Kingfisher Plus+ Hardware Manual

KINGFISHER PLUS+
Modular RTU Hardware Reference Manual 7.17
 Kingfisher Plus+ Hardware Manual

Document Control

Copyright 2000 - 2015

Copyright Semaphore Australia Pty Ltd. ABN 35 006 805 910
www.servelec-semaphore.com, [email protected]
 Kingfisher Plus+ Hardware Manual

Revision History

Version
Date Summary
Number
Update: adaptor ADP-22B (include Wavecom extend)
Update: temp sensor is white / white with a black strip
Update: power requirements of T option board
7.0 Update: power calculation tables
7.1 Update: Comms option boards selection table
28/10/2011 Update: safety warnings
7.12
Update: Lenses for PS-12 and PS-22
Update: Lens for MC-31
Proposed ‘Linked Backplane Example’ chapter removed
Update: Various errors found in first release
Corrected IO-5 power consumption
Added CP-12 power consumption
Added CP-30/MC-30/MC-31 to compatibility chapter
Corrected various spelling and grammatical mistakes
Outlined A3 / T3 simultaneous master and slave limitation in
rare use-cases
Added IO-5 Power Consumption
7.13 3/9/2012
Corrected RJC-ADP30 Diagram, RJ45 wiring error corrected
Updated T3 temp range
Added block diagrams for all IO Modules
Added Option Board installation guide
PS-x2 nominal voltage at low temperatures extended to 15°C
after further testing
Logo updated
Added new modules.
Added block diagrams for various modules.
Modules specifications reviewed and updated.
7.14 24/10/2014 Safety warnings updated.
Non-operational hyperlinks updated.
Logo and the document style updated.
Various corrections and updates.
MC-10/11/30 modules added.
PS-11 and PS-21 modules added.
7.15 18/11/2014
Option Board T2 added.
Various corrections and updates.
 Kingfisher Plus+ Hardware Manual

PS-x2 specifications adjusted

IO-5 temperature rating increased to -40...+85 °C
DO-1, DO-2 and TEL-REL_00x installation instructions updated
IO-2, IO-3 and IO-4 specifications updated (for Digital Outputs)
Dual Isolated Serial Option Board introduced
Information about environmental standards compliance added
Power consumption for Line and HART Option Boards updated
with more accurate figures (#557)
IO-4 wiring diagram corrected (#2496)
7.16 27/05/2015
IO-2 wiring diagram corrected (#2506)
The Maxon Intermax to Kingfisher Serial Port cable pinout
corrected (#2433)
Accuracy specification for AI-1, IO-3 and IO-4 modules
expanded for the whole operating temperature range (#2424)
RJC-ADP-30 drawing corrected to show resistor value (#2505)
Information about cables strain relief use added to the System
Installation section (#1203)
References to battery protection fuse type added (#1162)
Incorrect SRAM size fixed for CP-30 v2.x (#2525)
PS-x2 Battery Voltage Range corrected (#1332)
ADP-04 pinout corrected (#2557)
ADP-05 pinout corrected (#2574)
DI-5 wiring diagram corrected (#2722)
7.17 26/10/2015 A 2,000 m altitude limit added to the Option Board L and Option
Board D specifications
Grounding recommendation added for those cases when more
than three AC Power Supplies are installed
A3OB marked as “Class I LED Product”
“Class II” and “Class II with Functional Earthing” symbols
explained in the Glossary chapter
 Kingfisher Plus+ Hardware Manual

CONTENTS
1. INTRODUCTION ..................................................................................... 10

2. BACKPLANES ....................................................................................... 16
Overview .................................................................................................................... 16
BA-x-PLUS Backplanes.............................................................................................. 18
2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor ................................................ 18
2.2.2 BA-40-PLUS: 4-slot Backplane ............................................................................. 19
2.2.3 BA-6-PLUS: 6-slot Backplane ............................................................................... 20
2.2.4 BA-12-PLUS: 12-slot Backplane ........................................................................... 21
BP-x-PLUS Backplanes.............................................................................................. 22
Backplane Connectors ............................................................................................... 27
Linking Backplanes .................................................................................................... 28
2.5.1 Creating Racks ..................................................................................................... 28
2.5.2 Backplane Cables ................................................................................................. 29
2.5.3 Setting Bus Terminators ....................................................................................... 30
2.5.4 Setting Rack Number ............................................................................................ 30
2.5.5 Setting Slot Number Range .................................................................................. 33

3. POWER SUPPLY MODULES ................................................................... 35

Overview .................................................................................................................... 35
PS-x2 and PS-x1 Power Supply Modules ................................................................... 35
3.2.1 Overview .............................................................................................................. 35
3.2.2 Options and Ordering Info..................................................................................... 38
3.2.3 Theory of operation............................................................................................... 40
3.2.4 Battery Charging ................................................................................................... 41
3.2.5 Module LEDs ........................................................................................................ 42
3.2.6 PS-x2 Specifications ............................................................................................. 45
3.2.7 PS-x1 Specifications ............................................................................................. 47
3.2.8 Wiring Diagrams ................................................................................................... 49
PSU-x AC Power Supply Unit ..................................................................................... 53
Calculating Power Requirements................................................................................ 57
3.4.1 Total Current Consumption ................................................................................... 57
3.4.2 5 V Rail Overload Check....................................................................................... 59
3.4.3 Total Power Load.................................................................................................. 61
3.4.4 Battery Backup ..................................................................................................... 61

4. PROCESSOR MODULES ........................................................................ 62

Overview .................................................................................................................... 62
PC-1: Power & Processor Module .............................................................................. 63
4.2.1 Overview .............................................................................................................. 63
4.2.2 Part Numbers ....................................................................................................... 64
4.2.3 PC-1 Module LEDs ............................................................................................... 65
4.2.4 PC-1 Specifications .............................................................................................. 66
4.2.5 PC-1 Pinout .......................................................................................................... 68
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CP-12 Processor Module ........................................................................................... 69

4.3.1 Overview .............................................................................................................. 69
4.3.2 CP-12 Reset Procedures ...................................................................................... 69
4.3.3 CP-12 Module LEDs ............................................................................................. 70
4.3.4 CP-12 Specifications ............................................................................................ 71
4.3.5 CP-12 Ports .......................................................................................................... 72
CP-30: High Performance Processor Module ............................................................. 73
4.4.1 Overview .............................................................................................................. 73
4.4.2 CP-30 Options and Ordering Info.......................................................................... 73
4.4.3 Backup Battery / Reset to Factory Defaults........................................................... 75
4.4.4 CP-30 Module LEDs ............................................................................................. 78
4.4.5 CP-30 Specifications ............................................................................................ 81
4.4.6 CP-30 Ports .......................................................................................................... 82

5. COMMUNICATIONS MODULES ............................................................... 83

Overview .................................................................................................................... 83
MC-10/11/30 Communications Modules ..................................................................... 84
5.2.1 Overview .............................................................................................................. 84
5.2.2 MC-10/11/30 Module LEDs ................................................................................... 84
5.2.3 MC-10/11/30 Specifications .................................................................................. 85
5.2.4 MC-10/11/30 Block Diagram ................................................................................. 86
5.2.5 MC-10/11/30 Ports................................................................................................ 86
MC-12 Communications Module ................................................................................ 87
5.3.1 Overview .............................................................................................................. 87
5.3.2 MC-12 Module LEDs ............................................................................................ 88
5.3.3 MC-12 Specifications ............................................................................................ 89
5.3.4 MC-12 Ports ......................................................................................................... 90
MC-31 Communications Module ................................................................................ 91
5.4.1 Overview .............................................................................................................. 91
5.4.2 MC-31 Options and Ordering Info ......................................................................... 91
5.4.3 MC-31 Module LEDs ............................................................................................ 92
5.4.4 MC-31 Specifications ............................................................................................ 95
5.4.5 MC-31 Ports ......................................................................................................... 96

6. COMMUNICATIONS OPTION BOARDS .................................................... 97

Overview .................................................................................................................... 97
Compatibility ............................................................................................................... 97
Installing and removing Option Boards ....................................................................... 98
Option Board I: Isolated Serial .................................................................................. 101
6.4.1 Overview ............................................................................................................ 101
6.4.2 Serial Option Board Connections ........................................................................ 102
Option Board I2: Dual Isolated Serial........................................................................ 104
6.5.1 Overview ............................................................................................................ 104
6.5.2 Dual Serial Option Board Connections................................................................ 105
Option Board F: Fibre Optic Serial Board ................................................................. 106
Option Board D: 33.6 kbps Dial Option Board .......................................................... 107
Option Board L: Line/Analogue Radio Interface ........................................................ 109
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6.8.1 Line Board Connections...................................................................................... 109

6.8.2 Connecting a Radio ............................................................................................ 110
6.8.3 2-Wire Line, point-to-point................................................................................... 111
6.8.4 2-Wire Line, multi-drop........................................................................................ 111
6.8.5 4-Wire Line, point-to-point................................................................................... 112
6.8.6 4-Wire Line, multi-drop........................................................................................ 112
Option Board H: HART Interface .............................................................................. 115
6.9.1 HART Board Connections................................................................................... 115
Option Boards T3 & T2: 10/100 Ethernet Controller................................................ 118
Option Board A3: Fibre Optic Ethernet ................................................................... 119
Option Board R2: Australian Spread Spectrum Radio ............................................ 120
Option Board R3: International Spread Spectrum Radio ......................................... 122
Option Board R4: US/Canada Spread Spectrum Radio .......................................... 124

7. PC-1 OPTION BOARDS ........................................................................ 126

PC-1 Serial Option Board ......................................................................................... 126
PC-1 Modem Board PL: Two Wire Line .................................................................... 127
PC-1 Modem Board: Analogue Radio Interface ........................................................ 128

8. IO MODULES OVERVIEW ..................................................................... 129

9. ANALOGUE INPUT MODULES .............................................................. 133

AI-1: 8 Channel Analogue Current Input Module ...................................................... 133
9.1.1 Overview ............................................................................................................ 133
9.1.2 AI-1 Module LEDs............................................................................................... 135
9.1.3 AI-1 Specifications .............................................................................................. 136
9.1.4 AI-1 Wiring Diagram ........................................................................................... 137
AI-10: 8 Channel High Impedance Analogue Input Module ...................................... 139
9.2.1 Overview ............................................................................................................ 139
9.2.2 AI-10 Module LEDs............................................................................................. 142
9.2.3 AI-10 Specifications ............................................................................................ 143
9.2.4 AI-10 / AI-10-V Wiring Diagram........................................................................... 144

10. ANALOGUE OUTPUT MODULE ........................................................... 146

AO-3: Analogue Output Module .............................................................................. 146
10.1.1 Overview........................................................................................................... 146
10.1.2 AO-3 Module LEDs ........................................................................................... 148
10.1.3 AO-3 Specifications .......................................................................................... 149
10.1.4 AO-3 Wiring Diagram ........................................................................................ 150

11. DIGITAL INPUT MODULES ................................................................. 152

Overview ................................................................................................................ 152
DI-5: DC Input 16 Channel Digital Input Module ..................................................... 152
11.2.1 Overview........................................................................................................... 152
11.2.2 DI-5 Module LEDs ............................................................................................ 153
11.2.3 DI-5 Specifications ............................................................................................ 154
11.2.4 DI-5 Wiring Diagram ......................................................................................... 155
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DI-10: AC or DC Input, 16 Channel ........................................................................ 157

11.3.1 Overview........................................................................................................... 157
11.3.2 DI-10 Options and Ordering Info ....................................................................... 158
11.3.3 Theory of operation ........................................................................................... 159
11.3.4 Configurable Functions ..................................................................................... 160
11.3.5 Sequence of Events Recording......................................................................... 161
11.3.6 GPS Time Synchronisation (Optional) .............................................................. 161
11.3.7 DI-10 Module LEDs .......................................................................................... 163
11.3.8 DI-10 Specifications .......................................................................................... 165
11.3.9 DI-10 Wiring Diagram ....................................................................................... 168

12. DIGITAL OUTPUT MODULES .............................................................. 170

Overview ................................................................................................................ 170
Switching Inductive Loads ...................................................................................... 170
DO-1: 8 Channel Isolated Relay Output Module ..................................................... 172
12.3.1 Overview........................................................................................................... 172
12.3.2 DO-1 Module LEDs ........................................................................................... 174
12.3.3 DO-1 Specifications .......................................................................................... 175
12.3.4 DO-1 Wiring Diagram ....................................................................................... 176
DO-2: 16 Channel Relay Output Module ................................................................ 178
12.4.1 Overview........................................................................................................... 178
12.4.2 DO-2 Module LEDs ........................................................................................... 180
12.4.3 DO-2 Specifications .......................................................................................... 180
12.4.4 DO-2 Wiring Diagram ....................................................................................... 181
DO-6: 16 Channel Open Drain Output Module ....................................................... 183
12.5.1 Overview........................................................................................................... 183
12.5.2 DO-6 Module LEDs ........................................................................................... 184
12.5.3 DO-6 Specifications .......................................................................................... 184
12.5.4 DO-6 Wiring Diagram ....................................................................................... 185

13. RELAY EXPANSION BOARDS ............................................................ 187

Overview ................................................................................................................ 187
TEL REL 002: SPDT Relay Board .......................................................................... 189
13.2.1 Overview........................................................................................................... 189
13.2.2 TEL REL 002 Specifications ............................................................................. 189
13.2.3 TEL REL 002 Wiring Diagram ........................................................................... 191
TEL REL 003: SPST Relay Board .......................................................................... 193
13.3.1 Overview........................................................................................................... 193
13.3.2 TEL REL 003 Specifications ............................................................................. 193
13.3.3 TEL REL 003 Wiring Diagram ........................................................................... 194
TEL REL 004: DPDT Relay Board .......................................................................... 196
13.4.1 Overview........................................................................................................... 196
13.4.2 TEL REL 004 Specifications ............................................................................. 196
13.4.3 TEL REL 004 Wiring Diagram ........................................................................... 198

14. COMBINATION IO MODULES ............................................................. 200

IO-2: Combinational Digital IO Module ................................................................... 200
14.1.1 Overview........................................................................................................... 200
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14.1.2 IO-2 Module LEDs ............................................................................................ 202

14.1.3 IO-2 Specifications............................................................................................ 202
14.1.4 IO-2 Wiring Diagram ......................................................................................... 203
IO-3: Combinational Analogue/Digital IO Module .................................................... 205
14.2.1 Overview........................................................................................................... 205
14.2.2 IO-3 Module LEDs ............................................................................................ 207
14.2.3 IO-3 Specifications............................................................................................ 208
14.2.4 IO-3 Wiring Diagram ......................................................................................... 210
IO-4: Combinational Analogue / Digital IO Module .................................................. 213
14.3.1 Overview........................................................................................................... 213
14.3.2 IO-4 Module LEDs ............................................................................................ 215
14.3.3 IO-4 Specifications............................................................................................ 216
14.3.4 IO-4 Wiring Diagram ......................................................................................... 218
IO-5: Combinational Analogue / Digital IO Module .................................................. 220
14.4.1 Overview........................................................................................................... 220
14.4.2 IO-5 Module LEDs ............................................................................................ 223
14.4.3 IO-5 Specifications............................................................................................ 224
14.4.4 IO-5 Wiring Diagram ......................................................................................... 226

15. ADAPTORS AND CABLES .................................................................. 228

Overview ................................................................................................................ 228
RTU Test Cables .................................................................................................... 230
Device Cables and Adaptors .................................................................................. 231

16. ACCESSORIES .................................................................................. 242

MBR-3: 19” Rack Mounting for BA-12-PLUS .......................................................... 242
TEL-RAK-002: 19” Rack Mounting for BA-4/6/40.................................................... 243
Battery Bracket: 7 Ah Battery Mounting Bracket ..................................................... 244

17. GLOSSARY ........................................................................................ 245

18. APPENDIX A: SYSTEM INSTALLATION.......................................................... 247

 Kingfisher Plus+ Hardware Manual

1. INTRODUCTION
This manual details the specifications for each type of module, option board, cable and
accessory available for use with a Kingfisher Plus+ Remote Terminal Unit (RTU).
A Kingfisher Plus+ Modular RTU is a highly configurable device that can monitor and control
a wide range of equipment. Kingfisher Plus+ modular RTUs are easy to install and configure,
can be large or small, use interchangeable modules, have advanced communications, and
support powerful programming languages.

RTU Features
• Two-, four-, six- and twelve-slot backplanes.
• Backplanes can be linked together vertically or horizontally providing up to 64 modules
per RTU.
• AC (100 to 240 VAC) and DC (20 to 60 VDC) power supply modules.
• Battery backup and built-in battery charger.
• Powerful 32-bit Industrial CPUs.
• Up to 16 communication ports.
• Eight-channel analogue input modules.
• Four-channel analogue output modules.
• Eight and sixteen channel digital input/output modules.
• High speed scanning of I/O-signals.
• Electrical isolation of I/O and communication circuits.
• Designed and tested to comply with International Environmental (climatic) Standards
(IEC 60068-2-1, IEC 60068-2-2, IEC 60068-2-78).
• Full support for IEC 61131-3 via the ISaGRAF™ programming environment.
• Multiple pre-defined function blocks for communications and diagnostics.
• Support for multiple protocols including – Modbus, DNP3, Allen Bradley® DF1, and
User Defined.
• Event logging of data (time and date stamped).
• Redundant Power Supplies, Processors and Communications
• Self-configuring of I/O modules at start up.
• PC based configuration and diagnostic software – Toolbox PLUS software with
ISaGRAF™ Workbench.
• Local and remote configuration.
• Low power operation – suitable for low cost solar installation.

Product Description
The Kingfisher Plus+ RTU offers many desirable features in addition to the abovementioned
items, including small physical size for ease of mounting and handling, changeable port
types (e.g. RS232/422/485, PSTN, Ethernet, private line etc), front panel LED status and
diagnostic display.
Kingfisher Plus+ RTUs may be configured to user I/O, communication circuit requirements,
power supply requirement and processing functionality by selecting the appropriate modules

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from the available range. Selected modules are simply installed on the backplanes and
secured with a single screw.
Larger modular RTUs are configured using one or more backplanes together with a
processor module, a power supply module(s) and optional I/O and communication modules.
The RTU size permits flexible and simple mounting in industry standard enclosures. An RTU
using a 12-slot backplane can be 19” rack mounted with the aid of additional brackets.

RTU Configuration Options

Each modular RTU requires a backplane, a power supply and a CPU module. There are
three types of Kingfisher Plus+ modular RTUs identified by the processor module they
contain: PC-1, CP-12 or CP-30.

PC-1 CP-12 CP-30

A PC-1 RTU is powered using an external AC/DC power supply. A PC-1 processor module
is only used on a BA-4 PLUS backplane (4 slot).
A CP-12 or CP-30 RTU is powered using a power supply module (or modules) and utilizes
one of three backplanes: a BA-40-PLUS (4 slot), a BA-6-PLUS (6 slot) or a BA-12-PLUS
(12 slot). A Powered Backplane (BP-x-PLUS) can also be used.
An RTU can also have any combination of I/O and communication modules as required.
Modular RTUs support up to 64 modules and 1008 I/O (input/output) points. To obtain more
communications ports, one or more communications modules can be added to the RTU.
Examples of various RTU configurations are shown below.

