48 or 24VDC rated power supplies.
4. Separate circuit breakers must be installed and separately identified.
5. Equipment must be installed according to the applicable country wiring codes.

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
2.3 HIPOT (Dielectric Strength) Testing

HIPOT (Dielectric Strength) Testing

Disconnect Braided Cable (1) and Braided Cable (2) during

HIPOT (dielectric strength) testing!

Braided Cable (1) Braided Cable (2)

Power Supply Power Supply
#1 #2

Fig. 2.3.1 HIPOT (Dielectric Strength) Testing

NOTE: Units which are to be “HIPOT” tested in the field must have the braided ground
cable(s) disconnected (see Fig. 2.3.1) during the HIPOT test. This is required in order to
prevent the transient/surge suppression circuitry, which is connected to Surge Ground (see
Fig. 2.2.1), from being activated during the HIPOT test.

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
2.4 Failsafe Output Wiring and Specifications
RS1600 Failsafe Relay Outputs

Normally Closed Common Normally Open

*** Normal contact state prior to power being applied to unit. ***

Fig. 2.4.1 Failsafe Output Relay

Load Resistive load (p.f. = 1) Inductive load (p.f. = 0.4)

Rated Load 0.40A @ 30 VAC, 2A @ 30VDC 0.2A @ 30 VAC, 1A @ 30VDC
Carry Current 3A
MAX operating Voltage 220VAC, 250VDC
MAX operating Current 3A (AC), 3A (DC) 1.5A (AC), 1.5A (DC)
MAX switching Capacity 50VA, 60 W 25VA, 30W
Table 2.4.1 Failsafe Output Relay – Contact Ratings

The “Failsafe” output relay is provided to signal critical error conditions that may occur on the
RS1600 series switches. The contacts are energized upon power up of the unit and remain
energized until a critical error occurs. Control of the output is user selectable and can be
programmed if the unit is a managed switch (i.e. “MS” option is in the order code) via the RS232
port. One common application for this output, regardless of whether the switch is managed or
unmanaged, is to signal an alarm if a power failure or removal of control power occurs.

NOTE: Care should be taken not to exceed the contact ratings as shown in Table 2.4.1.

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
2.5 RS232 Port Wiring

PIN5 PIN 1 PIN SIGNAL

1 n.c.
2 TXD
3 RXD
4 n.c.
5 GND
RS232 Port 6 n.c.
7 n.c.
8 n.c.
9 n.c.

PIN9 PIN 6
Fig 2.5.1 RS232 Port Signals

The RS232 port is used for configuring the RS1600 / RS1600T when the management CPU is
present. This is true if the order code for the unit contains the “MS” option (e.g. RS1600-xx-xx-xx-
MS-xx). A regular “straight through” serial cable with a DB-9 connector is required. There is no
need to cross over the TXD and RXD signals from the PC side this has been done internally as is
shown Fig. 2.5.1 RS232 Port Signals.

NOTE: This port is not intended to be a permanent connection and the cable length should
not exceed 2m (6.5ft).

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2.6 RJ45 Twisted-Pair Data Ports

Some of the RS1600 series switches have several 10/100BaseTX ports that allow connection to
standard CAT-5 UTP cable with RJ45 male connectors. All RJ45 RuggedSwitch products feature
auto-negotiating, auto-polarity, and auto-crossover functions with the exception of the base
RS1600 model (port 15 and 16 only). The base RS1600 (RS1600-XX-XX-XX-XX-RJ) is not auto-
crossover capable. Fig. 2.6.1 shows the RJ45 port pins configuration.

The RJ45 receptacles used can accept and take advantage of screened (commonly known as
“shielded”) cabling.

Although transient suppression circuitry is present on all RJ45 ports, they cannot protect the RJ45
port from severe high power, high amplitude transients that can potentially damage the RS1600
and its link partners. In general, RuggedCom strongly recommends limiting connections used by
the RJ45 ports to those that are less than 3m in length, or limited to environments sufficiently
protected from such transients.

PIN 8 PIN 1

PIN SIGNAL
1 RX+
2 RX-
3 TX+
4 n.c.
5 n.c.
6 TX-
7 n.c.
8 n.c.

Fig. 2.6.1 shows the RJ45 port pins configuration.

NOTE: For substation applications the RJ45 ports are intended for connectivity to other
communications equipment such as routers or telecommunications multiplexers installed
in close proximity (i.e. less than 3m/10ft) to the RS1600. It is not recommended to use these
ports to interface to field devices across distances which could produce high levels of
ground potential rise (GPR), (i.e. greater than 2500V) during line to ground fault conditions.

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
3 Technical Specifications
3.1 Power Supply Specifications

Power Supply Input Range Fuse Max. Power Consumption

Type Min Max Rating RS1600 RS1600T RS1600F
24 VDC 18 VDC 36 VDC 5A(F) 2

48 VDC 36 VDC 72 VDC 3.15A(T) 2

26 W 19 W 34 W
HI (125/250 VDC) 1 88 VDC 300 VDC
3.15A(T) 2
HI (110/230 VAC) 1 85 VAC 265 VAC
Notes: 1 – This is the same power supply for both AC and DC.
2 – (F) Denotes fast-acting fuse, (T) denotes time-delay fuse

CAUTION: For continued protection against risk of fire, replace only with same type and rating of
fuse.