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BP-2-PLUS – based RTU BA-40-PLUS – based RTU

BA-6-PLUS – based RTU

Small RTUs examples

Medium RTU example

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Large RTU example (only one processor module is required for the entire RTU)

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Kingfisher Plus+ RTU Components

Each RTU requires a Processor module installed into a backplane and a Power Supply
source as a minimum. Communications and I/O modules are optional. The modules that are
currently available are listed below:

Module Description
BACKPLANES
BA-4-PLUS Backplane, 4-slot (for PC-1 processor only)
BA-40-PLUS Backplane, 4-slot
BA-6-PLUS Backplane, 6-slot
BA-12-PLUS Backplane, 12-slot
BP-2-PLUS Backplane with integrated 5 V power supply, 2-slot
BP-4-PLUS Backplane with integrated 5 V power supply, 4-slot
BP-6-PLUS Backplane with integrated 5 V power supply, 6-slot
POWER SUPPLIES
AC-DC Power Supply Module
PS-12-0
Input 100-240 VAC / 50-60 Hz

PS-22-0 DC-DC Power Supply Module

Input 20-60 VDC

AC-DC Power Supply Module

PS-12-C
Input 100-240 VAC / 50-60 Hz, additional 24 Volt Auxiliary Output
DC-DC Power Supply Module
PS-22-C
Input 20-60 VDC, additional 24 Volt Auxiliary Output
AC-DC Power Supply Unit
PSU-3
Input 90-260 VAC / 50-60 Hz, 40 W
AC-DC Power Supply Unit
PSU-4
Input 90-260 VAC / 50-60 Hz, 60 W
AC-DC Power Supply Unit
PSU-5
Input 90-260 VAC / 50-60 Hz, 70 W
PROCESSOR MODULES
Power and Processor Module
PC-1
Integrated Power Supply, 16 MHz 16-bit CPU, Fixed Serial Port + 1x Optional Port
Processor Module
CP-12
40 MHz 16-bit CPU, Fixed Serial Port + 2x Optional Ports
Processor Module
CP-30
166 MHz 32-bit CPU, Fixed Ethernet Port + 2x Optional Ports
COMMUNICATIONS MODULES
Communications Module
MC-12
up to 3 communications ports (incl. fixed serial port)
Communications Module
MC-31
up to 3 communications ports (incl. fixed Ethernet port)

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Module Description
ANALOGUE MODULES
Analogue Input Module
AI-1
8 analogue current inputs, 1 common per module
Analogue Input Module
AI-10
8 analogue high impedance inputs, 1 common per module
Analogue Output Module
AO-3
4 analogue 0-20 mA / 4-20 mA outputs, 4 commons per module
DIGITAL MODULES
Digital DC Input Module
DI-5
Bipolar dry contact inputs, 16 Points, 1 common per module
Digital AC/DC Input Module
DI-10
Intelligent AC/DC inputs, 16 Points, 1 common per module
Digital Relay Output Module
DO-1
NO/NC (SPDT), 8 Points, 4 commons per module
Digital Relay Output Module
DO-2
NO (SPST), 16 Points, 2 commons per module
Digital Solid State Module
DO-6
Open Drain Outputs, 16 Points, 2 commons per module
I/O MODULES
Combination Digital I/O Module
IO-2
8 digital inputs / 8 digital outputs, 2 commons per module
Combination Analogue/Digital I/O Module
IO-3 4 relay outputs / 4 analogue inputs / 4 digital inputs / 1 analogue output, 4 commons per
module
Combination Analogue/Digital I/O Module
IO-4
2 relay outputs / 2 analogue inputs / 8 digital inputs, 3 commons per module
Combination Analogue/Digital I/O Module
IO-5 4 analogue inputs / 1 analogue output / 4 digital inputs / 4 sinking outputs, 4 common per
module
EXPANSION BOARDS
SPDT Relay Expansion Board
TEL REL 002
16 SPDT relay outputs, 1 common per channel
SPST Relay Expansion Board
TEL REL 003
16 SPST relay outputs, 1 common per channel
DPDT Relay Expansion Board
TEL REL 004
16 DPDT relay outputs, 2 commons per channel

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2. BACKPLANES

Overview
The purpose of a backplane is to host all Kingfisher Plus+ modules that make an RTU and to
allow the processor module to communicate with all other modules within the same RTU.
The backplane also distributes power to each module. Some backplanes can be linked
together to create an RTU containing up to 64 modules.
There are two families of Kingfisher Plus+ backplanes available:
• BA-x / BA-x-PLUS – passive backplanes that require a power supply module to be
installed in one of the slots to make the RTU working. These backplanes range is a
flexible solution for creating medium- to large-scale RTUs of any desired configuration.
• BP-x-PLUS – backplanes with an integrated 5 V power converter that require only one
external +12 VDC power supply to run the RTU. These backplanes have limited
expansion and configuration capabilities and mainly aimed for building small-scale low-
cost RTUs.
Seven versions of backplanes are available in total:
BA-4 / BA-4-PLUS 4-slot backplane for use with PC-1 processor module
BA-40 / BA-40-PLUS 4-slot backplane
BA-6 / BA-6-PLUS 6-slot backplane
BA-12 / BA-12-PLUS 12-slot backplane
BP-2-PLUS 2-slot backplane with integrated 5 V power supply
BP-4-PLUS 4-slot backplane with integrated 5 V power supply
BP-6-PLUS 6-slot backplane with integrated 5 V power supply
Note: Where the number of slots is not important, the backplanes will be referred to as
‘BA-x-PLUS’ (for all passive backplanes) and ‘BP-x-PLUS’ (for all backplanes with a built-in
power supply) further in this document. The part numbers with the ‘-PLUS’ suffix use the
green pluggable terminal blocks for the inter-rack data connectors, while the old (will be
referred to as ‘BA-x’) backplanes use black crimp connectors (Harwin Datamate M80) for
that purpose.
All Kingfisher Plus+ backplanes are designed to be surface mounted. Mounting brackets
(2 pieces) are supplied for user fitting. The backplanes can also be mounted in a 19" rack
(see “Accessories” chapter for details).

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Module Dimensions

Module mounted on a backplane

Installing Modules onto a Backplane

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BA-x-PLUS Backplanes
2.2.1 BA-4-PLUS: 4-slot Backplane for PC-1 Processor
A BA-4-PLUS backplane is designed to be used with a PC-1 power and processor module.
The PC-1 is installed into the leftmost slot and any other modules can be installed in the
remaining 3 slots.
Please use a BA-40-PLUS backplane if requiring a 4-slot backplane for use with a CP-xx
processor and a PS-xx power supply.

BA-4-PLUS backplane
For information on the BA-4-PLUS backplane connectors please refer to the
“Backplane Connectors” section below.

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2.2.2 BA-40-PLUS: 4-slot Backplane

A BA-40-PLUS backplane is identical to a BA-4-PLUS backplane but with the J6 Power
Connector and the PC-1 Power Connector are removed.
This backplane is designed to be used with a PS-xx power supply and a CP-xx processor
module or linked to any other backplane to provide additional slots.

BA-40-PLUS backplane
For information on the BA-40-PLUS backplane connectors please refer to the
“Backplane Connectors” section below.

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2.2.3 BA-6-PLUS: 6-slot Backplane

A BA-6-PLUS six-slot backplane is designed to support any power supply, IO or
communications module in any slot position. This backplane is intended to be used with a
PS-xx power supply and a CP-xx processor module or linked to any other backplane to
provide additional slots.

BA-6-PLUS backplane
For information on the BA-6-PLUS backplane connectors please refer to the
“Backplane Connectors” section below.

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2.2.4 BA-12-PLUS: 12-slot Backplane

A BA-12-PLUS twelve-slot backplane is designed to support any power supply, IO or
communications module in any slot position. It is intended to be used with a PS-xx power
supply and a CP-xx processor module or linked to any other backplane to provide additional
slots.

BA-12-PLUS backplane
For information on the BA-12-PLUS backplane connectors please refer to the
“Backplane Connectors” section below.

2.2.5 BA-x-PLUS-Specifications
Specifications of the BA-x-PLUS backplanes are summarised in the table below.

PARAMETER VALUE

Operating Temperature Range -40 to +85 °C

Rack Number 1-4

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BP-x-PLUS Backplanes
BP-x-PLUS backplanes are available as two-, four- and six- slot versions (BP-2-PLUS, BP-4-
PLUS and BP-6-PLUS correspondingly).
The BP-x-PLUS backplanes serve the same purpose as the BA-x-PLUS backplanes, the
main difference is that these backplanes have an integrated 5 VDC / 5 A power converter on
board and, as a result, do not require a PS-xx power supply for the RTU to work. In order to
operate, the BP-x-PLUS backplanes need only be powered from a single external 12 VDC
power source. If a backup power source is required then a 12 V lead-acid battery can be
connected in parallel with an input power supply with its output adjusted to 13.8 V level. The
BP-x-PLUS backplanes do not provide any battery charging means by themselves.

BP-2-PLUS backplane

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BP-4-PLUS backplane

BP-6-PLUS backplane

For information on the BP-x-PLUS backplanes connectors please refer to the

“Backplane Connectors” section below.

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The BP-x-PLUS backplane provides switchable 12VAUX output for powering extra circuits
(e.g. an external radio) with its voltage derived directly from the BP-x-PLUS input and
therefore not regulated. The output is in ON-state by default and can be controlled by the
Toolbox PLUS software or user logic (implementation pending).
The status of BP-x-PLUS power rails is indicated by corresponding LED indicators shown on
the figure below.

BP-x-PLUS LED Indicators

5V-rail status (top row of LEDs):

• Green (left) LED — 5 VDC power is normal.
• Red (right) LED — 5 VDC level is out of range due to overload or circuit fault.

12VAUX-rail status (bottom row of LEDs):

• Green (left) LED — 12 VDC AUX power is turned ON and is normal.
• Red (right) LED — 12 VDC AUX level is out of range due to overload or circuit fault.
• Both LEDs OFF — 12 VDC AUX power is turned OFF.
The BP-x-PLUS backplanes offer the following protection features:
• Input is protected from overvoltage and reverse polarity (crowbar protection level set to
18 VDC), and from overcurrent (a polyfuse rated at 6 A @ 25 °C).
• 5 VDC output is protected from overload (5 A maximum output current).
• 12 V AUX output is protected from overload (2 A maximum output current).

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Note that the crowbar protection circuit will latch when its voltage is either below -0.5 V or
above +18.5 V (approximately). It will clamp the input power rail voltage to a very low value:
± (0.5 – 2.5) V depending on the clamp current supplied by a power source. If the power
source can provide current exceeding a polyfuse trip current (3-24 A depending on the
ambient temperature), it may trip also, limiting the clamp current to several milliamperes.
To recover protective circuit after tripping, the input voltage should be removed completely.
A 5-10 s pause before re-applying input power may be required to allow for the polyfuse to
cool down if it has tripped.
WARNING. Install BP-x-PLUS as close to the power source as practically possible. To avoid
tripping of the overvoltage / reverse polarity protection circuit, that may occur due to voltage
overshoots caused by the parasitic inductances of the long wires, the power wires length
should not exceed 3 m. Install a 330 - 1000 µF (rated 25 V minimum) capacitor as close as
practical to the input power terminals of the BP-x-PLUS backplane if high levels of
electromagnetic interferences may be present at the installation site.
There are no adjustable or serviceable parts on the BP-x-PLUS backplanes. Since these
backplanes are not configurable, their rack number is always fixed to #1 and their slot
numbering always starts from 1. Therefore, only one BP-x-PLUS backplane can be used in
the RTU. However, Power and/or Data Connectors to extend the RTU using BA-x-PLUS
backplanes are available.
Block-diagram of the BP-x-PLUS backplanes is shown in the figure below.

BP-x-PLUS backplane Block Diagram

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Specifications of the BP-x-PLUS backplanes are summarised in the table below.

PARAMETER VALUE COMMENT

Operating Temperature
-40 to +85 °C
Range
Input Power Rating 10-16 VDC; 5 A
Derated at high temperatures, refer to the
Output Power Rating 5 VDC ± 5%;
“BP-x-PLUS 5V Output Derating Curve” graph
(5V output) 5 A max
below for details.
Non-regulated.
Output Power Rating 10-16 VDC;
The output is ON by default but can be
(12V AUX output) 2 A max
controlled by processor software1.
Rack Number 1 Not configurable.
1-2 2-slot version (BP-2-PLUS). Not configurable.
Slot Numbers 1-4 4-slot version (BP-4-PLUS). Not configurable.
1-6 6-slot version (BP-6-PLUS). Not configurable.

Notes:
1
) Implementation pending.

BP-x-PLUS 5V Output Derating Curve

The BP-x-PLUS backplanes are fully compatible with all other Kingfisher Plus+ modules
except Power Supply units (PS-xx). Although accidental installation of PS-xx module into a
powered backplane will not cause any damage, this is not recommended as the BP-x-PLUS
modules are intended to supply power independently and not designed to share power with
other power sources.

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Backplane Connectors
There are several connectors located at the right-hand side of the Kingfisher Plus+
backplanes which are used for wiring power and/or signals outside of a backplane. The type
and quantity of the connectors depend on the model of the backplane. Please refer to the
pictures of the backplanes shown earlier in this chapter and/or the connector reference
designators to determine which connectors exist on your backplane. All connectors are
described in the table below.

Designator Connector Type Connector Pinout

6-pin 4.2 mm male header (white).

J14
Molex P/N 39-28-8060
(mating part P/N 39-01-2065). Note: the ‘24V’ pin may be used for
other purposes such as time-
synchronisation between backplanes.

7-pin 3.5 mm male header (green).

J13, J15*
Phoenix P/N 1843651
(mating part P/N 1840418).

9-pin 5.08 mm male header (orange).

J6
Weidmuller P/N 1520260000
(mating part P/N 1716390000).

4-pin 3.5 mm male header (green).

J5
Phoenix P/N 1843622
(mating part P/N 1840382).

* - J15 for BA-x-PLUS backplanes only; not present on BP-x-PLUS units.

It is recommended to cover all unused backplane connectors in harsh environmental

conditions (e.g. by fitting the mating connector). The parts suitable for the Power and Data
connectors are listed in the table above. The suitable mating parts for the 32-pin module slot
connectors are listed below:
1. Oupiin P/Ns: 9001-3532 / 9001-3520 / 9001-3732 / 9001-3720.
2. Harting P/Ns: 09 22 132 7922 / 09 22 132 6922 / 09 22 132 2922 / 09 22 132 7921 /
09 22 132 6921 / 09 22 132 2921.

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Linking Backplanes
2.5.1 Creating Racks
A single RTU can consist of up to 64 modules by using a six-bit number adopted in the
Kingfisher Plus+ systems:

In order to organise connection of up to 64 modules into one RTU, backplanes should be

linked together into ‘racks’. Each rack can have a maximum of 16 slots. A single RTU can
support up to 4 racks thus providing a total of 64 module slots.
The figure below shows one full rack (16 slots) consisting of a BA-40-PLUS linked to a BA-
12-PLUS.

The BA-x-PLUS backplanes have an IN and an OUT connectors (J13 and J15 described
earlier in the “Backplane Connectors” section) linking them to the RTU data bus. The BP-x-
PLUS backplanes have only one (OUT) connector linking them to the RTU data bus (J13).
The reason for this is that the BP-x-PLUS backplane must always be the first in an RTU.

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2.5.2 Backplane Cables

While building an RTU, it may become necessary to organise signals and/or power
connections between backplanes. To implement the required interconnections the cables will
be required that can be either assembled (based on the data on the backplane connectors
provided above) or ordered from Semaphore. The following cables are available for order:
To be used with Backplanes
Order Code Description
(Connectors)
POW ER CA B L E S
BPC-01 Interrack 6-way Power Cable, 0.6 m All (J14 to J14)
BPC-02 Interrack 6-way Power Cable, 1.1 m All (J14 to J14)
CO M M C A B L E S
Interconnect cable, 0.5 m,
BAC-01 BA-x (J13/J15 to J13/J15)
8-pin clip on both ends
Interconnect cable, 1.0 m,
BAC-02 BA-x (J13/J15 to J13/J15)
8-pin clip on both ends
Interconnect cable, 0.5 m, BA-x (J13/J15) to BA-x-PLUS (J13/J15)
BAC-INT-01
8-pin clip to 7-pin terminal plug BA-x (J13/J15) to BP-x-PLUS (J13)
Interconnect cable, 1.0 m, BA-x (J13/J15) to BA-x-PLUS (J13/J15)
BAC-INT-02
8-pin clip to 7-pin terminal plug BA-x (J13/J15) to BP-x-PLUS (J13)
Interconnect cable, 0.5 m, BA-x-PLUS (J13/J15 to J13/J15)
BAC-PLUS-01
7-pin terminal plug on both ends BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)
Interconnect cable, 1.0 m, BA-x-PLUS (J13/J15 to J13/J15)
BAC-PLUS-02
7-pin terminal plug on both ends BA-x-PLUS (J13/J15) to BP-x-PLUS (J13)
S P EC I AL C A B L E S
Interrack 2-way Cable, 1.1 m
(24V / SYNC and GND pins only)
BPC-02-GPS All (J14 to J14)
To distribute GPS time-sync pulse
across racks without power distribution
BPC-SPLIT BPC Splitter Cable, 6-way, 0.1 m All (J14) to 2x BPC-0x / BPC-02-GPS cables

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2.5.3 Setting Bus Terminators

Each BA-x-PLUS backplane has data bus terminators (resistors) that can be Enabled or
Disabled by the first six switches of the DIP-switch installed on the backplane PCB (please
refer to the information printed on the backplane board surface for exact details on possible
switch configurations). A chain of backplanes requires the terminators to be switched ON
(Enabled) for the first and the last backplane in the chain. All intermediate backplanes must
have terminators switched OFF (Disabled). The BP-x-PLUS backplanes have their
terminating resistors always enabled as they are designed to be the first backplane in a rack.

IO-bus terminators control switches CM-bus terminators control switches

2.5.4 Setting Rack Number

While the rack number value of the BP-x-PLUS backplanes is always fixed (and equal to #1),
the BA-x-PLUS backplanes allow that their rack number to be configured with the switches
#7 and #8 of the on-board DIP-switch (please refer to the information printed on the
backplane board surface for exact details on possible switch configurations).

Rack Number control switches

The following table outlines the DIP switch configuration required for the most recent
hardware revisions of the BA-backplanes (v2.x and v3.x). For previous hardware versions
please refer to the Superseded Products manual available on Semaphore Helpdesk.

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T o t al Nu m b e r o f R ac ks i n RT U

Switch
1 Rack 2 Racks 3 Racks 4 Racks
Settings

1st Rack

2nd Rack

3rd Rack

4th Rack

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Backplane Switch Configuration Example (revision 2.x and 3.x):

Note that supplementary to the data bus connections shown, each backplane requires either
a Power Supply Module installed or a power cable connected to J14.
For previous backplane hardware revisions please refer to the Superseded Products
Manual.

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2.5.5 Setting Slot Number Range

Backplanes have hard-coded slot numbers which, for the BA-x-PLUS modules, can be set to
four different ranges determined by the rack number (please refer to the ‘Setting Rack
Number’ section of this chapter for details). The BP-x-PLUS backplanes slot numbering
range is not configurable and always starts from #1.
The BP-x-PLUS, BA-6-PLUS and BA-12-PLUS backplanes occupy the start of each rack,
while the BA-4-PLUS (and BA-40-PLUS) occupies the last four slot numbers in each rack
(e.g. #13 to #16 in Rack 1). Starting from v3.3, the BA-4-PLUS / BA-40-PLUS backplanes
can be used in the beginning of the rack as well. To achieve this, the BA-4-PLUS / BA-40-
PLUS backplanes are equipped with an extended 10-way DIP-switch. Switches #9 and #10
are used to configure the desired slot numbering range (see the figure below for possible
switch configurations).

Slots numbered from 1 to 4 (for Rack 1) Slots numbered from 13 to 16 (for Rack 1)

Slot Number Range control switches (BA-4-PLUS & BA-40-PLUS only)

The configuration when both #9 and #10 switches are turned ON (factory default setting) is
equal to the left picture above (Slots are numbered from 1 to 4 for Rack 1) but increases
current consumption from the 5V rail by 3 mA approximately. The configuration with both #9
and #10 switches turned OFF should not be used as the slot numbering setting becomes
undefined.
An example of the possible RTU configuration, explaining rack and slot numbering
sequence, is shown on the picture below.

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3. POWER SUPPLY MODULES

Overview
The Kingfisher Plus+ Power Supply Modules allow real time monitoring of currents, voltages
and temperatures supplied to the RTU and the backup battery. The monitoring capability
also allows the RTU to determine when a supply has failed if in a redundant configuration.
If fitted, auxiliary supplies can be overridden manually or by logic to allow for external
equipment or sensor loops to be shut down or reset.

PS-x2 and PS-x1 Power Supply Modules

3.2.1 Overview
• Monitoring of rail voltages, supply & battery currents and temperature
• AC or DC input
• Support for redundancy (several supplies per backplane)
• Isolated DC output
• Sealed Lead Acid battery connection with charging/monitoring and low voltage
protection
• Software controlled power to the Backplane and Aux Outputs

Note: PS-x1 is a SUPERSEDED product and is not being manufactured currently.

Fire Risks

A supply voltage outside the specified limits

may cause fire.

Risques d'Incendie

Une tension d’alimentation en dehors des limites spécifiées peut

provoquer un incendie.

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Electrical Hazards
Only appropriately qualified and trained personnel
can install and service this equipment.
Mains Power must be connected in accordance with local national
wiring rules and regulations. Building installation shall provide
appropriate short-circuit backup protection.
Always remove input mains voltage (by disconnecting power cord
from the mains power outlet or by switching off an external circuit
breaker, depending on installation) before performing any
operation on this product.
Disconnect power cord from the Power Supply Module
before wiring, removing or servicing.
Failure to do so may cause fire and may result in a
serious personnel injury or even death.

Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
L’alimentation secteur doit être raccordée conformément aux
règles et réglementations nationales de câblage locales. Les
équipements du bâtiment doivent assurer une protection
appropriée contre les courts-circuits.
Toujours enlever la tension d’alimentation (en débranchant le
cordon d’alimentation de la prise d’alimentation secteur ou en
coupant le disjoncteur externe en fonction de l’installation) avant
d’effectuer toute opération sur ce produit.
Débranchez le cordon d’alimentation du module d’alimentation
avant le câblage, le retrait ou l’entretien.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves du personnel ou même la mort.

Warning

The Earth Terminal in the mains power inlet provides only

FUNCTIONAL EARTH connection.
It cannot be relied upon for safety purposes.

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Avertissement de Sécurité

Le terminal de terre à l’entrée de l’alimentation secteur est

uniquement une connexion de TERRE FONCTIONNELLE.
On ne peut pas compter sur lui pour assurer la sécurité.

Warning
If an RTU has more than three AC Power Supplies (PS-1x)
installed then the Earth Terminals in the mains power inlets must
be connected to PROTECTIVE EARTH in accordance with local
safety requirements.
Refer to Appendix A for wiring recommendations.

Avertissement de Sécurité

Si une unité terminale distante (RTU) a plus de trois alimentations

alternatives (PS-1x) installées alors les connections de terre des
prises d’alimentations secteurs doivent être reliées à la TERRE DE
PROTECTION conformément aux exigences de sécurité locales.
Reportez-vous à l’annexe A pour les recommandations de câblage.

The PS-x2/PS-x1 modules provide AC-DC (PS-12 and PS-11 only) or DC-DC conversion
from mains power into 12 VDC and 5 VDC for the backplane, as well as 12 VDC and optional
24 VDC auxiliary outputs. Both auxiliary outputs can be controlled by the RTU logic
configuration.
An isolated 24 VDC output rated at 6 W (250 mA) is an option available for powering a limited
number of analogue loops or digital circuits. It cannot be used with inductive loads such as
coils, contactors etc. Power for these is to be provided from a separate supply.
The PS-x2/PS-x1 is supplied with an internal temperature sensor to monitor its PCB
temperature and an optional external temperature sensor to monitor a backup battery. When
the battery is connected, the supplied external sensor should be mounted in the vicinity of
the battery negative terminal to ensure correct temperature compensation. If readings from
the external temperature sensor are out of range, internal sensor data is used. Boost charge
is disabled when external temperature sensor is faulty, not connected or if the battery
temperature is out of range. Please note the charge circuitry is designed for float operation
and short term boost of batteries already charged and in good condition. Use of this supply
on flat or fully discharged batteries may cause damage to the module.
The 12V Rail Voltage, Supply Current, Battery Current, internal and, optionally, external
temperature monitoring circuits, various status and controls registers enable the RTU to

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monitor and to control all functions of the PS-x2/PS-x1 module. The Processor Module has
access to many of these values as analogue and digital points in the system.
If the Mains power interrupted and the system is powered from the backup battery, the
PS-x2/PS-x1 enters Low Battery Shutdown when battery voltage drops below 10.6 V. All
outputs are switched OFF for battery preservation, including Backplane power as well –
effectively meaning that the whole RTU will be shut down. PS-x2/PS-x1 switches itself to the
lowest power consumption mode possible, further preserving the battery from deep
discharge. PS-x2/PS-x1 checks rail voltage regularly, and the Backplane power will be
restored when +12V_RAIL voltage rises above 12.4 V (if no Mains present) or 11.2 V (if
Mains present).
Besides various hardware protection features, PS-x2/PS-x1 firmware provides additional
protection from overload. If output power exceeds its maximum specified power, the Switch-
mode Power Supply (SMPS) will enter an Overload Mode. Its output voltage will be ramped
down and, if overload still persists when it reaches 10.0 V (minimal output voltage), it will
switch all outputs off, similar to Low Battery Shutdown. PS-x2/PS-x1 will attempt to switch
the Backplane ON again regularly. RTU power will be restored permanently when overload
condition is removed.
Several Power Supply modules of any type can be installed on a backplane thus providing
redundant and alternative power source configurations. Note, however, that while some load
sharing does occur naturally if more than one Power Supply Unit is active on a backplane,
the PS-x2/PS-x1 modules do not support true load sharing with output currents balancing.
For this reason, several Power Supplies can be installed in parallel for the purpose of
redundancy only, and the total power budget should not exceed the limits specified for a
single (least capable) Power Supply Unit present in a system.
PS-x2/PS-x1 modules can be swapped while RTU is running, providing that there is an
alternative power source in the system for the RTU to be powered during such swap – e.g.
another (redundant) PS-xx module.

3.2.2 Options and Ordering Info

Since PS-x1 modules are superseded, this section does not contain ordering information for
PS-11 and PS-21 modules.
Unless explicitly noted, all hardware versions of PS-x2 modules are described in this
manual. The newer PS-x2 version (v1.5) has some differences in the module features and
specifications comparing with its predecessor (v1.3); in particular the available current for the
5V rail has increased from 3 A to 5 A and the operating temperature range has been
extended to -40 °C to +85 °C.
The PS-x2 modules with ‘-C’ suffix in their Order Code have an additional isolated DC-DC
converter board DC-10 installed into the main PS-x2 board. It provides isolated 24 V power
to the 24VAUX output.
PS-x2 options, ordering info and main specification differences are summarised in the table
below:

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Mains 5 V max Operating

H/W 24V AUX current, A temperature, °C
Order Code Input
version power
Power 3.0 5.0 3 -20 - +70 -40 - +85
v1.31  
PS-12-0 100–240 V,
v1.52 50-60 Hz  
v1.31 or  
PS-12-C 96-300 VDC 
v1.52  
v1.31  
PS-22-0
v1.52  
20-60 VDC
v1.31  
PS-22-C 
v1.52  
Notes:
1
) And earlier versions (here and further in this Manual).
2
) And later versions (here and further in this Manual).
3
) Linearly derated to 4.0 A from +60 °C to +85 °C.

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3.2.3 Theory of operation

A combined block-diagram of the PS-x2 and PS-x1 modules is shown on the picture below.

PS-x2/PS-x1 Block Diagram

When Mains power is supplied to the SMPS, it generates a DC output voltage on the internal
+12V_RAIL of the PS-x2/PS-x1. Voltage level on this rail is controlled by the microcontroller
(MCU). Supply Current Sensor is used to measure current supplied by the SMPS.
When 12VBP SWITCH is activated, power from the internal rail is fed to the backplane and
to the 5VBP converter that powers 5VBP rail on the backplane, providing power to all
modules installed there. Both 12VBP and 5VBP outputs are connected to the backplane
outputs via ideal diodes that allow for redundant connection of the PS-x2/PS-x1 modules.
24VAUX ISOLATED Converter (option ‘-C’ only) and 12VAUX SWITCH can be switched ON
and OFF with user logic, providing power to the corresponding outputs of the field connector
as required.
Any device connected to the ‘B’ terminals of the Field Connector (J22 for PS-x2; ), including
a battery, is connected directly to the internal +12V_RAIL of the PS-x2/PS-x1. Battery
Current Sensor is used to measure current flowing to or from ‘B’ terminals. Assuming that a
battery is connected to these terminals, positive current flows into the battery when it is
charged and negative current flows out of the battery when it supplies power to the RTU.
The PS-x2/PS-11 battery input has a crowbar protection circuit with series polyfuse to
protect it from over-voltage and reverse-polarity connection. The crowbar protection circuit
will latch when its voltage is either below -0.5 V or above +18.5 V (approximately). It will
clamp the input power rail voltage to a very low value: ± (0.5 – 2.5) V depending on the
clamp current supplied by a power source. If the power source can provide current
exceeding a polyfuse trip current (2-16 A depending on the ambient temperature, see the
RUE(F)400 fuse specifications for further details), it may trip also, limiting the clamp current
to several milliamperes. To recover protective circuit after tripping, the input voltage should

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be removed completely. A 5-10 s pause before re-applying input power may be required to
allow for the polyfuse to cool down if it has tripped.

3.2.4 Battery Charging

PS-x2/PS-x1 power supply modules are designed with provisions for the backup battery
charging and monitoring. They can charge 12 V Sealed Lead Acid (SLA) batteries with the
capacity from 6 Ah to 25 Ah connected to the ‘B+’ and ‘B-’ terminals. SLA batteries of higher
capacity or unsealed (wet) lead-acid batteries can be used if required but the PS-x2/PS-x1
will not be able to fully charge them and to maintain / properly calculate its internal charge
level (required for making correct decisions by charging control algorithms). As a result, their
performance cannot be guaranteed.
When more than 100 mA is drawn out of (or is supplied to) ‘B’ terminals (e.g. when a battery
is connected), the PS-x2/PS-x1 logic assumes that a fully discharged battery has just been
connected and starts its Boost charge. Boost charge is not possible if external temperature
sensor is not connected, or it is faulty, or when battery temperature is below -20 °C or above
+60 °C.
After boost charging the battery for the estimated time (3-10 hours, BATT DET and BATT
BST LEDs ON, see below for details), the power supply will switch to Float charging (BATT
DET and BATT FLT LEDs ON).
PS-x2/PS-x1 maintains an estimated charge level of the attached battery and this value is
used for making a decision for switching to the Boost charge when the battery charge level
drops below 40% of its nominal capacity. For this algorithm to work properly, a correct
battery capacity should be provided to the PS-x2/PS-x1 via the Toolbox software
configuration setup. When battery is initially detected, it is assumed to be fully discharged.
Boost charging time mentioned earlier is calculated based on the provided battery capacity
value. Estimated battery charge level is increased by integrating measured charge current
flowing into the battery over the time till it reaches the stated battery capacity. When battery
current becomes negative (for instance, if Mains power is out and the RTU runs from the
battery), this current is integrated over the time and subtracted from the estimated battery
charge level till it reaches zero.
Please note that PS-x2/PS-x1 is not able to distinguish between the real battery connection
and the connection of any other (generic) load or power source to the battery terminals, as it
detects such connections only by measuring the Battery Current. As a result, all battery
status related LEDs may exhibit several various patterns depending on kind of load / source
connected to the ‘B’ terminals.

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3.2.5 Module LEDs

PS-x2 LEDS

PS-12-x PS-22-x

LED State Description

ON Module operating normally.

960 ms ON,
OK No communications with RTU Processor Module.
80 ms OFF

OFF Power off or Module fault.

ON Mains present / SMPS running1,2.

VIN
OFF Mains not present / SMPS not running.
65 ms ON, In Overload Mode. Output voltage is being ramped down (when powered
450 ms OFF from Mains).
OVLD
OFF PS-x2 is not in Overload Mode.

ON The PS-x2 is sending data to Processor Module via Backplane.

Tx
OFF No data being sent to Processor Module.
ON Any RTU module sends data via Backplane.
Rx
OFF No data being sent by other modules.
BATT (Battery) LEDs
ON Battery or load or DC source connected to B terminals.
DET
OFF No battery nor load nor DC source connected to B terminals3.
ON Battery is slow (float) charging.
FLT
OFF Battery is not in Float Charge mode.
ON Battery is fast (boost) charging.
10 ms ON, Boost charge is not possible (either external temperature sensor not
BST
2.0 s OFF connected or it is faulty or battery temperature is out of -20 °C to +60 °C).
OFF Battery is not in Boost Charge mode.

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LED State Description

ON Battery sources current of more than 0.1 A4 to the PS-x25.
SUPP
OFF Battery does not supply current to the PS-x2.
ON +12V_RAIL voltage has fallen below 11.5 V5.
40 ms ON,
LOW Battery Low Shutdown.
5.0 s OFF
OFF +12V_RAIL voltage has raised above 12.4 V5.
OUT (Outputs) LEDs
ON Backplane power is switched ON.
12BP
OFF Backplane power is switched OFF (either start-up or shutdown).
ON Backplane power is switched ON.
5BP
OFF Backplane power is switched OFF (either start-up or shutdown).
ON 12VAUX is switched ON.
12AUX
OFF 12VAUX is switched OFF.
ON 24ViAUX is switched ON.
24AUX
OFF 24ViAUX is switched OFF.
FAULT LEDs
ON Backplane power is switched ON and 12VBP is below 9 V5.
12BP
OFF Backplane power is switched OFF or it is ON and 12VBP is above 9 V5.
ON Backplane power is switched ON and 5VBP is below 2 V5.
5BP
OFF Backplane power is switched OFF or it is ON and 5VBP above 2 V5.
ON 12VAUX is switched ON and it is below 9 V5.
12AUX
OFF 12VAUX is switched OFF or it is ON and above 9 V5.
24ViAUX is switched ON and it is below 18 V5 (or no DC-10 / Option –C
ON
module installed).
24AUX
OFF 24ViAUX is switched OFF or it is ON and above 18 V5.

Notes:
1
) May keep switching ON and OFF intermittently at a very light or no load (v1.3 only).
2
) May keep switching ON and OFF intermittently at very heavy loads (hardware hick-up
mode).
3
) Short flashes every 2 s may indicate that PS-x2 is trying to detect battery.
4
) Current value given to the Processor Module is negative.
5
) Approximate values.

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PS-x1 LEDS

PS-11-x PS-21-x

LED State Description

ON Module operating normally.
960 ms ON,
OK1 No communications with RTU Processor Module.
80 ms OFF
OFF Power OFF or Module fault.
ON Mains present / SMPS running
Vsup1,2
OFF Mains not present / SMPS not running.

ON Battery detected (the current into or out of the battery exceeds 100 mA)
Vb1
2.0 s ON, No battery nor load above 100 mA nor DC source connected to B
40 ms OFF terminals.
ON Backplane power is switched ON.
5V1
OFF Backplane power is switched OFF (either start-up or shutdown).

ON Auxiliary 24 V supply is installed, switched ON and output voltage is OK

Vaux1
Auxiliary 24 V supply is either not installed or switched OFF or output
OFF
voltage is out of range

BATT ON Battery is being charged (current into battery > 100 mA)
CHG1 OFF Battery is not being charged (current into battery < 100 mA or negative)
ON Battery is in slow charging (Float Charge) mode.
FL1
OFF Battery is not in Float Charge mode.
ON Battery is fast (Boost Charge) charging mode.
BO1
OFF Battery is not in Boost Charge mode.
ON Battery voltage has reached discharge condition (< 11.5 V ± 0.2 V)
LO1
OFF Battery voltage has reached charged condition (> 12.4 V ± 0.2 V)
Notes:
1
) Redundant Power Supply will have all LEDs turned ON when the Power Supply module
is switched OFF.
2
) If the input supply source is disconnected from the redundant Power Supply, the Vsup
LED will go OFF.

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3.2.6 PS-x2 Specifications

PS-12 and PS-22 Power Supply Modules Specifications
Mains Power
Input PS-12-x PS-22-x
AC Rated Voltage Range 100 - 240 V, 50 - 60 Hz
Not applicable
(Maximum Input Current) (1.5 A)
DC Rated Voltage Range 96 - 300 VDC 20 - 60 VDC
(Maximum Input Current) (1.5 A) (4.0 A)
Power Inlet
Connector PS-12-x PS-22-x
Phoenix PC 4/3-ST-7.62
Terminal Block Plug (7.62 mm) Phoenix GMSTBA 2.5/3-G-7.62
Dinkle EC762V-03P
Phoenix KGG-PC 4/3 (plastic)
Cable Housing (optional) or Not available
PS-AC-COVER-S (rubber)
Phoenix PC 4/3-G-7.62 Phoenix
PCB Header (7.62 mm)
Dinkle ECH762R-03P GMVSTBR 2.5/3-ST-7.62

‘B’ Input / Output

DC Rated Voltage Range 10.5 – 16.0 VDC
(Maximum Input Current) (4.5 A)
Backup Battery Type Sealed Lead-Acid (SLA)
Maximum Battery Capacity 25 Ah1
Output Power

Total Rated Output Power 60 W 2

Maximum Logic
Output Voltage Range Protection
Current Control
12 V Backplane3 10.5 - 15.6 V 4.5 A Firmware No
3.0 A (v1.3) / No
5 V Backplane 5 V ± 5% Electronic
5.0 A (v1.5)4
Polyfuse with crowbar No
over-voltage and
Battery3 10.5 - 15.6 V 4.5 A
reverse polarity
protection
Polyfuse (v1.3) /
12 V aux3 10.5 - 15.6 V 2.0 A Yes
Electronic (v1.5)
24 V Isolated aux5 24 V ± 5% 0.25 A Polyfuse Yes
Field Connector
WECO 120-M-111/07
Terminal Block Plug (5.0 mm)
Phoenix MSTB 2.5/7-G
WECO 120-A-111/07
PCB Header (5.0 mm)
Phoenix MSTB 2.5/7-ST

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PS-12 and PS-22 Power Supply Modules Specifications

Monitoring
Parameter Range Accuracy
Rail Voltage
9.0 - 15.6 V ± 2%
(12 VBP, Battery, 12 VAUX)
Supply Current 0.0 - 4.0 A ± 10%
Battery Current6 ±4.0 A ± 10%
External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Internal Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Safety Isolation / Maximum Working Voltage
Primary (Mains) to Secondary
3.0 kVRMS / 4.2 kVDC
(Backplane, Field, Functional
In accordance with IEC 60950
Earth) isolation
Maximum Working Voltage on
42.4 VPEAK / 60 VDC
any contact of the Field
relative to system (backplane) ground
Connector
Environment
-20 to +70 °C (v1.3)
Operating Temperature
-40 to +85 °C (v1.5)
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Altitude 2000 m max

Notes:
1
) Batteries exceeding quoted maximum capacity can be used. However, full charging
and estimated battery charge level cannot be guaranteed.
2
) For PS-12 the total output power is linearly de-rated to 30 W from +65 °C to +85 °C
(de-rating factor is 1.5 W / °C above +65 °C).
3
) Nominal value is 13.8 V @ 25 °C. These voltages are electrically linked and are
controlled by the PS-x2 module when charging a battery. They will depend only on
backup battery voltage when RTU runs from the battery (e.g. when there is a Mains
outage).
4
) Linearly de-rated to 4.0 A from +60 °C to +85 °C (de-rating factor is 40 mA / °C above
+60 °C).
5
) Linearly de-rated to 100 mA from +70 °C to +85 °C (de-rating factor is 10 mA / °C
above +70 °C).
6
) Negative: current flows from the battery (battery supplies power)
Positive: current flows to the battery (battery is charged).

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3.2.7 PS-x1 Specifications

PS-11 and PS-21 Power Supply Modules Specifications
Mains Power
Input PS-11-x PS-21-x
AC Rated Voltage Range 100 - 240 V, 50 - 60 Hz
Not applicable
(Maximum Input Current) (1.5 A)
DC Rated Voltage Range 96 - 300 VDC 20 - 60 VDC
(Maximum Input Current) (1.5 A) (4.0 A)
Power Inlet
Connector PS-11-x PS-21-x
Phoenix PC 4/3-ST-7.62 JST VHR-3M (housing)
Mains Connector Plug
Dinkle EC762V-03P JST SVH-41T-P1.1 (contact)
Cable Housing (optional) Phoenix KGG-PC 4/3 Not available
Phoenix PC 4/3-G-7.62
Mains Connector PCB Header JST S3P-VH
Dinkle ECH762R-03P
‘B’ Input / Output
DC Rated Voltage Range 12.0 – 15.0 VDC
(Maximum Input Current) (4.5 A)
Backup Battery Type Sealed Lead-Acid (SLA)
Maximum Battery Capacity 25 Ah1
Output Power
Total Rated Output Power 60 W 2
Maximum total current 4.5 A
Maximum Logic
Output Voltage Range Protection
Current Control
PS-11 : Electronic
12 V Backplane3 10.2 - 14.4 V 4.5 A No
PS-21 : No
5 V Backplane 5 V ± 5% 3.0 A Electronic No
Battery3 10.8 - 15.0 V 4.5 A Polyfuse4 No
PS-11 : Electronic
12 V Auxiliary3 10.8 - 15.0 V 4.0 A Yes
PS-21 : No
24 V Auxiliary Isolated 24 V ± 5% 0.25 A Polyfuse Yes
Field Connector
WECO 120-M-111/07
Terminal Block Plug (5.0 mm)
Phoenix MSTB 2.5/7-G
WECO 120-A-111/07
PCB Header (5.0 mm)
Phoenix MSTB 2.5/7-ST

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PS-11 and PS-21 Power Supply Modules Specifications

Monitoring
Parameter Range Accuracy
Rail Voltage
9.0 - 15.6 V ± 2%
(12 VBP, Battery, 12 VAUX)
Supply Current 0.0 - 4.0 A ± 10%
Battery Current5 ±4.0 A ± 10%
External Temperature -20 to +80 °C ± 2 °C typ @ 25 °C
Internal Temperature 0 to +80 °C ± 2 °C typ @ 25 °C
Safety Isolation / Maximum Working Voltage
Primary (Mains) to Secondary
3.0 kVRMS / 4.2 kVDC
(Backplane, Field, Functional
In accordance with IEC 60950
Earth) isolation
Maximum Working Voltage on
42.4 VPEAK / 60 VDC
any contact of the Field
relative to system (backplane) ground
Connector
Environment
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Notes:
1
) Batteries exceeding quoted maximum capacity can be used. However, full charging
and estimated battery charge level cannot be guaranteed.
2
) For ambient temperatures for up to +50 °C.
3
) Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and are
controlled by the PS-x1 module when charging a battery. They will depend only on
backup battery voltage when RTU runs from the battery (e.g. when there is a Mains
outage).
4
) In addition to polyfuse, the PS-11 module has a crowbar over-voltage and reverse
polarity protection. The battery input of the PS-21 module does not have auto-resetting
protection against reverse-polarity. Please ensure the battery is connected correctly.
5
) Negative: current flows from the battery (battery supplies power)
Positive: current flows to the battery (battery is charged).

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3.2.8 Wiring Diagrams

Safety Warning
Ensure that the power cord is disconnected from the power source
before uncoupling it from the PS-x2/PS-x1 mains power inlet.
Disconnect power cord from the PS-x2/PS-x1 before wiring,
removing or servicing the module.
Connect PS-x2/PS-x1 to Mains supply in accordance with the
relevant requirements of national wiring regulations.
Mains connections of PS-x2/PS-x1 must comply with all installation
requirements listed in this Manual.

Avertissement de Sécurité
Assurez-vous que le cordon d’alimentation est débranché de la
source d’alimentation avant de le débrancher de l’entrée
alimentation secteur du module PS-x2/PS-x1.
Débranchez le cordon du module PS-x2/PS-x1 avant le câblage, le
retrait ou la réparation du module.
Connectez le module PS-x2/PS-x1 à l’alimentation secteur en
respectant toutes les règles applicables des réglementations et
normes électriques locales.
L’alimentation secteur connexions du module PS-x2/PS-x1 doit se
conformer à toutes les exigences d'installation répertoriées dans ce
manuel.

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Power Supply with battery backup

PS-x2/PS-11 Wiring Diagram

PS-21 Wiring Diagram

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Notes:
1. The PS-12 and PS-11 modules can be powered using either AC (100 – 240 VAC) or DC
(96 – 300 V). The modules cannot be powered simultaneously via both AC and DC
sources.
2. AC mains power can be supplied to the PS-12 and PS-11 modules only.
WARNING. Supplying AC mains power to a PS-22 or PS-21 module will destroy it.
3. DC mains power to the PS-12 and PS-11 modules can be supplied in any polarity.
4. DC mains power to the PS-22 and PS-21 modules can be supplied only as shown on
the diagrams above.
WARNING. Supplying DC mains power to the PS-22 or PS-21 module in reverse polarity
may severe damage the modules, as there is no protection against reverse polarity on
this input.
5. External temperature sensor should be installed directly onto the battery near its
negative terminal. Connect the negative sensor wire to B- or R- contact of the Field
Connector.
WARNING. Connecting the temperature sensor in reverse polarity will cause permanent
damage to the sensor.
6. The polarity of the temperature sensor wires are colour-coded. One of the following
colour pairs will be supplied based on availability:

Positive Terminal (+) Negative Terminal (-)

connected to TS connected to B- or R-
Black striped White Black
Grey Black
White Black
Red Black
Black Black striped Grey

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Powered from 12 – 16 V D C Supply:

PS-x2/PS-x1 Wiring Diagram

Notes:
1. A battery, a solar system or any other low voltage DC supply can be connected to the
‘B’ terminals to power the PS-x2/PS-x1 module.

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PSU-x AC Power Supply Unit

The PSU-x AC to DC power supply module is intended to be used as a standalone unit to
provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-x units do not have
any power monitoring functions. Power monitoring is performed by the PC-1 processor
module.
The range of supplied PSU-x modules consists of three unit types (PSU-3, PSU-4 and
PSU-5), specifications of each are shown below.

Fire Risks

A supply voltage outside the specified limits may cause fire.

Risques d'Incendie

Une tension d’alimentation en dehors des limites spécifiées peut

provoquer un incendie.