3.2 Networking Standards Supported

Parameter 10Mbps Ports 100Mbps Ports Notes

IEEE 802.3 10BaseT / 10BaseFL
IEEE 802.3u 100BaseTX / 100BaseFX
IEEE 802.3x Full Duplex Operation
IEEE 802.1D MAC Bridges
IEEE 802.1Q VLAN (Virtual LAN)
IEEE 802.1p Priority Levels

3.3 Data Port Specifications

Data Port Media Distance Connector Type

10/100 Mbps* Cat 5 UTP 100m RJ45
* Available as an option on RS1600

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3.4 Fiber Optical Specifications

10Mbps Ports 100Mbps Ports

Parameter
Multi-Mode Multi-Mode Single-Mode3
Speed Standard 10BaseFL 100BaseFX
Connector Type ST MTRJ LC
Max Segment
2 2+ 15+
Length1 (km)
Optical Wavelength (nm) 820nm 1300nm 1310nm

Cable Size Core/Cladding (µm) 62.5/125 62.5/125 9/125

Optical Tx Power Min/Max
-13.5/-7.6 -16/-11 -15/-8
(dBm Peak2)
Optical Rx Sensitivity
-34.4 -33.5 -31
(dBm Average2)
Max Optical Rx Power
-8.2 -11 -5
(dBm Peak2)
Typical Optical
22 17 16.5
Power Budget (dB)

Notes:
1. Maximum segment length is greatly dependent on factors such as fiber quality, and
number of patches and splices. Please consult RuggedCom sales associates when
determining maximum segment distances.
2. To convert from average to peak add 3dBm. To convert from peak to average, subtract
3dBm.
3. Single-mode is available as an option.

3.5 Networking Performance Specifications

10Mbps Ports 100Mbps Ports

Parameter Notes
(10BaseFL) (100BaseFX)
Latency 16us + frame time 5us + frame time
Filtering Rate 14 880 148 800 Frames/sec
MAC Address Table 8192
VLAN Address Table 4096

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3.6 Type Test Specifications

Electrical Safety Levels Comments

Dielectric Withstand 2 kV rms for 1 minute ANSI/IEEE C37.90 (1989)
IEC 60255-5 (Section 6)
High Voltage Impulse 5 kV peak IEC 60255-5 (Section 8)
Insulation Resistance 500 VDC for 1 minute IEC 60255-5 (Section 6

Electrical Environment Levels Comments

High Frequency Disturbance 2.5 kV @ 1MHz for 2s ANSI/IEEE C37.90.1
(Oscillatory) IEC 60255-22-1
IEC Surge 4 kV / 2 kV IEC 61000-4-5
(Level 4)
IEC Fast Transient 2 kV / 1 kV IEC 61000-4-4
(Level 4)
ANSI/IEEE Fast Transient 4 kV ANSI/IEEE C37.90.1
IEC Radiated RFI Immunity 10 V/m IEC 61000-4-3
ANSI/IEEE Radiated RFI 35 V/m
ANSI/IEEE C37.90.2
Immunity
ESD 15 kV (air discharge) IEC 61000-4-2
(Electrostatic Discharge) 8 kV (contact) (Level 4)

Atmospheric Environment Levels Comments

Temperature (Dry Cold) -40°C IEC 60068-2-1
Test Ad: 16 hrs @ -40°C
Temperature (Dry Heat) 85°C IEC 60068-2-2
Test Bd: 16 hrs @ 85°C
Humidity 95% IEC 60068-2-30
non-condensing Test Db: 6 cycles, 55°C, 95% Humidity

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3.7 Operating Environment

Parameter Range Comments

Ambient Operating -40 to 85°C Ambient Temperature as
Temperature measured from a 30cm
radius surrounding the
center of the RS1600
enclosure.
Ambient Relative Humidity 5% to 95% Non-condensing
Ambient Storage -40 to 85°C
Temperature

3.8 Mechanical Specifications

Parameter Value Comments
Dimensions 18.29 x 10.17 x 1.74 inches (Length x Width x Height)
(464,57) x (258,32) x (44,20) mm with mounting brackets
installed
Weight 8 lb (3.6 Kg)
Enclosure 18 gauge Galvanized Steel

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© 2004 RuggedCom Inc. All rights reserved Rev 3.3
3.9 Agency Approvals

Agency Standards Comments

CSA CSA C22.2 No. 60950, UL 60950 Approved
CE EN 60950, EN 61000-6-2 CE Compliance is claimed
via Declaration of Self
Conformity Route
FCC FCC Part 15, Class A Approved
CISPR EN55022, Class A Approved

4 Warranty
Five (5) years from date of purchase, return to factory. For warranty details, visit
www.ruggedcom.com or contact your customer service representative.

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