Warning

The Earth Terminal in the mains power inlet provides only

FUNCTIONAL EARTH connection.
It cannot be relied upon for safety purposes.

Avertissement de Sécurité

Le terminal de terre à l’entrée de l’alimentation secteur est

uniquement une connexion de TERRE FONCTIONNELLE.
On ne peut pas compter sur lui pour assurer la sécurité.

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Electrical Hazards
Only appropriately qualified and trained personnel
can install and service this equipment.
Mains Power must be connected in accordance with local national
wiring rules and regulations. Building installation shall provide
appropriate short-circuit backup protection.
Always remove input mains voltage (by disconnecting power cord
from the mains power outlet or by switching off an external circuit
breaker, depending on installation) before performing any
operation on this product.
Disconnect power cord from the Power Supply Module
before wiring, removing or servicing.
Failure to do so may cause fire and may result in a
serious personnel injury or even death.

Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
L’alimentation secteur doit être raccordée conformément aux
règles et réglementations nationales de câblage locales. Les
équipements du bâtiment doivent assurer une protection
appropriée contre les courts-circuits.
Toujours enlever la tension d’alimentation (en débranchant le
cordon d’alimentation de la prise d’alimentation secteur ou en
coupant le disjoncteur externe en fonction de l’installation) avant
d’effectuer toute opération sur ce produit.
Débranchez le cordon d’alimentation du module d’alimentation
avant le câblage, le retrait ou l’entretien.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves du personnel ou même la mort.

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Specifications
PSU-x Power Supply Modules Specifications

Parameter PSU-3 PSU-4 PSU-5

90 to 260 VAC 50/60 Hz,

Input Supply
125 to 370 VDC

Output Voltage Adj. Range 13.5 to 16.5 VDC

Output Voltage
+13.8 VDC
(factory preset)

Max Output Current* 2.8 A 4A 5A

Load Capacity* 40 W 60 W 70 W

Isolation
3 kVAC
(AC input to DC output)

Isolation
1.5 kVAC 2 kVAC 1.5 kVAC
(AC input to Functional Earth)

Connector Screw Terminals

Operating Temperature* -10 to +60 °C -25 to +70 °C

Storage Temperature
-20 to +85 °C -40 to +85 °C
(at 10 – 95 % RH)

Operating Humidity 20 to 90 % RH (non-condensing)

Weight
440 g 510 g 410 g
(without mounting bracket)
*) Refer to the “PSU-x Output Derating Curve” graph below.

PSU-x Output Derating Curve

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PSU-x Block Diagram

The block diagram of the PSU-x modules is shown below.

PSU-x Block Diagram

PSU-x Mounting

PSU-x Mounting and Connections

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Calculating Power Requirements

This chapter aims to assist you in selecting an appropriate power supply module/s and
backup battery for your RTU. It also allows the power requirements of the RTU to be
checked to ensure the power supplies are not overloaded.
Note that there is an Excel™ spreadsheet that can perform the following calculations
automatically available from “Kingfisher RTU Power Budget, Backup Battery and Solar Panel
Calculator”.

3.4.1 Total Current Consumption

PS-22 Typical current consumption at various DC voltages (mA)

Input Voltage 20 V 40 V 60 V
Basic Module, no options 34 20 19
24 VDC Aux Converter Installed 49 27 25

PS-12 Typical efficiency at various AC supply voltages

Input Voltage 100 V 170 V 240 V

Efficiency 85% 87% 88%
Note: No DC-DC converter installed.

Communications/Processor Modules current consumption (mA at 13.8 VDC)

Item CP-12 / MC-12 CP-21 CP-30 / MC-31

Basic Module, no options 70 147 135

PC-1 Typical current consumption (mA at 13.8 VDC)

24 V Aux Converter Option S Board Option R Board Option P Board

Bare Module
Installed Installed Installed Installed
54 +53 59 62 59

For Communications Option Boards please refer to the 5 V Rail Overload Check chapter.

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IO Module typical current consumption (mA at 13.8 VDC)

Extra Extra
Extra Extra
current current Absolute
24 V 24 V current current
Part per per maximum
Converter Converter per per
number Analogue Digital current
OFF ON Analogue Digital
Output Output draw
Input ON Input ON
ON ON
AI-1 11 80 +50 [+0] - - - 480
AI-10 v1.x 25 185 +62 [+3] - - - 681
AI-10 v2.x 15 50 +38 [+0] - - - 354
AO-3 5 180 - +50 - - 380
DI-5 23 - - - +7 [+2] - 135
DI-10 40 - - - +11 [+5] - 216
DO-1 7 - - - - +31 255
DO-2 7 - - - - +13 215
DO-5/6 3 - - - - +1 19
IO-2 5 - - - +7 [+3] +12 157
IO-3 10 53 +46 [-1] +42 +10 [+1] +12 367
IO-4 8 44 +44 [-2] - +9 [+1] +12 228
IO-5 13 97 +89 [0] +42 +14 [2] +12 389
Note: Values shown are for inputs powered by the IO module itself when power is available
from the 13.8 VDC supply. Values in square brackets ‘[ ]’ denote current consumption when
inputs are powered by an external supply.

Relay Output Modules power consumption:

Item Per Output Maximum Consumption

TEL-REL 02 530 mW 8.5 Watts
TEL-REL 03 800 mW 12.8 Watts
TEL-REL 04 530 mW 8.5 Watts

Superseded Communications Modules current consumption (mA at 13.8 VDC)

Item CP-11 / MC-11 / MC-30

Basic Module, no options 165

Superseded IO Module typical current consumption (mA at 13.8 VDC)

24 V 24 V Extra current Extra current Extra current Extra current Absolute

Part
Converter Converter per Analogue per Analogue per Digital per Digital maximum
number
OFF ON Input ON Output ON Input ON Output ON current draw
AO-2 11 115 - +55 - - 335

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MC-xx / CP-xx Option Board typical 5 V Rail consumption (mA at 13.8 VDC)

Option Board Type Port label Consumption

A3 Fibre Optic Ethernet Board A3 272
Dial (PSTN) D 75
Fibre Optic Serial F 23
HART H 9
Isolated Serial (RS-232) I 32
Dual Isolated Serial I2 43
Private Line or Analogue Radio Interface L 9
2.4 GHz (50 mW) Spread Spectrum Radio:
Transmitting R3 41
Receiving 35
900 MHz (1 W) Spread Spectrum Radio:
Transmitting R2 / R4 275
Receiving 41
T3 Ethernet Option Board T3 136

3.4.2 5 V Rail Overload Check

The PS-12 and PS-22 modules supply 5 VDC to the backplane for powering modules. A
maximum of 3 A (5 A for PS-x2 v1.5 or above) can be drawn on the 5 VDC rail from each
power supply module.
Please ensure that this limit is not exceeded by totalling the 5 V current requirements for
your RTU.

CP-xx and MC-xx typical 5 V Rail current consumption (mA from 5 VDC)

CP-11
CP-12 CP-30
MC-11 CP-21
MC-12 MC-31
MC-30
310 150 360 290

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CP-xx and MC-xx Option Boards typical 5 V Rail consumption (mA from 5 VDC)

Option Board Type Port label Consumption

ACTIVE
A3 Fibre Optic Ethernet A3 600
Dial (PSTN) D 165
Fibre Optic Serial F 50
HART H 20
Isolated Serial (RS-232) I 70
Dual Isolated Serial I2 95
Private Line or Analogue Radio Interface L 20
2.4 GHz (50 mW) Spread Spectrum Radio:
Transmitting R3 100
Receiving 85
900 MHz (1 W) Spread Spectrum Radio:
Transmitting R2 / R4 670
Receiving 100
T3 Ethernet T3 300
SUPERSEDED
10/100 Base-T Ethernet ENET-T 130
100 Base-FX (Fibre Optic) Ethernet ENET-A 650
10/100 Base-T Ethernet ENET-T2 310
10/100 Base-T Ethernet ENET-E 0 idle / 850 max
Serial (RS-232) SER-S 5
Line (original version) L(1) 120
Image Capture J 1000

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IO Module 5 V Rail current consumption (mA from 5 VDC)

Module All IO inactive All IO active and powered by module
AI-1 22 27
AI-10 15 66
AO-2 22 28
AO-3 9 30
DI-5 6 40
DI-10 54 85
DO-1 15 27
DO-2 9 39
DO-5/6 48 39
IO-2 10 37
IO-3 26 36
IO-4 23 37
IO-5 37 151

3.4.3 Total Power Load

The total current required to power the RTU is as follows:

𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 𝐼𝐼𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝑀𝑀𝑀𝑀−𝑥𝑥𝑥𝑥 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 + 𝐼𝐼𝐼𝐼𝐼𝐼 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇

Total Power load is therefore:
13.8 [𝑉𝑉] × 𝐼𝐼𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 [𝑚𝑚𝑚𝑚]
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 [𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊] =
1000
• The Total Current Load for a PS-12/22 should not exceed 4.5 A.
• The Total Current Load for a PC-1 should not exceed 4 A. Loads greater than 4 A will
require a PS-12/22 supply to be installed.
• Users should be mindful of the current draw on the 5 VDC rail. See the “5 V Rail
Overload Check” chapter for more details.

3.4.4 Battery Backup

To maximise the service life of the battery, the depth of its discharge should not exceed 50%
of available capacity. E.g. for a 7 Ah battery, there is 3.5 Ah of backup power. Therefore the
battery can supply 3.5 Amps for 1 hour or 1 Amp for 3.5 hours etc.
The size of the backup battery required depends on how long the RTU needs to be able to
run without mains power. In addition to the Total Current Load above, a backup battery will
also need to power the PS-12/22 if present (not applicable if using a PC-1 processor).

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4. PROCESSOR MODULES
Overview
The processor module is the core part of any RTU. It is responsible for running user logic
and facilitating inter-module interactions (via backplane) and communications with the
SCADA system and other RTUs and various 3rd party devices (via communications ports) as
required. The amount of memory, speed, and flexibility of an RTU is determined by the
processor module selected.
There are three processor modules available in the Kingfisher Plus+ modular RTU range.
Each of them has one resident communications port, with an ability to add up to two
additional communications ports.
Processor modules summary:

Parameter / Feature PC-1 CP-12 CP-30

Processor Speed 16 MHz 40 MHz 166 MHz
Flash Memory 128 KB 512 KB 16 MB
SDRAM - - 64 MB1
NV RAM 256 KB 512 KB 512 KB2
Port 1 (resident) RS-232 RS-232 10BASE-T / 100BASE-TX Ethernet
Optional Ports 13 24 24
Structured Text, Ladder Diagram, Function
Programming Languages Ladder Logic Ladder Logic Block Diagram, Instruction List, Sequential
Function Chart and Flow Chart
Notes:
1) 32 MB for CP-30 v1.x.

2) 128 KB for CP-30 v1.x.

3) See PC-1 Option Boards for available options.

4) See the Communications Options Boards chapter for available options and compatibility.

Lithium Battery

This product contains a lithium battery. Risk of explosion if battery is

replaced by an incorrect type. Dispose of used batteries in
accordance with local regulations or return to the supplier.

Pile au Lithium
Ce produit contient une pile au lithium. Il y a un risque d’explosion
si la pile est remplacée par un modèle incorrect. Jetez les piles
usagées conformément aux réglementations locales ou retournez-
la au fournisseur.

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PC-1: Power & Processor Module

4.2.1 Overview
• Monitoring of battery and input supplies
• Isolated DC Outputs
• 16 MHz Processor
• DC Input Supply
• Up to two communications ports
• Low Voltage Battery Protection
• 256 KB SRAM
The PC-1 is well suited to small and mid-size installations as it features an integrated power
supply, reduces the system complexity by negating the need for additional power supply
modules.
With remote installations in mind the PC-1 was designed to be capable of running from a
backup battery, and has a fully isolated low power DC output for external equipment.
To configure the PC-1, a PC running the Toolbox 32 software is required. The Toolbox 32
software allows the user to implement ladder logic.
The PC-1 can only be installed in the first slot of a 4-slot backplane (BA-4) and operates
from a nominal +12 VDC supply (typically 13.8 VDC). The module has one fixed RS-232 port
and one option port.
With a special firmware update, the existing PC-1 module can be converted to a Power
Supply unit (PC-1-PS) compatible with new CP-12 and CP-30 processor modules. This
provides a simple and low cost upgrade path from PC-1 to CP-12 or CP-30 processors that
allows existing installations to remain physically untouched. The firmware, along with
technical note explaining how the modified PC-1-PS will behave, can be downloaded from a
Knowledgebase article.

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A PC-1 has two links that can be accessed from the rear of the module as shown below.

The SRAM battery is enabled at shipping time

by the factory. The user can clear the SRAM
by removing the SRAM link for five minutes.
This will clear the RTU configuration and
ladder logic.

4.2.2 Part Numbers

The PC-1 is available with 3 options (A, P, M) as detailed below.

PC - A P M
24 V 10 W Auxiliary Port 2
Device: Memory
Supply Converter Option Board Type
0 = Not Fitted 0=128 KB RAM
0 = Not Fitted R = Radio, V.23 FSK* (obsolete)
Part Number:
C = Fitted P = 2-Wire Line, V.23 FSK 1=256 KB RAM
S = Serial RS-232/RS-485 (standard)
* Radio Option boards must be factory modified to suit Maxon Radios (resistor R15 (3K3) is
replaced with a 150K resistor). The default Radio Option card is used with Trio and Tait
radios. Please indicate which Radio you are using when ordering a radio option card.
Example: PC-1-CR1 is a PC-1 with 24 VDC auxiliary converter, radio option port and extra
RAM.

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4.2.3 PC-1 Module LEDs

PC-1
Both of the communications ports have Tx, Rx, RTS and CD LEDs in a vertical group as
shown above.

PC-1 LED Description

OK ON when module is functioning OK
DC +5V ON when the internal 5 V supply is OK. This LED should always be on
ON when the internal 12 V supply is OK. This LED should always be on (software
+12V
controlled)

T1 Test LED 1. Flashes during Power Down mode.

ON when the Auxiliary 24 V supply is OK (will only display if the 24 V converter is
+Vs
installed).
BATT
ON when the battery is being charged
CHG*
DIS* ON when the battery is being discharged
ON when the battery voltage is low (For a PC-1 this occurs when the supply voltage is
LO
less than about 11.2 VDC)

T2 Test LED 2. Not currently used.

Tx ON when port is transmitting

Rx ON when port is receiving

RTS Request to send. Set ON to begin transmitting

CD Carrier detect: ON while a communications signal is detected.

WD Processor Watchdog Timer. Set ON when the processor is reset.
* The battery charging (BATT CHG) and battery discharging (DIS) LEDs will sometimes
flicker on and off when the battery is charged to the optimum level or if no battery is
connected.

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4.2.4 PC-1 Specifications

PROCESSOR SPECIFICATIONS
Processor Type Intel 80C188
16 Bit internal data bus
W ord Size
8 Bit external data bus

Clock Speed 16 MHz

BIOS Yes
Flash Memory 128 KB Total. 28 KB for firmware drivers.

SRAM 256 KB
Real-time Clock Accuracy 1 minute per month (± 20 ppm)
W atchdog Timer Yes

Status Indication Yes

Batter y Type Lithium. Not rechargeable.

Batter y Life (module unpowered) 7 years @ 25°C

Communications Ports 2
Port 1 (RS-232) Serial, 300 to 115200 Baud
Serial, Analogue Radio Interface, 2-Wire Line or 4-Wire
Port 2 (Optional) Line
300 to 115200 Baud (depending on port type)
Modem Port 2 CCITT V23
1200 Baud
(Optional)
Configuration Software Toolbox 32

Diagnostics Software Yes

Basic Configuration Auto on power-up

RTU Address Range 1 – 249

Communications Protocol Kingfisher, DNP3, Modbus, plus many more…

Analogue Block Processing Yes

PID Block Processing Yes

Redundant Power Supplies Not supported

Redundant Processors Not supported

Redundant Communications Yes

Internal Power Consumption 120 mA from +5 VDC

I/O Bus Data Rate 250 kbps

CM Bus Data Rate 83 kbps

Cyclic Redundanc y Port 1 and 2

Operating Temperature -20 to +70 °C

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Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Not supported. Removing the PC-1 will power down the
Hot Swap
RTU.

PC-1 POWER SUPPLY SPECIFICATIONS

11.5-15 VDC / 4 A maximum (60 W)
Input Supply to PC-1
Typically 13.8 VDC if backup battery connected
+5 VDC / 1 A maximum (5 W) to Backplane
+12 VDC / 4 A maximum to Backplane*
Outputs From PC-1 +12 VDC / 2 A maximum to Vr*
+24 VDC / 400 mA (10 W) Optional Auxiliary Output (3 kV
Isolation)#

Backup Batter y 12 V
RTU Shutdown at 10.6 V
Deep Discharge Protection
RTU Start-up at 11.8 V
Supply Fuse 7 A (Maximum Current into the PC-1)

Batter y Fuse 7 A (Maximum Current into or out of battery)

Combined Vr and 24 V D C Fuse 3 A Polyfuse

Parameter Accuracy
Battery Current ± 10%
Monitoring PC-1 Supply Voltage ± 5%
PC-1 Supply Current ± 10%
PC-1 Temperature ± 5%

* Note: backplane rail voltages are dependent on power supply to the PC-1. Most PC-1s are
powered using the 40 W PSU-3 Power Supply set to 13.8 VDC when using a 12 VDC backup
battery.
#
the +24 V converter is optional and must be ordered with the PC-1.

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4.2.5 PC-1 Pinout

Port 1 Pins Direction RS-232 signal
1 OUT DTR
2 OUT +12 V low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXD
8 OUT TXD

Please refer to the PC-1 Option boards for more information regarding port 2 option boards.

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CP-12 Processor Module

4.3.1 Overview
• Support for Processor and Communications Redundancy
• Up to 3 communications ports
• 40 MHz x86 CPU
The CP-12 processor module has up to three independent communications ports. Ports 2
and 3 can house option boards while port 1 is a fixed serial port (RS-232).
This processor is targeted at the application space that is too complex for the PC-1 but does
not required the additional features made available with a CP-30 based system. The CP-12
has extended functionality over the PC-1 such as redundant processor and communications
modules support, and is compatible with Ethernet based boards.
The CP-12 uses the same configuration software as the PC-1 processor, and as such is
programmable with ladder logic.
The CP-12 has 512 KB of flash memory for operating code and system parameter storage,
and 512 KB of battery backed SRAM for all configuration and event storage data.

4.3.2 CP-12 Reset Procedures

The SRAM battery is enabled from the factory by default.

The user can clear the SRAM by removing the SRAM
link for five minutes.
This will clear the RTU configuration and Ladder Logic.

Behind the LED lens of the CP-12 there is a diagonally mounted jumper. This is a hardware
feature unique to the CP-12 processor.
When the jumper pins are shorted while the module is being reset (or power cycled), the
processor will enter Monitor Mode (the Kingfisher bootloader) and perform a read/write test
of the SRAM. This will forcefully clear SRAM, having the same effect as removal of the
SRAM link on the back of the CP-12 module.
Monitor Mode is a deterministic and efficient way of clearing a Processor as the module
does not need to be removed from the Backplane, and as the SRAM is forcibly overwritten.

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Note: The RAM test is extremely fast. The CP-12 will clear the RAM nearly instantly. To exit
monitor mode, remove the short and power cycle the unit again.

4.3.3 CP-12 Module LEDs

CP-12 LED Description

OK ON when Processor is functioning correctly
MON ON when Processor is in Monitor mode
ON when Processor watchdog timer overflows, such as in the event of a
W DT
software crash.

RST ON when in reset. Will be lit for 200 ms when cold starting.

TxD ON when transmitting data on corresponding Port

RxD ON when receiving data on corresponding Port

RTS ON when asserting Request To Send on corresponding Port

DCD ON when Data Carrier Detect affirmed on corresponding Port

10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port

100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port

LINK ON when Ethernet Link is established

COL ON when Ethernet Collision is detected

IOTX Intensity is proportional to load on backplane IO Bus

IORX (this bus is used to poll all IO modules)

CMTX Intensity is proportional to load on load on backplane Communications Bus

CMRX (this bus is used for communications modules data transmission)

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4.3.4 CP-12 Specifications

PROCESSOR SPECIFICATIONS
Processor 40 MHz x86

W ord Size 16 bit data bus

BIOS Yes

Flash Memory 512 KB

SRAM 512 KB
Batter y Type Lithium Primary (not rechargeable)
Batter y Life
7 years @ 25°C
(module unpowered)
Real-time Clock Accuracy 1 minute per month (+/- 20 ppm)
W atchdog timer Yes
Status Indication Yes

Communications Ports 1-3 (1 fixed, 2 option ports)

Port 1 (RS-232) 300 to 115200 Baud (factory default 9600 8-N-1)
For supported port types, please see the Option Boards
Ports 2 and 3 (Optional)
chapter

Configuration Software Toolbox 32

RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)

Communications Protocol Kingfisher, Modbus + many more
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)

Analogue Block Processing Yes

PID Block Processing Yes
Yes. Two CP-12 modules can be installed in the one RTU.
Redundancy One processor module must be installed in an odd numbered
slot and one in an even numbered slot.
Internal Power Consumption
150 mA from +5 VDC bus on backplane
(without Option Boards)
I/O Bus Data Rate 250 kbps
CM Bus Data Rate 83 kbps

Operating Temperature -20 to +70 °C

Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)

Hot Swap Yes*

*) When 2 processors are present on the backplane, one processor can be swapped while the RTU
is still running. However, a hot swap will cause a Warm Start of the remaining processor. All ports
will be re-initialized and ready for communications within 6 seconds. New data received during the
changeover may be lost. To preserve data and for more information please see the Redundancy
appendix in the Toolbox 32 manual.

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4.3.5 CP-12 Ports

The CP-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option
boards. For more information regarding communications capabilities please refer to the
Communications Option Boards Chapter.

Port 1 Pins Direction RS232 signal

1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD

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CP-30: High Performance Processor Module

4.4.1 Overview
• Compliant with IEC-61131 programming languages
• Up to 3 communications ports
• Supports Communications and Processor Redundancy
The CP-30 is a high performance processor module that can provide exceptional speed,
memory and functionality to your RTU.
Targeting large RTU systems, the CP-30 is equipped with a 166 MHz ARM9 CPU, capable
of running all IEC-61131-3 certified languages, and utilises an Ethernet port as the default
connection and configuration medium.
To configure the CP-30, a PC with an Ethernet port and the Toolbox PLUS software is
required.
Toolbox PLUS features ISaGRAF™ software, which provides logic programming in the
IEC-61131 standard languages: Structured Text, Ladder Diagram, Function Block Diagram,
Instruction List, Sequential Function Chart and Flow Chart.
The processor module has up to three independent communications ports. Ports 2 and 3
can use plug-in option boards while port 1 is fixed as Ethernet (both 10 Mbps and 100 Mbps
modes are supported).
RTUs can use a second CP-30 module to provide processor redundancy. One processor
must be installed in an even-numbered backplane slot (the active processor on power up)
and the other in an odd-numbered backplane slot (the passive processor on power up). The
active processor continuously scans all backplane slots (among other tasks) so that it can
detect, control and monitor all other RTU modules. The passive (standby) processor will
switch to active mode when it detects that communications on the backplane stopped for
longer than a predefined maximum time that may be caused (but not limited to) by:
• Failure, removal or reset of the active processor
• Download of the configuration, logic or firmware to the active processor
The CP-30 flash memory is used for the storage of all operating code, RTU configuration
and event logs. It also has 32 MB (v1.x) / 64 MB (v2.x) of SDRAM for program operation and
general data storage and 128 KB (v1.x) / 512 KB (v2.x) of battery backed SRAM for non-
volatile data such as retained variables and system log.
The module is powered from the +5 VDC rail on the backplane.

4.4.2 CP-30 Options and Ordering Info

Unless explicitly noted, the description in this manual apply to all hardware versions of the
CP-30 module. The new CP-30 version (v2.3) has some different features and specifications
from the previous version (v1.6); in particular the amount of battery backed SRAM has
increased from 128 KB to 512 KB, the amount of SDRAM has increased from 32 MB to
64 MB, a quick reset to factory defaults has been added, the backup battery has been made
user replaceable, and the operating temperature range has been extended to -40 °C to
+85 °C.

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Note that despite the changes, all versions of CP-30 modules remain fully compatible with
each other and with all other hardware. This means that any version of CP-30 firmware can
be loaded onto any version of the CP-30 processor (as long as all CP-30 and MC-31
modules in a system use the same firmware version), any combination of CP-30 modules
can be used for making a redundant configuration, and any version of CP-30 module can act
as a plug-in replacement for any other version.
CP-30 options, ordering info and main specification differences are summarised in the table
below:

Order H/W version

Item
Code v1.6 1 V2.3 2
BB RAM size 128 KB 512 KB

SDRAM size 32 MB 64 MB
Backup Battery Soldered User Replaceable
Module has to be removed
CP-30-x3y4 From the front of
Factory Reset from the slot (takes 5 min
the module (quick)
waiting time minimum)
Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C
Maximum current consumption
290 mA 200 mA
from +5VDC rail on backplane

Notes:
1
) And earlier versions (referred to as v1.x further in this Manual).
2
) And later versions (referred to as v2.x further in this Manual).
3
) ‘x’ designates a code of the communications option board installed on Port 2.
4
) ‘y’ designates a code of the communications option board installed on Port 3.

Communications Option Boards codes:

Code Short Description Code Short Description

0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud
A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)
A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz
D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)
F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps
H HART Interface T21 Ethernet, Copper, 10/100 Mbps
I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps
I2 Dual Isolated Serial RS232/422/485

Notes:
1
) Discontinued products.

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4.4.3 Backup Battery / Reset to Factory Defaults

CP-30 modules include lithium coin backup battery for Real Time Clock operation and for
preserving content of the battery backed SRAM when power is removed from the module.
Backup battery on v1.x is soldered to the PCB assembly of the CP-30 module. A battery
retainer is used on v2.x, allowing the user to replace the battery without any special tools.

CAUTION: After removing and re-installing the SRAM link or after

replacing the battery, ensure that the CP-30 is powered up for at
least 1 s.
This will assure the backup battery functioning for the specified life
span.

Battery Backed RAM is connected to the backup battery via SRAM link located on the back
of the CP-30 module as shown on the diagram below. The SRAM link is installed at shipping
time by the factory.
The user can perform reset to factory defaults / clear the battery backed SRAM.
Note. Reset to factory defaults clears RTU configuration and user logic but it will not clear
the system log.
To perform reset to factory default using the SRAM link:
1. Remove CP-30 module from the backplane.
2. Remove the SRAM link for at least 5 min.
3. Install the SRAM link back on its header.
4. Install CP-30 on the backplane.
5. Switch backplane power ON (if it was OFF).

An alternative way of resetting the module to factory defaults has been added to the CP-30
v2.x hardware. It allows performing a quick reset to factory defaults:
1. Switch off power to the corresponding RTU rack.
2. Short together pins of the 2-pin header (located underneath LED display, on the front edge
of the module) using a jumper link or another suitable conductive object (e.g. a metal
screwdriver, ball-point pen, etc.).

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3. Keeping the pins shorted, turn on the RTU power.

4. The short can be removed any time after that.

WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit board
components.

CP-30 v2.x modules allow for a backup battery to be replaced by the user:
1. Obtain (purchase or order from Semaphore) a new battery.
WARNING. Only CR2450N batteries from Renata are specified for operating
temperature range from -40°C to +85°C.

2. Disassemble the CP-30 module and pull the PCB out from enclosure as per ‘Installing
and Removing Option Boards’ (steps 1 to 5).
WARNING. Follow Anti-Static Procedures to avoid permanent damage to the circuit
board components.

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3. Remove old battery and safely dispose it of in accordance with your local regulations.
4. Insert the new battery all the way in into the battery holder observing correct polarity
(negative terminal of the battery should face PCB surface).
WARNING. Inserting battery in reverse polarity may permanently damage CP-30
module.
5. Reassemble the module as per ‘Installing and Removing Option Boards’ (steps 7 and 8).

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4.4.4 CP-30 Module LEDs

CP-30-xy (v1.x) CP-30-xy (v2.x)

LED State Description

ON Normal operation.

0.5 s ON,
OK1,2 Firmware/configuration update in progress.
0.5 s OFF

OFF Power off or module faulty.

0.25 s ON,
Port 2 configuration error.
0.25 s OFF
F11,2
OFF Normal operation.

0.25 s ON,
Port 3 configuration error.
0.25 s OFF
F21,2
OFF Normal operation.

ON Normal operation (active CP-30).

1 s ON,
Normal operation (standby CP-30).
1 s OFF

F31,2 One of the following may be indicated:

• Module is booting up.
OFF • Initial synchronisation with standby processor in progress.
• Module fault (ISaGRAF™ not started).
• Logic cycle is longer than normal (blinks momentarily, on active
CP-30 only).

F4 – F73 n/a Reserved for future use.

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LED State Description

P1 (Port 1) LEDs

ON Linked at 10 Mbps (no data activity).

104 Flashing Data activity (transmit or receive) at 10 Mbps.

OFF Port not connected or no link at 10 Mbps.

ON Linked at 100 Mbps (no data activity).

1005 Flashing Data activity (transmit or receive) at 100 Mbps.

OFF Port not connected or no link at 100 Mbps.

ON Linked at either 10 or 100 Mbps.

LNK6
OFF Port not connected or no Ethernet link established.

ON Ethernet collision(s) detected.

COL6
OFF No collisions detected.

P2 (Port 2) and P3 (Port 3) LEDs:

I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options

Flashing Port is transmitting serial data.

Tx6
TxD / 10ACT3
OFF Port is not transmitting.

Flashing Port is receiving serial data.

Rx6
RxD / 100ACT3
OFF Port is not receiving.

Request to Send output is asserted.

ON It is usually asserted to signal readiness to transmit data to a serial
RTS6
device.
RTS / LINK3
OFF Request to Send output is not asserted.

ON Carrier Detect input is asserted by a connected serial device.

CD6
DCD / COL3
OFF Carrier Detect input is not asserted.

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LED State Description

P2 (Port 2) and P3 (Port 3) LEDs:

Ax and Tx (Ethernet) options

Flashing Data activity (transmit or receive) at 10 Mbps.

Tx6
TxD / 10ACT3
OFF No data activity at 10 Mbps.

Flashing Data activity (transmit or receive) at 100 Mbps.

Rx6
RxD / 100ACT3
OFF No data activity at 100 Mbps.

ON Linked at either 10 or 100 Mbps.

RTS6
RTS / LINK3
OFF Port not connected or no Ethernet link established.

ON Ethernet collision(s) detected.

CD6
DCD / COL3
OFF No collisions detected.

Notes:
1
) Progressively set ON during booting sequence.
After a successful start-up: OK is ON; F1 and F2 are OFF; F3 is ON (for active processor)
or flashing (for standby processor).
2
) Flash rapidly to indicate firmware upgrade error.
3
) CP-30 v2.x only.
4
) Duplicated by the bottom LED of the Port 1 Ethernet connector.
5
) Duplicated by the top LED of the Port 1 Ethernet connector.
6
) CP-30 v1.x only.

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4.4.5 CP-30 Specifications

CP-30 Processor Module Specifications

Parameter v1.x v2.x

Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus

SRAM (Battery Backed) 128 KB 512 KB

Flash Memory 16 MB

SDRAM 32 MB 64 MB

Real-time Clock Accuracy ±1 min / month (± 20 ppm) max

Backup Battery

Battery type CR2470 with tabs (solder type) CR2450 (coin, user replaceable)

Battery Life
7 years @ 25 °C
(module unpowered)

Communications Ports

Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)

Optional 2 (for supported port types, please see the Option Boards chapter)

Input Power

Voltage 5 V ± 5%

Current1 290 mA 200 mA

Isolation

Port 1 Transient Voltage 1 kV

Environment

Operating Temperature -20 to +70 °C -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Notes:
1
) No communications option cards installed on Ports 2 and 3.

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4.4.6 CP-30 Ports

Port 1 Pins Ethernet Signal
1 Tx+
2 Tx-
3 Rx+
4 n/c
5 n/c
6 Rx-
7 n/c
8 n/c

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5. COMMUNICATIONS MODULES
Overview
Communications modules can be utilized to add additional ports and multiple protocol
capability to your RTU. Each module is equipped with two expansion ports that can house a
wide range of specialized option boards (for more information regarding option boards and
their compatibility, please refer to the Communications Option Boards chapter).

Lithium Battery

These products contain a lithium battery.

There is a risk of explosion if battery is replaced by an incorrect
type. Dispose of used batteries in accordance with local
regulations or return to the supplier.

Pile au Lithium

Ce produit contient une pile au lithium. Il y a un risque d’explosion

si la pile est remplacée par un modèle incorrect. Jetez les piles
usagées conformément aux réglementations locales ou retournez-
la au fournisseur.

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MC-10/11/30 Communications Modules

5.2.1 Overview
• Up to three communications ports per module
• Wide range of available option boards
• Fixed Serial (RS-232) port on Port 1
Note: MC-10/11/30 is a SUPERSEDED product and is not being manufactured any more.
The MC-10/11/30 multi-communications module provides up to three additional
communications ports. Ports 2 and 3 are optional and use plug-in option boards while Port 1
is fixed as a serial (RS-232) port.
This module consumes power from the +5 VDC bus on the backplane. It also requires
+12 VDC. The MC-10/11/30 modules can be installed in any I/O slot of a 4, 6 or 12 slot
backplane. An RTU can have up to 16 ports.

5.2.2 MC-10/11/30 Module LEDs

MC-10/11/30

LED Description
OK ON when Module is functioning correctly
Tx ON when port is transmitting

Rx ON when port is receiving

RTS Request to send. Set ON when transmitting
CD Carrier Detect. ON while a communications signal is detected

L1, L2 Not used

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5.2.3 MC-10/11/30 Specifications

MC-10/11/30 Communications Module Specifications
Processor Intel 80C386EX
32 bit internal data bus
W ord Size
16 bit external data bus

Clock Speed 25 MHz

BIOS Yes
Flash Memory 1 MB

Static CMOS RAM 1 MB

RTC (Real-Time Clock) Yes
W DT (W atchdog Timer) Yes

Status Indication Yes

Communications Ports 1-3 (1 fixed, 2 option ports)

Port 1 (RS-232) 300 to 115200 Baud

For supported port types, please see the
Ports 2 and 3 (Optional)
Communications Option Boards chapter

Communications Protocol Kingfisher, DNP3, Modbus + many more

Maximum of 16 ports per RTU
MC-10/11/30 modules per RTU
For example, can use 5 MCs if each has 3 ports
Internal Power Consumption
310 mA from +5 VDC bus on backplane
(without Option Boards)
Operating Temperature -20 to +70 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Yes. Module can be swapped while RTU is running.
However, Hot Swap will cause a Warm Start of the
Hot Swap
processor. All ports will be re-initialised and ready for
communications within 6 seconds.

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5.2.4 MC-10/11/30 Block Diagram

5.2.5 MC-10/11/30 Ports

The MC-10/11/30 module features up to three serial ports accessible by RJ45 connectors on
the front of the module and covered by the snap on cable cover. Port 1 is at the top for
RS232 connections only. Port 2 and 3 can be configured using plug-in option boards.

Port 1 Pins Direction RS232 signal

1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD

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MC-12 Communications Module

5.3.1 Overview
• Up to 3 communications ports per module
• Supports Communications Redundancy
• Wide range of available option boards
• Fixed Serial (RS-232) port on Port 1
The MC-12 multi-communications module provides up to three additional communications
ports. Ports two and three can house option boards while port 1 is fixed as a serial (RS-232)
port.
An MC-12 supports a maximum baud rate of 83 kbps between itself and the RTU processor
module. This bandwidth can be split across a maximum of 16 ports. Users should be mindful
of this limitation when determining the number of ports used simultaneously in one
installation.
The MC-12 is identical to the CP-12 with the exception of labelling, the lens cover, and
firmware.
The MC-12 module is only for use with PC-1 or CP-10/11/12 based RTUs.
This module consumes power from the +5 VDC bus on the backplane. It also requires
+12 VDC. One or more MC-12 modules can be installed in any I/O slot of a 4, 6 or 12 slot
backplane.

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5.3.2 MC-12 Module LEDs

MC-12 LED Description

OK ON when Module is functioning correctly
MON ON when Module is in Monitor mode
ON when Module watchdog timer is overflows, such as in the event of a software
W DT
crash.

RST ON when in reset. Will be lit for 200 ms when cold starting.

TxD ON when transmitting data on corresponding Port

RxD ON when receiving data on corresponding Port

RTS ON when Request To Send on corresponding Port is asserted

DCD ON when Data Carrier Detect affirmed on corresponding Port

10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port

100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port

LINK ON when Ethernet Link is established

COL ON when Ethernet Collision is detected

IOTX Brightness of each indicates load on backplane IO Bus

IORX (this bus is used to poll all IO modules)

CMTX Brightness of each indicates load on backplane Communications Bus

CMRX (this bus is used for communications modules data transmission)

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5.3.3 MC-12 Specifications

MC-12 Communications Module Specifications
Processor 40 MHz x86

W ord Size 16 bit data bus

BIOS Yes

Flash Memory 512 KB

W atchdog timer Yes

Status Indication Yes

Communications Ports 1-3 (1 fixed, 2 option ports)

Port 1 (RS-232) 300 to 115200 Baud (factory default = 9600 bps)

Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
For supported port types, please see the
Ports 2 and 3 (Optional)
Communications Option Boards chapter

Configuration Software Toolbox 32

RTU Address Range 1 – 249 (expandable to 2000 by using multiple masters)

Communications Protocol Kingfisher, Modbus + many more

Analogue Block Processing Yes

Internal Power Consumption
150 mA from +5 VDC bus on backplane
(without Option Boards)
I/O Bus Data Rate 250 kbps
CM Bus Data Rate 83 kbps

Operating Temperature -20 to +70 °C

Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)

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5.3.4 MC-12 Ports

The MC-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option
boards. For more information regarding communications capabilities please refer to the
Communications Option Boards chapter.

Port 1 Pins Direction RS232 signal

1 OUT DTR
2 - n/c
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RxD
8 OUT TxD

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MC-31 Communications Module

5.4.1 Overview
• Up to 3 communications ports
• Fixed Ethernet (Twisted Pair) port on Port 1
• Supports Communications Redundancy
• Wide range of available communications option boards
The MC-31 Communications Module provides three additional communications ports for an
RTU. Port 1 is a fixed Ethernet port while Ports 2 and 3 are optional and can house variety of
option boards.
The MC-31 hardware is identical to the CP-30 with the exception of labelling, the lens cover
and firmware.
The MC-31 Communications modules can be used only with the CP-30 Processor modules.
They are powered from the +5 VDC rail on the backplane and can be swapped while RTU is
running without causing RTU restart. One or more MC-31 modules can be used in the
system.

5.4.2 MC-31 Options and Ordering Info

MC-31 v1.5 and v1.6 modules have been supplied to the market for several years. At the
time of publication of this Manual (3q2014), a new version of MC-31modules, hardware v2.3,
has been released for production. This new version has some differences in the module
features and specifications; in particular the operating temperature range has been extended
to -40 °C to +85 °C.

MC-31 options, ordering info and main specification differences are summarised in the table
below:

Order H/W version

Item
Code v1.6 1 V2.3 2
MC-31-x3y4 Operating Temperature Range -20 °C to +70 °C -40 °C to +85 °C

Notes:
1
) And earlier versions (referred to as v1.x further in this Manual).
2
) And later versions (referred to as v2.x further in this Manual).
3
) ‘x’ designates a code of the communications option board installed on Port 2.
4
) ‘y’ designates a code of the communications option board installed on Port 3.

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Communications Option Boards codes:

Code Short Description Code Short Description

0 No Option Board installed L Private Line 2/4 Wire, FSK, 1200 Baud
A1 Ethernet, Fibre Optic, 10/100 Mbps R2 Spread Spectrum Radio 900 MHz (AU)
A3 Ethernet, Fibre Optic, 10/100 Mbps R3 Spread Spectrum Radio 2.4 GHz
D PSTN Modem, 38.4 kbps R4 Spread Spectrum Radio 900 MHz (US)
F Serial Fibre Optic T1 Ethernet, Copper, 10/100 Mbps
H HART Interface T21 Ethernet, Copper, 10/100 Mbps
I Serial Isolated RS232/422/485 T3 Ethernet, Copper, 10/100 Mbps
I2 Dual Isolated Serial RS232/422/485
Notes:
1
) Discontinued products.

5.4.3 MC-31 Module LEDs

MC-31-xy (v1.x) MC-31-xy (v2.x)

LED State Description

ON Normal operation.

0.5 s ON,
OK1,2 Firmware/configuration update in progress.
0.5 s OFF

OFF Power off or module faulty.

0.25 s ON,
Port 2 configuration error.
0.25 s OFF
F11,2
OFF Normal operation.

0.25 s ON,
Port 3 configuration error.
0.25 s OFF
F21,2
OFF Normal operation.

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LED State Description

F31,2 OFF Normal operation.

F4 – F73 n/a Reserved for future use.

P1 (Port 1) LEDs

ON Linked at 10 Mbps (no data activity).

104 Flashing Data activity (transmit or receive) at 10 Mbps.

OFF Port not connected or no link at 10 Mbps.

ON Linked at 100 Mbps (no data activity).

1005 Flashing Data activity (transmit or receive) at 100 Mbps.

OFF Port not connected or no link at 100 Mbps.

ON Linked at either 10 or 100 Mbps.

LNK6
OFF Port not connected or no Ethernet link established.

ON Ethernet collision(s) detected.

COL6
OFF No collisions detected.

P2 (Port 2) and P3 (Port 3) LEDs:

I & F (serial) / D (Dial-up) / L (line) / H (HART) / Rx (radio) options

Flashing Port is transmitting serial data.

Tx6
TxD / 10ACT3
OFF Port is not transmitting.

Rx6 Flashing Port is receiving serial data.

RxD /
100ACT3 OFF Port is not receiving.

Request to Send output is asserted.

ON It is usually asserted to signal readiness to transmit data to a serial
RTS6
device.
RTS / LINK3
OFF Request to Send output is not asserted.

ON Carrier Detect input is asserted by a connected serial device.

CD6
DCD / COL3
OFF Carrier Detect input is not asserted.

P2 (Port 2) and P3 (Port 3) LEDs: Ax and Tx (Ethernet) options

Flashing Data activity (transmit or receive) at 10 Mbps.

Tx6
TxD / 10ACT3
OFF No data activity at 10 Mbps.

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LED State Description

Rx6 Flashing Data activity (transmit or receive) at 100 Mbps.

RxD /
100ACT3 OFF No data activity at 100 Mbps.

ON Linked at either 10 or 100 Mbps.

RTS6
RTS / LINK3
OFF Port not connected or no Ethernet link established.

ON Ethernet collision(s) detected.

CD6
DCD / COL3
OFF No collisions detected.

Notes:
1
) Progressively set ON during booting sequence.
After a successful start-up: OK is ON; F1, F2 and F3 are OFF.
2
) Flash rapidly to indicate firmware upgrade error.
3
) MC-31 v2.x only.
4)
Duplicated by the bottom LED of the Port 1 Ethernet connector.
5)
Duplicated by the top LED of the Port 1 Ethernet connector.
4
) MC-31 v1.x only.

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5.4.4 MC-31 Specifications

MC-31 Communications Module Specifications

Parameter v1.x v2.x

Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus

SRAM (Battery Backed) 128 KB 512 KB

Flash Memory 16 MB

SDRAM 32 MB 64 MB

Communications Ports

Fixed 1 Ethernet (Twisted Pair, 10/100 Mbps, auto negotiation)

Optional 2 (for supported port types, please see the Option Boards chapter)

Input Power

Voltage 5 V ± 5%

Current1 290 mA 200 mA

Isolation

Port 1 Transient Voltage 1 kV

Environment

Operating Temperature -20 to +70 °C -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Notes:
1
) No communications option cards installed on Ports 2 and 3.

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5.4.5 MC-31 Ports

Port 1 Pins Ethernet Signal
1 Tx+
2 Tx-
3 Rx+
4 n/c
5 n/c
6 Rx-
7 n/c
8 n/c

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6. COMMUNICATIONS OPTION BOARDS

Overview
The following option boards are available for the CP-12/30 processor modules and the
MC-12/31 communications modules (and the LP-3 stand-alone RTU). For PC-1 option
boards please see the PC-1 Option Boards chapter.
These are the currently available option boards:

Part Number Option Board Description

I Isolated Serial
I2 Dual Isolated Serial
F Fiber Optic Interface
D Dialup Modem (PSTN) V34 33.6 kbps
L Private Line or Analogue Radio Interface
H HART / Bell 202 interface
A3 Ethernet MTRJ Fiber Optic Interface
T3 Ethernet RJ45 Copper – 10/100 Mbps
R2 900 MHz Spread Spectrum Radio for Australia
R3 2.4 GHz Spread Spectrum Radio for International
R4 900 MHz Spread Spectrum Radio for USA

Compatibility
Not all option boards are universally compatible with all processors and communications
modules. The list of modules that can support a particular Option Board is provided in the
corresponding Option Board specifications table. The following table summarises
compatibility information to offer a selection guide for assuring the hardware you have
selected will function as expected.

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Communications Option Boards Compatibility Summary

CPU/Comms
A A3 D E F H I I2 L R2 R3 R4 T T2 T3
Module

CP-30               
MC-31               
MC-30
firmware v276 or later               
CP-11
firmware v1.45b or later               
CP-10/11
firmware v1.45a or earlier               
CP-12               
CP-21               
MC-10/11
firmware v159 or earlier               
MC-11
firmware v160 or later               
MC-12               
PC-1 with MC-10/11               
PC-1 with MC-12               
Note: The above table was correct at the time of writing. Please refer to Semaphore Helpdesk for any
recent changes.

Installing and removing Option Boards

Caution: Follow anti-static procedures

Electronic components can be damaged by even small amounts of

static discharge. It is highly recommend that antistatic procedures be
used. Avoid touching any components and metal parts. Do not store
cards near strong electrostatic, electromagnetic, or radioactive fields.

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1. Insert a small screwdriver into the second hole at

the bottom of the module case.
Lever the side of the case outwards.
Release the tab by firmly pulling the corner of the
cover.

2. Insert the screwdriver into the second hole on the

other side of the module.
Lever the side of the case outwards.
Release the tab by firmly pulling the corner of the
cover.

3. Repeat steps 1 and 2 above

for the top of the module.

4. Once all 4 tabs have been

released, remove the front cover.

5. Remove the circuit board from the

case by using a ‘toggling’ action

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6. Unplug the old option board (if

applicable) and insert the new option
board.
Please ensure that all of the option
board pins line up with the socket.

7. Slide the circuit board into the

channel on the left side of the case.
Hook the top of the cover into the
case.

8. Press the bottom of the cover onto

the case. At the same time, please
ensure that the option boards line up
with the cutouts.
Ensure the cover is fully inserted and
that the 4 tabs have all engaged.

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Option Board I: Isolated Serial

6.4.1 Overview
The isolated serial option board provides an RS-232, RS-485
or an RS-422 interface. The port is software configurable for
any of these modes. When RS-485 is configured for an
isolated serial option board, the RTS and CD LEDs are set ON
and when RS-422 is configured the RTS LED is set ON (there
are no LEDs set on for RS-232). RS-485 requires a 120 Ω
terminating resistor at each end of the transmission line and
RS-422 requires a 100 Ω terminating resistor at the receiver
end of the transmission line only (please see the
wiring diagrams at the end of this section).

Option Board I Specifications

Baud rate 300 – 115200 bps
Internal Power
70 mA from +5 VDC Bus on backplane
Consumption
Output Power +4.3 V / 100 mA maximum
RS-422 Line drive 10 Receivers
RS-485 Line drive 32 Receivers

Communications 8 data bits, no parity, 1 stop (8, N, 1)

Isolation Transient voltage: 2.5 kV
Operating Temperature -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
CP-10/11/12/21/30 Port 2 or Port 3
RTU Hardware Required MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4

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6.4.2 Serial Option Board Connections

RJ45 Pin Direction RS-232 RS-422 / RS-485
1 OUT DTR N/A
2 OUT 4.3 V N/A
3 OUT RTS TX+
4 IN DCD N/A
5 Common GND GND
6 IN CTS RX+
7 IN RxD RX-
8 OUT TxD TX-

RS-232 Wiring Diagram (Null Modem Cable)

Note: maximum recommended RS-232 cable length is 15 meters.

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RS-485 Wiring Diagram

Each RTU can transmit/receive to any RTU, one at a time. Up to 32 RTUs (or other RS-485
devices) can be connected to the RS-485 bus. Maximum RS-485 wire length: 1200 m.

If the ground wire is not available, each GND terminal can be tied to EARTH locally via
100 Ω 0.5 W resistor. If the 100 Ω resistor is not available, the Ground wire can be
connected directly to EARTH.
For short cable runs (less than 5 m) a single 60 Ω terminating resistor can be used at one
end of the RS-485 cable.

RS-422 Wiring Diagram

The master RTU can transmit/receive to any one outstation RTU at any time or each
outstation can transmit/receive to the master RTU, one at a time. Note: outstation RTUs
cannot communicate with each other. Up to 10 RTUs (or other RS-422 devices) can be
connected to the RS-422 bus. Maximum RS-422 wire length: 1200 m.

If GND wire is not available, each GND terminal can be earthed locally via 100 Ω 0.5 W
resistors. If the 100 Ω resistor is not available, the Ground wire can be connected directly to
EARTH.

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Option Board I2: Dual Isolated Serial

6.5.1 Overview
The dual isolated serial option board provides two
independent RS-232, RS-485 or RS-422 interfaces on a single
board. The ports are software configurable for any
combination of these modes. RS-485 requires a 120 Ω
terminating resistor at each end of the transmission line and
RS-422 requires a 100 Ω terminating resistor at the receiver
end of the transmission line only (please see the wiring
diagrams in the “Serial Option Board Connections” chapter).

Option Board I2 Specifications

Baud rate 300 – 115200 bps
Internal Power
95 mA from +5 VDC Bus on backplane
Consumption
RS-422 Line drive 10 Receivers
RS-485 Line drive 32 Receivers
Isolation
Transient voltage: 2.5 kV
(Field to Backplane)
Operating Temperature -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
RTU Hardware Required 1 CP-30 Port 2 or Port 3
MC-31 Port 2 or Port 3

1) Check CP-30 / MC-31 firmware Release Notes for I2 Option Board support details. Older versions

of Toolbox Plus software do not support I2 Option Boards configuration either.

I2OB front view

Data transfer activity of the normally operating I2 Option Board ports is indicated by
corresponding Tx (for data transmission) and Rx (for data reception) LEDs mounted on the
RJ45 connector as shown on the picture above. Activity indication of the Port 1.x is also
duplicated on the corresponding front panel LEDs of the hosting CP-30/MC-31 module.

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6.5.2 Dual Serial Option Board Connections

RJ45 Pin Direction RS-232 RS-422 / RS-485
1 OUT DTR N/A
2 N/A N.C. N.C.
3 OUT RTS TX+
4 IN DCD N/A
5 Common GND GND
6 IN CTS RX+
7 IN RxD RX-
8 OUT TxD TX-

Wiring diagrams for each port of the Dual Serial Option Board are the same as shown in the
“Serial Option Board Connections” chapter earlier.

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Option Board F: Fibre Optic Serial Board

The fibre optic serial option board provides a serial
interface via a fibre optic cable. A fibre optic port is
treated the same way as a standard serial port except a
fibre optic cable is used for the communications
medium. A fibre optic link offers excellent electrical
isolation and a high data rate. Two fibre optic cables are
required for each fibre optic port.

Option Board F Specifications

Maximum Baud rate 115.2 kbps (equivalent to RS-232 port)

Communications 8 data bits, no parity, 1 stop (8, N, 1)
Maximum Fiber Optic
Approx. 4 km (depends on cable and other factors)
Cable Length
Supported Fiber Optic Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um
Cables HCS
Option Board Connectors Tx: ST female (light grey port)
(use male connectors on
Rx: ST female (dark grey port)
cable)
Power Consumption (Tx) 50 mA maximum from +5 VDC Bus on backplane
Line drive 1 Receiver (point to point)

Electrical Isolation 15 kV
-20 to +70 °C (v1.0)
Operating Temperature
-40 to +85 °C (v1.0.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
CP-10/11/12/21/30 Port 2 or Port 3
RTU Hardware Required MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4
# Refer to the label on the PCB assembly of the Option Board F which indicates its hardware version.
If there is no label then check the PCB silkscreen for the version number of the board.

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Option Board D: 33.6 kbps Dial Option Board

The dial option board provides a V34 PSTN interface to the
Kingfisher Plus+ RTU. The port speed is software configurable,
and the dial board is designed to be compliant with
telecommunications standards worldwide.

Dial Option Board Connections

RJ45 Pin PSTN Function

1 -
2 -
3 Reserved
4 Line -
5 Line +
6 Reserved
7 -
8 -

Telecommunication Line Cord

To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger

telecommunications line cord.

Ligne de Télécommunication Cordon

Pour réduire les risques d’incendie, utilisez seulement du câble d’une

section minimale de 0.13 mm² (26 AWG) pour les connections de
télécommunications.

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Dial Option Board Specifications

PSTN Modem / Data
V.34, 300 to 33600 bps, auto-negotiating
Rate
RTU DTE Port Speed 300 – 115200 bps
Line Impedance 600 Ω
Approval International
Transmit level -10 dBm
Receive level -43 dBm to -9 dBm
Dialling Pulse or Tone
Internal Power
165 mA from +5 VDC Bus on backplane
Consumption
Maximum working voltage in respect to system earth/ground must
Isolation not exceed TNV-2 limits (80 V)
Transient voltage: 5 kV

Recommended D Option: AT&FE0V0S0=2&W

Initialization String Original D Option: AT&FE0V0S0=2X0&W (ignores dial tone)
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Altitude 2000 m max
Can be installed in any of the following ports:
CP-10/11/12/21/30 Port 2 or Port 3
Compatibility MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4

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Option Board L: Line/Analogue Radio Interface

The line option board provides a Private Line or analogue radio
interface and is software configurable for either of these modes.
The board is optically isolated, operates at 1200 bps and
provides FSK CCITT V.23 modulation.

6.8.1 Line Board Connections

Line / Radio
RJ45 Pin Direction
Function
1 OUT Tx -
2 IN Rx -
3 OUT RTS/PTT
4 IN CD
5 IN GND (0 V)
6 IN 12 V
7 IN Rx +
8 OUT Tx +

Telecommunication Line Cord

To reduce risk of fire, use only 26 AWG (0.13 mm2) or larger

telecommunications line cord.

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Ligne de Télécommunication Cordon

Pour réduire les risques d’incendie, utilisez seulement du câble d’une

section minimale de 0.13 mm² (26 AWG) pour les connections de
télécommunications.

6.8.2 Connecting a Radio

As the port is isolated it is necessary to use an external voltage source (normally from the
RTU ‘radio’ connection +12 V) to power not only the radio but also the carrier detect circuit.
Some radios have a very low audio interface level (TX Audio), e.g. Maxon DM 0530,
DM-2850, SD-125 and Tait T2010 / 2015. These radios will most likely require a resistor
network external to the port to drop the TX Audio level.
Some radios (e.g. Maxon) have an internal pull up resistor to +5 V on the carrier detect line,
if +12 V is used on the carrier detect optocoupler and then run to the carrier detect output on
the radio, the optocoupler will always be driven. There are several ways to get around this:
1. Use a radio without an internal pull up to +5 V (Trio SR, possibly Tait).
2. Modify the radio by removing the internal pull up, as per manufacturer’s instructions.
3. Use +5 V to supply the carrier detect optoisolation circuit. (DO NOT USE +5 V FROM
THE BACKPLANE CONNECTOR AS IT IS NOT ISOLATED).

Line / Radio Option Board Interface

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6.8.3 2-Wire Line, point-to-point

Either RTU can transmit/receive one at a time.

Note: line termination is required.

6.8.4 2-Wire Line, multi-drop

Any RTU can transmit/receive one at a time.

Note: line termination is required.

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6.8.5 4-Wire Line, point-to-point

Either RTU can transmit/receive at any time.

Note: line termination is required.

6.8.6 4-Wire Line, multi-drop

Master RTU can transmit/receive to any one outstation RTU at any time or each outstation
can transmit/receive to master RTU, one at a time.
Note that outstations cannot communicate to each other.

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Line/Radio Option Board Specifications

Baud rate 1200 Baud

Modulation FSK, CCITT V.23

Optical isolation
Carrier detect input Active low or high
Min. input 2 mA (70 VDC maximum)
Optical isolation
Open collector output
Active low
30 VDC maximum / 20 mA maximum
RTS/PTT output
Microwave networks typically use a negative supply rail for the
carrier detect circuit. The more positive rail should be connected
to pin #6 (RTS/PTT) and the difference between the rails must
not exceed 30 VDC.

Output impedance 30 kΩ

Input impedance 30 kΩ

Line termination 600 Ω

2 or 4 wire
The port is not full duplex and cannot use the full duplex
Line configuration functionality of a 4-wire configuration.
4-wire configurations eliminate the ability to communicate peer
to peer but allow an increased number of drops on one link.

Line drive in multi-drop 10 drops for 2 wire

configuration 20 drops for 4 wire
-6 dBm (LINE-2)
Transmit output level
-6 to -21 dBm software configurable (LINE-L)

Receive level -43 dBm to -9 dBm

Internal Power
20 mA from +5 VDC Bus on backplane
Consumption
Allowing 3dB for background noise and a 10dB fade margin, up
to 24dB of cable loss can be tolerated. Therefore, transmission
Transmission Distance distance = 24 / cable loss per Km (dB). Note: if there are more
than 2 RTUs (or other devices) on the line, reduce the allowable
cable loss (24) by 1dB per additional RTU or device.
Maximum working voltage in respect to system earth/ground
Isolation must not exceed TNV-2 limits (80 V)
Transient voltage: 3.88 kV
-20 to +70 °C (v1.2 and below)
Operating Temperature
-40 to +85 °C (v1.2.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Altitude 2000 m max

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Can be installed in any of the following ports:

CP-10/11/12/21/30 Port 2 or Port 3
Compatibility MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4
# Refer to the label on the PCB assembly of the Option Board L which indicates its hardware version.
If there is no label then check the PCB silkscreen for the version number of the board.

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Option Board H: HART Interface

The HART option board provides a Bell 202 interface to devices
supporting the HART protocol. Each HART option board can
communicate with up to 15 Hart devices. Two HART option boards can
be installed on the one RTU allowing up to 2 point-to-point circuits or 2
multi-drop circuits.

In a point-to-point installation, the loop current can be measured using an RTU analogue
input channel. If using two separate point to point circuits and reading the loop current in
each, the RTU analogue input channels must be isolated from each other.
In a multi-drop installation, the loop current is not used or measured.
For more information regarding HART configurations please refer to the
“HART Implementation Guide” available on Semaphore Helpdesk.

6.9.1 HART Board Connections

RJ45 Pin HART Function

1 Line +

2 to 7 n/c

8 Line -

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Point-to-point Wiring Configuration (Utilising Analogue Input)

Note: the resistor value can be from 50 to 500 Ohm. The 24 VDC field power output of the
Analogue Input Module is used to power the current loop in this case. A generic power
supply can be used instead.

Multi-drop Wiring Configuration

Note: the resistor value can be from 50 to 500 Ohm. The more HART devices connected, the
closer the resistor value needs to be to 50 Ohm.
When using multiple HART networks on a single RTU, be sure to isolate the 24 V supplies.

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HART Option Board Specifications

Baud-rate 1200 Baud, Half Duplex
Modulation Bell 202
1 = 1200 Hz
Logical Frequencies
0 = 2200 Hz
Internal Power
20 mA from +5 VDC Bus on backplane
Consumption
Maximum No. HART
15 (multi-drop)
Devices
HART and loop current for point-to-point
Data Available
HART only for multi-drop
Maximum working voltage in respect to system earth/ground
Isolation must not exceed TNV-2 limits (80 V)
Transient voltage: 3.88 kV
-20 to +70 °C (v1.2 and below)
Operating Temperature
-40 to +85 °C (v1.2.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
Compatibility CP-10/11/12/30 Port 2 or Port 3
MC-30/31 Port 2 or Port 3
# Refer to the label on the PCB assembly of the Option Board H which indicates its hardware version.
If there is no label then check the PCB silkscreen for the version number of the board.

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Option Boards T3 & T2: 10/100 Ethernet Controller

The Ethernet Option Boards provide full duplex Ethernet connectivity over UTP cables. The
option boards feature automatic speed and MDI/MDI-X negotiation. Technical specifications
of the T3 (currently in production) and T2 (superseded product) Ethernet Option Boards are
described below.

Ethernet Option Board T3 Ethernet Option Board T2

Ethernet Option Board Specifications

Parameter T3 Option Board T2 Option Board
Connection Speed 10/100 Mbps (auto negotiated)
Connection Durability Approximately 750 cycles
300 mA 310 mA
Power Consumption
(from +5 VDC Bus on backplane) (from +5 VDC Bus on backplane)
Operating Temperature -40 to +85 °C -20 to +70 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Storage Temperature -40 to +85 °C
Can be installed in any of the Can be installed in any of the
following ports: following ports:
CP-11/12/30 Port 2 or Port 3 CP-30 Port 2 or Port 3
Compatibility
MC-11/12/31 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
LP-2 Port 4
LP-3 Port 3 or Port 4

Ethernet
Port 1 Pins
Function
1 Tx+
2 Tx-
3 Rx+
4 n/c
5 n/c
6 Rx-
7 n/c
8 n/c

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Option Board A3: Fibre Optic Ethernet

The A3 option board provides Ethernet connectivity via fibre optic

cable. The A3 is functionally equivalent to a T3 Ethernet board,
but fibre optical cabling is used in place of copper cabling
allowing for excellent electrical isolation.
Class I LED product

A3 Ethernet Option Board Specifications

Connection Speed 10/100 Mbps
Full ATM 100 Mbps physical layer
Optical Compliance
Full 100 Mbps-FX (IEEE802.3u)
Fiber Optic Transceiver AFBR-5903Z
Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um
Supported Fiber Optic Cables
HCS
MTRJ connector.
Option Board Connectors
(use male connectors on cable) Available from Semaphore are the MTRJ-SC and MTRJ-ST
adaptors.
Internal Power Consumption 600 mA from +5 VDC Bus on backplane
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Can be installed in any of the following ports:
CP-11/12/30 Port 2 or Port 3
Compatibility MC-11/12/31 Port 2 or Port 3
LP-2 Port 4
LP-3 Port 3 or Port 4

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Option Board R2: Australian Spread Spectrum

Radio
The R2 Spread Spectrum radio option board uses the Digi
900 MHz RF module to provide a high speed data link in
Australia. This radio uses the public frequency band and
does not need to be licensed.

When installed in a Communications or processor, the corresponding port CD

(Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should
always be fitted to avoid damage.

Warning: RF Exposure
900 MHz Spread Spectrum Radio
This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be
installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction
with any other antenna or transmitter.

Avertissement: l'Exposition aux RF

Radio 900 MHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils
mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour
garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec
n’importe quel autre antenne ou émetteur.

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Modifications

Use of unauthorised antenna or other changes or modifications not

expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.

Modifications

L’utilisation d’antennes non autorisées ou d’autres changements

ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour
l’utilisateur de faire fonctionner ce produit.

R2 Spread Spectrum Radio Board Specifications

Countries Supported Australia
Frequency 915-928 MHz
Transmit Power 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate — RTU to Radio 9600 bps
Data rate — Radio to Radio 115200 or 9600 bps
Power Consumption 3.7 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -110 dBm @ 9600 bps
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
CP-10/11/12/30 Port 2 or Port 3
Compatibility MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4
Please see http://www.digi.com for more information on XTend® 900MHz wireless module
(P/N XTH9-MI-NA) specifications.

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Option Board R3: International Spread Spectrum

Radio
The R3 Spread Spectrum radio option board uses the 2.4 GHz
RF module to provide a high speed data link anywhere in the
world (international). This radio uses the public frequency band
and does not need to be licensed.

When installed in a Communications or processor, the corresponding port CD

(Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should
always be fitted to avoid damage.

Warning: RF Exposure
2.4 GHz Spread Spectrum Radio
This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be
installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction
with any other antenna or transmitter.

Avertissement: l'Exposition aux RF

Radio 2.4 GHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils
mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour
garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec
n’importe quel autre antenne ou émetteur.

Modifications

Use of unauthorised antenna or other changes or modifications not

expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.

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 Kingfisher Plus+ Hardware Manual

Modifications

L’utilisation d’antennes non autorisées ou d’autres changements

ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour
l’utilisateur de faire fonctionner ce produit.

R3 Spread Spectrum Radio Board Specifications

Countries Supported International
Frequency 2.4000-2.4835 GHz
Transmit Power 50 mW
Range Indoors 180 m
Range Outdoors 5 km
Range with Yagi Up to 8 km
Data rate — RTU to Radio 19200 bps
Data rate — Radio to Radio 9600 bps
Power Consumption 0.75 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None#
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -105 dBm
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
CP-10/11/12/30 Port 3 only
Compatibility MC-10/11/12/30/31 Port 3 only
LP-2 Port4
LP-3 Port 3 or Port 4
#
Encryption by special request in the USA only.
Please see http://www.digi.com/ for more information on XStream® 2.4GHz wireless module
(P/N X24-019NMI) specifications.

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Option Board R4: US/Canada Spread Spectrum

Radio
The R4 Spread Spectrum radio option board uses the Digi
900 MHz RF module to provide a high speed data link in the
US and Canada. This radio uses the public frequency band
and does not need to be licensed.

When installed in a Communications or processor, the corresponding port CD

(Carrier Detect) LED will be lit when the board is functioning correctly.
During testing units should have a minimum separation of 60 cm, and an antenna should
always be fitted to avoid damage.

Warning: RF Exposure
900 MHz Spread Spectrum Radio
This equipment is approved only for mobile and base station
transmitting devices. Antenna(s) used for this transmitter must be
installed to provide a separation distance of at least 30 cm from all
persons and must not be co-located or operating in conjunction
with any other antenna or transmitter.

Avertissement: l'Exposition aux RF

Radio 900 MHz à spectre étalé (Spread Spectrum)
Cet équipement est approuvé uniquement pour les appareils
mobiles de transmission et pour la station de base. La ou les
antennes utilisées pour cet émetteur doivent être installées pour
garantir une distance d’au moins 30 cm de toutes personnes et ne
doivent pas être proche ou en opération en conjonction avec
n’importe quel autre antenne ou émetteur.

Modifications

Use of unauthorised antenna or other changes or modifications not

expressly approved by the party responsible for compliance could
void the user’s authority to operate this product.

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 Kingfisher Plus+ Hardware Manual

Modifications

L’utilisation d’antennes non autorisées ou d’autres changements

ou modifications non explicitement approuvées par la partie
responsable de la conformité pourrait annuler l’autorisation pour
l’utilisateur de faire fonctionner ce produit.

R4 Spread Spectrum Radio Board Specifications

Countries Supported US & Canada
Frequency 902-928 MHz
Transmit Power 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate — RTU to Radio 9600 bps
Data rate — Radio to Radio 115200 or 9600 bps
Power Consumption 3.7 W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None#
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sensitivity -110 dBm @ 9600 bps
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Can be installed in any of the following ports:
CP-10/11/12/30 Port 2 or Port 3
Compatibility MC-10/11/12/30/31 Port 2 or Port 3
LP-1/2 Port4
LP-3 Port 3 or Port 4
#
Encryption by special request in the USA only.
Please see http://www.digi.com for more information on XTend® 900MHz wireless module
(P/N XT09-MI-NA) specifications.

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7. PC-1 OPTION BOARDS

The PC-1 hybrid power supply and processor module has an accompanying range of
communications option boards. These are not compatible with the CP series boards.

PC-1 Serial Option Board

The serial option board provides a RS-232 or RS-485 interface.
The port is software configurable for either of these modes. When
RS-485 is used, a 120 Ω terminating resistor is required at each
end of the transmission line.

PC-1 Serial Board Connections

RJ45 Pin Direction RS-232 RS-485

1 OUT DTR N/A
+12 V
2 OUT N/A
low power
3 OUT RTS LINE - *
4 IN DCD N/A
5 COM GND (0 V) GND (0 V)
6 IN CTS N/A
7 IN RXD N/A
8 OUT TXD LINE + *
* Polarity is opposite to CP-xx

For RS-485 wiring diagram please refer to CP-xx/MC-xx serial board RS-485 Diagrams

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PC-1 Modem Board PL: Two Wire Line

The 2-wire (Private) line option board provides a 2-wire point-to-point
connection to another RTU with a line option board.
The board is optically isolated, operates at 1200 bps and utilizes FSK
CCITT V.23 modulation.

PC-1 Modem Board Connections

RJ45 Pin Direction Radio Function

1 OUT DTR
+12 V
2 OUT
low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXA
8 OUT TXA

PC-1 2 Wire Line Wiring Diagram (point-to-point)

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PC-1 Modem Board: Analogue Radio Interface

The analogue radio option board provides an FSK interface to
external analogue radios (typically Trio or Maxon).
Radio Option boards must be factory modified to suit Maxon
Radios (resistor R15 (3K3) is replaced with a 150K resistor).
The default Radio Option card is used with Trio and Tait radios.
Please indicate which Radio you are using when ordering a
radio option card.

PC-1 Analogue Radio Board Connections

RJ12 Pin Direction Radio Function

1 OUT DTR
2 OUT +12 V low power
3 OUT RTS
4 IN DCD
5 COM GND (0 V)
6 IN CTS
7 IN RXA
8 OUT TXA

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8. IO MODULES OVERVIEW
This chapter contains general overview of and wiring guidelines applicable to IO modules in
the Kingfisher Plus+ range. The types of available IO modules are listed in the table below.

Commons per
Part Number Description of Module I/O Points
Module

ANALOGUE MODULES
AI-1 Analogue Input Module 8 1
AI-10 Analogue Input Module (High Performance) 8 1
AO-3 Analogue Output Module 4 4

DIGITAL MODULES
DI-5 Digital DC Input Module 16 1
DI-10 Digital AC/DC Input Module 16 1
DO-1 Digital Relay Output Module (NO/NC) 8 4
DO-2 Digital Relay Output Module (NO) 16 2
DO-6 Digital Solid State Module 16 2

COMBINATIONAL I/O MODULES

IO-2 Combination Digital I/O Module 16 2
IO-3 Combination Analogue/Digital I/O Module 13 4
IO-4 Combination Analogue/Digital I/O Module 12 3
IO-5 Combination Analogue/Digital I/O Module 13 4

IO Modules Field Connector

Each IO module has a removable 20-terminal I/O connector block mounted on the front of
the module for connections from user devices. This allows the IO module to be swapped
without having to detach the field wiring from the I/O connector. The I/O connector is
secured to the module using two fastening screws as shown on the picture below.

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Actual terminals used and their pin-outs are shown in the specifications for the individual
modules.

Connecting an Analogue Input

An analogue device (e.g. transducer) can be connected using loop power (power from the
module) or it can be self-powered.
A loop-powered analogue device behaves like a variable load on the module. It is a two-wire
device with the positive wire being connected to the module’s Field Power output and the
negative wire being connected to the Analogue Input of the module as illustrated below.

Loop Powered Analogue Device Connected to Analogue Input

A self-powered analogue device behaves like a current source to the module. A self-
powered device has at least three wires. One wire is connected to a positive terminal of an
external supply or to the Field Power output of the module. The second wire is connected to

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the Analogue Input of the module and the third wire is connected to the module Ground pin
as illustrated below.

Self-Powered Analogue Device Connected to Analogue Input

Field Wiring
It is impossible to provide a practical guide for installation of equipment that covers all
possible real-world situations. However, some guidelines are suggested below.
To minimise capacitive loading and noise, all field connections to the module should be
wired to the I/O terminal board using a good grade of twisted, shielded instrumentation
cable.
Generally, the shield for inputs to a module should be grounded at the analogue source with
one point on the shield tied to the module as shown in the following figure.

Shield Connections for Analogue Inputs

For Analogue Outputs, the shield is normally grounded only at the source end (the module).
The shield connection provides access to the backplane (frame ground) resulting in superior
rejection of noise caused by any shield drain currents. In extreme noise environments, a
ground braid may be used to connect the frame ground on the base plate connector to earth
ground. This additional connection will bypass noise around the module. An internal link is

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factory fitted on each module for the GND connection and may be removed where high
isolation for cabling is required.

Shield Connections for Analogue Outputs

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9. ANALOGUE INPUT MODULES

Analogue input modules provide analogue inputs to the Kingfisher Plus+ RTU.
Each module is equipped with a fully isolated 24 VDC power supply for energizing field
equipment such as sensor loops.

AI-1: 8 Channel Analogue Current Input Module

9.1.1 Overview
• 12 Bit resolution
• 1.5 kV Field to Logic Isolation
• 2 ms scan rate
• 24 VDC isolated DC output
• 0 – 20 mA or 4 – 20 mA current inputs
• 0 – 5 VDC or 1 – 5 VDC Voltage Inputs (requires factory modification)
The analogue input module provides eight input channels, each capable of converting an
analogue input signal to a digital variable for use as required by your application. A link on
the rear of the module selects 4-20 mA or 0-20 mA for all 8 channels. The default range is
4 to 20 mA.
The module can also be factory modified to handle voltage inputs of 0-5 VDC or 1-5 VDC.
Conversion speed for each of the eight channels is 20 µs and this provides a total update
rate of two milliseconds for the module. Resolution of the converted signal is 12 bits binary
(1 part in 4096) over the range. The placement of the 12 bits from the A/D converter in the
#AI data word is as follows:
MSB LSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
If the current source is reversed into the input, or is less than the low end of the current
range, then the module will output a data word corresponding to the low end of the current
range (0000H in #AI). If an input that is out of range is entered (i.e. greater than 20 mA), the
A/D converter will output up to full scale (corresponding to 7FF8H in #AI).

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Scaling of the input is shown below:

Input protection for the module is sufficient to guarantee operation with reduced performance
with up to 1500 V common-mode. The module provides electrical isolation of externally
generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be
wired using a good grade of twisted, shielded instrumentation cable. The shields can be
connected to GND. The GND connection provides access to the backplane (frame ground).

This module can be installed in any I/O slot of a 4,

6 or 12-slot backplane.

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Block-diagram of the AI-1 module is shown on the figure below.

AI-1 Block Diagram

9.1.2 AI-1 Module LEDs

LED State Description

OFF Module fault (no power)

OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail
OFF Channel Input level < 1%
A1-A8
ON Channel Input level > 1%

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9.1.3 AI-1 Specifications

AI-1 Analogue Input Module Specifications

Input Current Ranges 4-20 mA and 0-20 mA

Input Voltage Ranges 1-5 V and 0-5 V *

Inputs per Module 8

Update Rate 2 ms (all eight channels)
± 0.25% @ 25 °C
Accuracy
± 0.50% @ -20 to +70 °C
Resolution 12 bit (no sign bit)
Common Mode Voltage 1500 V
Linearity < 1 Least Significant Bit
Isolation 1.5 kV between field and logic
Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection > 80 dB from DC to 1 kHz
250 Ω standard
Input Impedance 11 kΩ optional *. The internal load resistors can be factory
removed if high impedance voltage inputs are required.
Input Filter
2 kHz @ -3 dB
Cutoff Frequenc y
Output Power 24 VDC / 160 mA, Isolated
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Yes. Module can be swapped while RTU is running. Hot swap will
Hot Swap not cause a Warm Start. Inputs are cleared in RTU memory while
module is removed.

* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or
by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor,
so any combination of channels can be converted. It is recommended that modules be
returned to Semaphore for factory conversion if required. No responsibility will be taken by
Semaphore for damage caused to boards during modification performed by clients. The
circuit board resistors to change are: R9 to R16 (channels 1 to 8 correspondingly).

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9.1.4 AI-1 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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2 wire transmitter
(powered by module)

3 wire transmitter
(powered by module)

4 wire transmitter
(powered by module)

2 wire transmitter
(powered externally)

3 wire transmitter
(powered externally)

4 wire transmitter
(powered externally)

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AI-10: 8 Channel High Impedance Analogue Input

Module
9.2.1 Overview
• 16 Bit resolution
• 3 kV field to logic isolation
• Bipolar differential channels
• 24 VDC isolated DC output
• AI-10: Current / Low Impedance Inputs
• AI-10-V: High Impedance Voltage Inputs
• 10 ms (1 ms*) scan rate
• Mains noise rejection*
*
AI-10 hardware version 2.x only.
Unless explicitly noted, all hardware versions of AI-10 modules are described in this section.
The newer AI-10 v2.x modules can be recognised by the label on the side which indicates
the hardware version. If the version number is not printed on the label then the module is
v1.6 or older.

The AI-10-V modules (v1.x only) are identical to the AI-10 modules but have the 250 Ω
current sensing resistors disconnected. This increases the input impedance for each channel
to more than 1 MΩ which is suitably high for voltage transducers. Each channel has its own
current sensing resistor, so any combination of channels can be converted.
In order to modify AI-10 v1.x the current sensing resistors have to be physically
disconnected (either by lifting one pin or by complete removal of the resistor). The circuit
board resistors to change are: R64 to R71 (channels 1 to 8 correspondingly). It is
recommended that modules be returned to Semaphore for factory conversion if required. No
responsibility will be taken by Semaphore for damage caused to boards during modification
performed by clients.
The AI-10 v2.x has internal jumpers (shorting links) that allow the input to be configured for
either current or voltage measurement. If a jumper is installed (default) then the related input
is configured to measure current. If a jumper is removed then the related input is configured
to measure voltage. Note that the factory fitted jumpers are yellow in colour and of a higher
grade than commonly found. Use of other jumpers may result in degradation of
measurement accuracy and so should be avoided. Appropriate handling precautions have to
be observed to avoid ESD and other damage when removing or installing shorting links.

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All AI-10 modules provide:

• 8 analogue inputs with high electrical isolation between the field terminals and the RTU
logic.
• A 24 V isolated output that can be used to power field sensors / transducers
• 16 bit input resolution
• Full compatibility with the AI-1 and AI-4 analogue input modules but with enhanced
resolution.
• Full compatibility between different hardware versions (i.e. AI-10 modules v1.x and
v2.x can be interchanged without any field wiring or software configuration
modifications required).

The AI-10 supports various current input ranges as follows:

• 0-20 mA
• 4-20 mA
• ±10 mA1
• ±20 mA1
1
For AI-10 v2.x only unipolar current ranges are recommended for use. Bipolar ranges are
not calibrated for current measurement.

The AI-10-V supports various voltage input ranges as follows:

• ±2.5 V
• ±5 V
• ±10 V
To minimize the capacitive loading and noise, all field connections to the module should be
wired using a good grade of twisted, shielded instrumentation cable. The shields can be
connected to ground.
This module consumes power from the +5 VDC and +12 VDC RTU rails. A built-in 24V DC-DC
converter is used to provide isolated power to the analogue front-end and can also be
utilised to power the field devices if required.

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Block-diagrams of the AI-10 modules are shown on the figures below.

AI-10 v1.x Block Diagram

AI-10 v2.x Block Diagram

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9.2.2 AI-10 Module LEDs

AI-10 LEDs State Description

OFF Module Fault (no power)
ON Module OK
OK
1 s ON,
Module Fault
1 s OFF
Processor module has not communicated with the module for
1 s ON,
more than 15 seconds (e.g. no processor module is present in
1 s OFF
LED B rack)

(unlabelled) 0.1 s ON, Module Fault (Module running on internal clock source as the
1.9 s OFF1 external crystal is faulty – module needs repair)
OFF Normal operation

LED C ON1 Module Fault (firmware not loaded – module needs repair)
(unlabelled) OFF Normal operation
OFF AI-10 loop power OFF
DC OK
ON AI-10 loop power ON

1-8 OFF Channel Input level < 1%

(left side) ON Channel Input level > 1%

1-8 OFF Channel Normal

(right side) ON Channel Fault (under/over range, data invalid)
1
) On AI-10 v2.x only
Note: On power up some LEDs may come ON for a short time.

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9.2.3 AI-10 Specifications

AI-10 / AI-10-V Analogue Input Module Specifications
Parameter Hardware v1.x Hardware v2.x
Input Current ranges1,2 4-20, 0-20, ±20, ±10 mA (software selectable)
Input Voltage ranges3,4 ±2.5, ±5, ±10 VDC (software selectable)
Inputs per Module 8
The analogue subsystem of the AI-10 is fully isolated
Sub System Isolation
from the RTU’s digital system.
Isolation 3 kV Transient
AI-10 : 250 Ω standard, > 1 MΩ optional4
Input impedance
AI-10-V : > 1 MΩ
Input Filter
1.5 kHz @ -3 dB 9 Hz @ -3 dB
Cutoff Frequenc y
Common Mode Rejection 80 dB minimum 66 dB minimum
42dB minimum @ 50Hz
Mains Rejection None
45dB minimum @ 60Hz
±12 V to GND ±12 V to GND
Maximum Input Voltage
±12 V differential ±24 V differential
± 0.1% @ +25 °C ± 0.1% @ 0 to +50 °C2
Accuracy
± 0.25% @ -20 to +70 °C ± 0.2% @ -40 to +85 °C2
Resolution 16 bit (15 data bits and 1 sign bit)
Output Power Isolated 24 VDC, 160 mA maximum
Operating Temperature -30 to +80 °C -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Yes. Module can be swapped while RTU is running. Hot
Hot Swap swap will not cause a Warm Start. Inputs are cleared in
RTU memory while module is removed.
One range setting for all channels when used with a PC-1
or CP-11/12/21 processor.
Compatibility
Individual range setting for each channel when used with a
CP-30 processor.
1) AI-10 only.
2) For AI-10 V2.x only unipolar current ranges are recommended for use. Bipolar ranges are not
calibrated for current measurement and their accuracy can reach 1.4% of full scale when used to
measure current.
3) Analogue Input channels can be modified from low impedance to high impedance by disconnecting

the 250 Ω channel resistor.

4) The ±10 V input range can only be used on an AI-10 input channel if the current sensing resistor

has been disconnected. Resistors have already been disconnected in an AI-10-V.

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9.2.4 AI-10 / AI-10-V Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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2 wire transmitter
(powered by module)

3 wire transmitter
(powered by module)

4 wire transmitter
(powered by module)

2 wire transmitter
(powered externally)

3 wire transmitter
(powered externally)

4 wire transmitter
(powered externally)

Loop

* When using the +24 V output to power a transducer, the negative input terminal of the analogue input
channel (2, 4, 6, 8, 12, 14, 16 or 18) must be wired to the 0 V terminal (10 or 20). This will complete the
current loop due to electrical isolation between the input channel and the module +24 V Output.
Note: Any channels sharing the same power source (e.g. +24 V from module or a field power supply)
are no longer isolated from one other.

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10. ANALOGUE OUTPUT MODULE

The AO-3 analogue output module provides four 12-bit current loop outputs allowing a
Kingfisher Plus+ RTU to drive analogue loads.

AO-3: Analogue Output Module

10.1.1 Overview
• 12 bit resolution
• 3 kV field to logic isolation
• Open loop detection
• 0 – 20 or 4 – 20 mA outputs
• 3 kV channel group to channel group isolation
The AO-3 provides four current output channels that use 12-bit digital to analogue
converters (DAC). The AO-3 also provides open loop detection.
The sign bit is not used in the digital to analogue conversion process. The placement of the
12 bits within the data word is as follows:
MSB LSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

This module provides two output ranges. The default range is 4 to 20 mA with user data
scaled so that a count of 0 corresponds to 4 mA and a count of 32760 corresponds to
20 mA. A range link (on the rear of the module) selects either 4-20 mA or 0-20 mA for all four
channels. The default condition is 4-20 mA with the link on. The module provides 12 bits of
resolution in either range.
Scaling of the output is shown below.

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Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups that are isolated from
each other and from the backplane logic. Each group is powered by a separate DC-DC
converter module that produces an isolated voltage of +24 V to drive the current loop
outputs and analogue front-end.
The current loop drivers on the module are source type drivers. To minimize the capacitive
loading and noise, all field connections to the module should be wired using a good grade of
twisted, shielded instrumentation cable. The shields should be connected to E (Shield) on
the user terminal connector block. The E connection provides path to the backplane (frame
Earth / Ground) resulting in attenuation of noise caused by the shield drain currents. To
further improve noise immunity, direct connection of the analogue cable shields to the Earth /
Ground rails with metal clamps or similar method is recommended, especially in
environments with high electromagnetic noise levels.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane in a system. Up to
10 Analogue output modules can be installed on a single 12-slot backplane.

AO-3 configuration link location

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Block-diagram of the AO-3 module is shown on the figure below.

AO-3 Block Diagram

10.1.2 AO-3 Module LEDs

AO-3 LEDs State Description
OFF Module fault / no power
OK
ON Normal
OFF Module running
RST Module in Reset (power-on or
ON
watchdog)
OFF Channel output set to 0%
ANALOGUE OUT 1-4
ON Channel output greater than 0%
OFF Closed Loop (load detected)
OPEN LOOP 1-4
ON Open Loop (no load)

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10.1.3 AO-3 Specifications

AO-3 Analogue Output Module Specifications

4 to 20 mA [default] or 0 to 20 mA
Output Current Range
(loop current is supplied by module)

Outputs per Module 4

Isolated 24 VDC / 40 mA for outputs 1 & 2

Output Power
Isolated 24 VDC / 40 mA for outputs 3 & 4

Supply Voltage (nominal) +5 VDC and +12 VDC from backplane

250 ms (all channels)

Update Rate
Determined by I/O scan time and is application dependent

Resolution 12 bit (no sign bit)

± 0.2% @ 25 °C
Accuracy
± 0.5% @ -20 to +70 °C

Load Resistance 0 to 850 Ω

Load Capacitance 2000 pF maximum

Load Inductance 1 H maximum

Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups.
Each group is isolated from the other group and from the backplane
logic. There is no isolation between outputs 1 & 2 and no isolation
Isolation between outputs 3 & 4.
Transient voltage (Group to Group and Group to Logic): 5 kV.
Maximum working voltage in respect to system earth/ground must not
exceed SELV limits (42.4 VPEAK / 60 VDC).

Operating Temperature -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 90 % RH (non-condensing)

Yes. Module can be swapped while RTU is running. Hot swap will not
Hot Swap cause a Warm Start. Outputs will be restored within 2 seconds once
module is replaced.

Yes. Monitors output circuit for failure (e.g. cable breakage) or if the load
is disconnected.
Open Loop Detection
Note: when using the 0-20 mA range, Open Loop Detection cannot be
guaranteed on an output when set below 160 / 0.1 mA / 0.5%.

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10.1.4 AO-3 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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0 – 20 / 4 – 20 mA Current Loop
Receiver

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11. DIGITAL INPUT MODULES

Overview
The Digital Input Modules allow various level digital signals to be interpreted by your RTU.
All modules provide a minimum of 1 kV field isolation, 16 input channels and can be
configured to use counters and input buffers to count incoming pulses.
Summary:

Maximum input Channel group 1 Channel group 2

Module
Voltage maximum capture speed maximum capture speed
Channels 1 and 2 Channels 3 and 4
DI-5-1 28 VDC
10 kHz 255 Hz
Channels 1 and 2 Channels 3 and 4
DI-5-1-48 60 VDC
10 kHz 255 Hz
DI-10-1 +130 VDC Channels 1 to 4 Channels 5 to 16
DI-10-1-48 125 VAC 10 kHz 1 kHz
DI-10(-GPS) +130 VDC Channels 1 to 16
DI-10-48(GPS) 250 VAC 10 kHz

DI-5: DC Input 16 Channel Digital Input Module

11.2.1 Overview
• Pulse counting on channels 1 to 4 (up to 10 kHz)
• Positive or Negative Polarity Inputs
• Isolated DC Outputs for powering inputs
The DI-5 provides 16 input channels with one common. As a wide input voltage is accepted
a wide range of input devices can be used such as buttons, reed switches, line switches,
PIR sensors, and proximity sensors. Any combination of inputs powered externally or by the
modules own isolated DC supply (+12 V) can be used.
Applying a high input voltage results in logic 1 in the module’s status register. Low (or not
present) input voltages result in logic 0.
The DI-5 counter can also count pulses in the first 4 digital inputs. It is able to count up to
10 kHz on inputs 1 and 2 and can count up to 255 Hz on inputs 3 and 4. The pulse total and
the frequency for each of the first 4 digital inputs are stored.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane system.

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Block-diagram of the DI-5 module is shown on the figure below.

DI-5 Block Diagram

11.2.2 DI-5 Module LEDs

LED State Description

OFF Module fault (no power)
OK
ON Normal
OFF Digital Input OFF
1 - 16
ON Digital Input ON

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11.2.3 DI-5 Specifications

DI-5 Input Module Specifications

+ 12 to 24 VDC nominal (supports reverse polarity)

Rated Voltage Note: The DI-5-1-48 High Input Voltage module in the Custom Products
chapter supports higher DC input voltages (48 VDC nominal)
Inputs per Module 16

Impedance 2.7 kΩ
Channels 1 and 2 : 10 to 28 VDC maximum
ON-state Voltage
Channels 3 to 16 : 7.5 to 28 VDC maximum
Channels 1 and 2 : 0 to 3.5 VDC
OFF-state Voltage
Channels 3 to 16 : 0 to 3.0 VDC
ON-state Current 4.3 mA minimum
Input Characteristics
OFF-state Current 1 mA maximum

Channels 1 and 2 : 50 µs maximum

ON Response Time Channels 3 and 4 : 500 µs maximum
Channels 5 to 16 : 10 ms maximum

Channels 1 and 2 : 50 µs maximum

OFF Response Time Channels 3 and 4 : 500 µs maximum
Channels 5 to 16 : 17 ms maximum
Isolation 5 kV Transient
Output Power 12 VDC / 250 mA (3 W) isolated, supplied by module
Operating Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Pulse Totalisation Channels 1 to 4 : 0-65535 Pulses
Pulse Rates / Channels 1 and 2 : 10 kHz maximum
Frequency Channels 3 and 4 : 255 Hz maximum
Yes. Module can be swapped while RTU is running. Hot swap will not
Hot Swap cause a Warm Start. Inputs are cleared in RTU memory while module is
removed.

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11.2.4 DI-5 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Powered by Module:

External positive supply:

External negative supply:

Combined positive and negative power

supplies:

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DI-10: AC or DC Input, 16 Channel

11.3.1 Overview
• Frequency/Pulse/Quadrature counters on up to 7 inputs or input pairs
• Isolated DC Field Power Output
• Software Debounce
• AC or DC Inputs
• Sequence of events recording (with optional GPS time synchronisation)
• Hot Swappable

The DI-10 provides 16 AC or DC input channels allowing it to interface a wide range of input
devices to your RTU. Inputs can be powered by the module’s own +12 VDC Field Output
Power or from external AC or DC power sources.
Applying a high positive or AC input voltage results in a logical ‘1’ in the status register, no or
low input voltage results in a logical ‘0’. Negative DC input voltages cannot be used with
DI-10 modules.
The DI-10 features software configurable pre-conditioning of inputs such as debounce filters,
channel inversion and sequence-of-event recording selectable on any channel(s).
The DI-10 can also perform frequency, pulse or quadrature counting for up to 7 input
channels (or pairs of input channels for quadrature counters).
DI-10 modules can be swapped while RTU is running without causing RTU restart. Inputs
are cleared in RTU memory while module is removed.

Electrical Hazards
Only appropriately qualified and trained personnel can install and
service this equipment.
Always power down input voltages exceeding Safety Extra Low
Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this
product, including field wiring.
Failure to do so may cause fire and may result in a serious
personnel injury or even death.

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 Kingfisher Plus+ Hardware Manual

Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les
limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol)
avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves ou même la mort du personnel.

11.3.2 DI-10 Options and Ordering Info

Unless explicitly noted, all hardware versions of DI-10 modules are described in this manual.
Comparing with its predecessor (v3.2), the newer DI-10 version (v4.3) has some differences
in the module features and specifications and also has a new optional GPS time
synchronisation of the sequence of event recording.
The DI-10 modules without “-48” suffix in their Order Code have Digital Inputs compatible
with 12 V and 24 V control systems. The modules with the “-48” suffix in the Order Code
have elevated change-over thresholds of Digital Inputs designed for use in 48 V and higher
control systems.
Any DI-10 v4.3 module can be a GPS Slave, having its events timing synchronised to an
accurate timing signal generated by a DI-10-[48]GPS v4.3 module (GPS Master) that has an
additional interface for connection to an external 3rd party GPS device. Any number of GPS
Slaves and GPS Masters can be installed in the RTU. With more than one GPS Master
installed in the system, each of them will generate time synchronisation signal for the GPS
Slaves in parallel, providing system redundancy if it is required.

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DI-10 options, ordering info, the main features and / or main specification differences are
summarised in the table below:
H/W Target System
IEC 61131 High- GPS
version Voltage
Order Code types I & III speed
12 V & compliant inputs4
v3.21 v4.32 ≥48 V Slave Master
24 V3
DI-10-1   4
DI-10-1-48 5   4
DI-10    16 
DI-10-48 5    16 
DI-10-GPS 6    16  
DI-10-48GPS 5,6    16  

Notes:
1
) And earlier versions (here and further in this Manual).
2
) And later versions (here and further in this Manual).
3
) Will also work with higher input voltages within the specified input range.
4
) Up to 7 counters in total is currently supported by firmware.
5
) DI-10-48 refers also to DI-10-1-48 and to DI-10-48GPS models further in this
document.
6
) DI-10-GPS refers also to DI-10-48GPS model further in this document.

11.3.3 Theory of operation

Block-diagram of DI-10 v3.2 module is shown on the figure below.

DI-10 v3.2 Block Diagram

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Digital Inputs are connected to the input optocouplers via series diodes, resistors and
3.6 mA current limiters. Optocouplers with integrated Schmitt triggers are installed on first
four (high-speed) channels. When input voltage and, consequently, input current of an
optocoupler exceeds its threshold, microcontroller (MCU) reads this input as ‘1’, otherwise it
is ‘0’.
Block-diagram of DI-10 v4.3 module is shown on the picture below.

DI-10 v4.3 Block Diagram

Digital Inputs are connected to a digital serialiser via series diodes and over-voltage
protection circuits. The digital serialiser has its threshold input current set (and limited) to
2.51 mA. External signal sources should be able to supply 2.51 mA current to the DI-10 v4.3
module. When the input voltage exceeds its threshold, the microcontroller (MCU) reads this
input as ‘1’, otherwise it is ‘0’.

11.3.4 Configurable Functions

The first 4 channels of the DI-10 v3.2 and all channels of the DI-10 v4.3 are high speed and
capable of counting up to 10kHz, while channels 5 to 16 of the DI-10 v3.2 can count up to
1 kHz.
Seven user-configurable counters are available which appear as 16-bit unsigned integer
values in the analogue input register. Each of these counters can be configured either to
measure frequency, to count pulses or to decode quadrature signals. Any channel from 1 to
16 can be assigned as an input to any frequency or pulse counter. Any pair of eight channel
pairs (1-2, 3-4, etc.) can be assigned as inputs to any quadrature counter.
Channel inversion can be configured on any input channel. Normally a high voltage level
results in a logical HIGH state (1) to be set in the digital input register with the corresponding
LED illuminating on the front panel. By enabling channel inversion, a low voltage level
applied to an input will result in a logical HIGH (1).
Software debounce can be activated on any input channel. The time constant can be
configured from 1 ms to 250 ms. When AC inputs are used, the input channel must be
configured with the debounce filter set to ‘AC Filter’ as shown below.

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A 1 ms debouncing is automatically enforced when ‘AC Filter’ is chosen.

11.3.5 Sequence of Events Recording

Sequence-of-Event (SoE) recording can be configured for any input channel. When enabled,
any change of state (event) on the input is logged to 1 millisecond resolution. These events
are automatically included in the Event Log of the RTU. The DI-10 module has an internal
timer that is synchronised with the Real Time Clock of the processor.
Timestamps of the DI-10 v4.3 are guaranteed to be within ±2 ms of UTC time when optional
GPS synchronisation feature is used in the RTU system.
The DI-10 module has a buffer capable of storing 1000 events. This means bursts of up to
one thousand events can be recorded at a time. Events are uploaded into the processor
module at a maximum rate of 100 events per second allowing the DI-10 module to cope with
events at a sustained rate of 100 events per second.
Please note that SoE recording is not supported when using a PC-1 processor.

11.3.6 GPS Time Synchronisation (Optional)

When a GPS device is attached to the DI-10-GPS module, it will synchronise the time on the
CP-30 processor and all other DI-10 modules (GPS Slaves) in the RTU via signalling on the
backplane. SoE timestamps on all DI-10 v4.3 modules will then be synchronised to the GPS
time within 2 ms.
This feature does NOT work with other Kingfisher Plus+ processor modules (such as CP-12,
CP-11, CP-21 and PC-1) nor with DI-10 v3.2 modules.
The GPS time synchronisation feature requires at least one DI-10-GPS module (GPS
Master) per RTU. More than one GPS Master can be used to provide redundancy.
One of the unused backplane connections (24V power rail) is used to carry the time
synchronisation signal between DI-10 modules.
WARNING. Installing DI-10 v4.3 modules on 24V backplanes (that are used in some old
Kingfisher Plus+ installations) will damage DI-10 modules and void their warranty.
To support time synchronisation of the DI-10 modules across multiple backplanes, the time
synchronisation signal must be connected between them. This signal is available on
backplane power connector J14:

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Backplane Power Header J14

Only two rails (24V and 0V) are required to be connected for time synchronisation between
backplanes to work.
The following cables can be ordered from Semaphore to provide required connections:
• BPC-01 or BPC-02 Backplane Power Cables.
WARNING. All power rails of the connected backplanes will be connected as well.
• BPC-02-GPS time synchronisation cable.
• BPC-SPLIT splitter cable if more than two backplanes need to be connected.
The DI-10-GPS has an RJ-45 jack for direct connection of a Garmin GPS16x-HVS device. It
is located directly underneath the LED display of the DI-10-GPS module.

The Garmin GPS16x-HVS can be ordered from Semaphore directly or via many commercial
outlets.

RJ45 Jack for GPS device

RJ-45 pin-out and wire colours of the Garmin GPS16x-HVS are shown on the DI-10 v4.3
block-diagram. If a different model of GPS device is to be used, an adapter should be
constructed using signal information in the table below.

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RJ45 DI-10-GPS Direction Direction

Signal Level Note
Pin Signal (DI-10-GPS) (GPS Device)
Power for GPS (100 mA
1 +12V OUT IN +12 V
max)
2 GND - - - Power & Signal Ground
Open Drain to Pulled to GND: GPS ON
3 PWR_ONn OUT IN
GND Floating: GPS OFF
4 Din OUT IN RS-232 Serial Data to GPS
5 Dout IN OUT RS-232 Serial Data from GPS
6 PPS IN OUT 5 V TTL Pulse Per Second
7 nc Not connected
8 nc Not connected

11.3.7 DI-10 Module LEDs

DI-10-1 [-48] (v3.2) DI-10 [-48] (v4.3) DI-10-[48]GPS (v4.3)

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LED State Description

ON Module operating normally

0.5 s ON,
OK Internal Fault: (module needs repair)1
0.5 s OFF
OFF Power off
1 s ON, Backplane communications time-out (15 s) expired
1 s OFF (no polling received from the RTU processor module)
ERR1 0.1 s ON,
Module faulty and needs repair.
1.9 s OFF
OFF Normal
ON GPS serial port data detected and GPS is synchronised to the GPS network.
1 s ON, GPS serial port data detected but the GPS is not synchronised to the GPS
1 s OFF network.
1.8 s ON, Time Synchronized to another DI-10-[48]GPS (master). This implies that no
GPS1,2 0.2 s OFF GPS is connected to this module so it acts as a DI-10 (slave).
Timing error in GPS slave synchronisation signal. This stays active until the
0.2 s ON,
next properly timed synchronisation signal, which could be a few minutes. This
0.2 s OFF
implies that no GPS is connected to this module so it acts as a DI-10 (slave).
OFF No GPS detected.
1.8 s ON,
Time Synchronised to a DI-10-[48]GPS (master).
0.2 s OFF
SYNC1 0.2 s ON, Timing error in GPS slave synchronisation signal. This stays active until the
0.2 s OFF next properly timed synchronisation signal, which could be a few minutes.
OFF No time synchronisation signal detected.
ON +12V DC-DC converter on
PCON
OFF +12V DC-DC converter off. No digital input sampling occurs.
Digital Input ON
ON
(channel input level is above low-to-high threshold)
1-16
Digital Input OFF
OFF
(channel input level is below high-to-low threshold)

Notes:
1
) Only hardware v4.3 or later.
2
) Only on DI-10-GPS modules (GPS Master).

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11.3.8 DI-10 Specifications

DI-10 Digital Input Module Specifications

Parameter v3.2 v4.3

Digital Inputs per Module 16

Maximum Input Voltage 130 VDC / 125 VAC 130 VDC / 250 VAC

Maximum Current per Input1 3.7 mA 2.6 mA

Digital Input Levels

ON-state Voltage @ Input Current

≥7.5 VDC @ 1.0 mA (Ch. 1-4)

≥7.5 VDC @ 2.5 mA
≥7.5 VDC @ 0.5 mA (Ch. 5-16)
Standard modules
≥20.0 VAC @ 1.0 mA (Ch. 1-4)
≥20.0 VAC @ 1.2 mA
≥20.0 VDC @ 0.5 mA (Ch. 5-16)

≥35.0 VDC @ 1.0 mA (Ch. 1-4)

≥35.0 VDC @ 2.5 mA
≥35.0 VDC @ 0.5 mA (Ch. 5-16)
-48 modules
≥27.0 VAC @ 1.0 mA (Ch. 1-4)
≥27.0 VAC @ 1.2 mA
≥27.0 VDC @ 0.5 mA (Ch. 5-16)

OFF-state Voltage

≤3.0 VDC ≤3.0 VDC

Standard modules
≤3.0 VAC ≤3.0 VAC

≤24.0 VDC ≤24.0 VDC

-48 modules
≤15.0 VAC ≤15.0 VAC

Digital Input Thresholds2

Low-to-High Transition

5.4 VDC / 3.8 VAC (Ch. 1-4)

Standard modules 7.2 VDC / 5.1 VAC
5.3 VDC / 4.0 VAC (Ch. 5-16)

36.2 VDC / 27.6 VAC (Ch. 1-4)

-48 modules 26.4 VDC / 19.1 VAC
34.7 VDC / 24.9 VAC (Ch. 5-16)

High-to-Low Transition

5.1 VDC / 3.7 VAC (Ch. 1-4)

Standard modules 6.3 VDC / 4.4 VAC
5.1 VDC / 3.7 VAC (Ch. 5-16)

36.0 VDC / 25.5 VAC (Ch. 1-4)

-48 modules 25.5 VDC / 18.4 VAC
34.5 VDC / 24.3 VAC (Ch. 5-16)

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DI-10 Digital Input Module Specifications

Parameter v3.2 v4.3

Digital Input Timing

50 µs (DC, Ch. 1-4) 50 µs (DC)

ON Response Time (max) 500 µs (DC, Ch. 5-16)
30 ms (AC) 30 ms (AC)

50 µs (DC, Ch. 1-4) 50 µs (DC)

OFF Response Time (max) 500 µs (DC, Ch. 5-16)
30 ms (AC) 30 ms (AC)

Filtering None,1, 3, 10, 30, 100, 250 ms or AC Filter

Frequency, Pulse and Quadrature Counters

Total number of Counters 7 maximum

10 kHz (Ch. 1-4)

Maximum Frequency 10 kHz
1 kHz (Ch. 5-16)

Frequency Counting 1 Hz resolution on any input(s)

Pulse Counting 0-65535 Pulses on any input(s)

Quadrature Counting 0-65535 Pulses on any of the inputs pair(s) 1-2, 3-4, etc.

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DI-10 Digital Input Module Specifications

Parameter v3.2 v4.3

Sequence of Events

Time Stamp Resolution 1 ms

Events Time Stamp

Accuracy n/a ±2 ms to UTC time
with GPS synchronisation3

Events Buffer Size 1000 events

Events Transfer Rate

(via backplane to a 100 events/s maximum
Processor Module)

Output Power

To Field Devices Isolated 12 V 80 mA maximum

Isolated 12 V 100 mA
To GPS Device4 n/a
maximum

Isolation

Maximum Working Voltage

(in respect to system 130 VDC / 125 VAC 130 VDC / 264 VAC
earth / ground)

Transient Voltage 3 kV

Environment

Operating Temperature -20 to +70 °C -40 to +85 °C

Storage Temperature -40 to +85 °C

Operating Humidity 5 to 95 % RH (non-condensing)

Notes:
1) Limited by internal circuitry of a DI-10 module.
2) Approximate values for information only (not factory tested)
3) For systems without GPS, the time-stamping accuracy depends on the accuracy of the Real
Time Clock in the RTU Processor module, the SCADA / Network time management protocol
used, the Backplane time synchronisation latency (that is influenced by the type of the
Processor module used and by its loading with the RTU logic and communications), by the
number of installed DI-10 modules and by other system-dependent parameters.
4) Only on DI-10-GPS modules (GPS Master)

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11.3.9 DI-10 Wiring Diagram

An edge-pluggable terminal block Fujicon F5021 is used for wiring of Digital Inputs and
power outputs to the DI-10 module PCB. It can be un-coupled from the DI-10 board for
wiring convenience if required.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

Note 1. Pins 9 and 19 (+12V) are connected together internally.

Note 2. Pins 10 and 20 (0V) are connected together internally.

Powered by Module

External DC Power Supply

Note: DC voltage applied to any input channel must be positive in respect to 0V.

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External AC Power Supply

Note: AC filter must be enabled in the DI-10 configuration for this channel.
DC and AC powered inputs can be used simultaneously on the same module. Care should
be taken to ensure that the negative rail of each external power supply is connected to the
Common (0V) terminal.

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12. DIGITAL OUTPUT MODULES

Overview
The digital output modules provide relay and transistor outputs to the Kingfisher Plus+ series
of RTUs.
The DO-1 and DO-2 offer relay outputs, eight and sixteen respectively, while the DO-6 is
transistor based.
The DO-6 is compatible with the TEL-REL-00x series of relay output boards to allow for
higher current and voltage switching.

Switching Inductive Loads

When switching inductive loads, users should be mindful of possible reduced relay service
life due to back-EMF. To mitigate this negative effect, suppression circuits should be used
when switching inductive loads.

Switching DC Supplied inductive loads (high switching relay output)

Switching DC Supplied inductive loads (ground switching relay output)

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Switching AC supplied inductive loads (*MOV = Metal Oxide Varistor)

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DO-1: 8 Channel Isolated Relay Output Module

12.3.1 Overview
• 8 SPDT isolated relay outputs
• One common per channel pair
• Can switch AC or DC voltages
• 500 V channel pair isolation
• 3 kV coil to contact isolation
The DO-1 provides 8 normally open or normally closed relay circuits for controlling output
loads. All output channels are isolated from each other and arranged into pairs. Each
channel pair shares a separate common terminal (please see the “DO-1 Wiring Diagram”
section for more details).
The relay outputs can control a wide range of user supplied load devices such as motors,
starters, solenoids, and indicators. The user is required to supply the AC or DC power to
operate the field devices connected to this module. Internal fuses offer protection to the relay
contacts should their maximum load be exceeded.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.

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Electrical Hazards
Only appropriately qualified and trained personnel can install and
service this equipment.
Always power down input voltages exceeding Safety Extra Low
Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this
product, including field wiring.
Failure to do so may cause fire and may result in a serious
personnel injury or even death.

Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les
limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol)
avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves ou même la mort du personnel.

Electrical Hazards
If input voltage is expected to exceed Safety Extra Low Voltage
(SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth
and/or ground) then all commons must be connected to a single
power source and no other power sources are allowed to be
connected to this module.

Risques Électriques
Si l’on prévoit que la tension d’entrée dépasse les limites de la Très
Basse Tension de Sécurité (TBTS) (DC 60V ou AC 42 Vcrête par
rapport à la terre du système et/ou au sol) alors les connexions
communes doivent être connectées à une seule source
d’alimentation et aucune autre source ne peut-être connectée au
module.

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Block-diagram of the DO-1 module is shown on the figure below.

DO-1 Block Diagram

12.3.2 DO-1 Module LEDs

LED State Description
OFF Module fault (no power)
OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail

A1, A2 OFF Digital output OFF (open)

B3, B4
C5, C6
ON Digital output ON (closed)
D7, D8

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12.3.3 DO-1 Specifications

DO-1 Isolated Relay Output Module Specifications
Outputs per Module 8
Commons 4 (each common supplies 2 outputs)
Relay Type SPDT (Single Pole, Double Throw)
5 A at 250 VAC Resistive
Rated Load (per common) 5 A at 30 VDC Resistive
(20 A maximum per DO-1 module)
Maximum Operating Voltage 250 VAC, 125 VDC
Maximum Switching Power -
1250 VA, 150 W
Resistive
Maximum Switching Power -
375 VA, 80 W
Inductive
Minimum Load 10 mA at 5 VDC
Relay Operations 100,000 minimum at 1800 operations per hour at rated load
-20 to +70 °C (v2.2 and below)
Operating Temperature
-40 to +85 °C (v2.3.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Altitude 2000 m max
3 kV coil to contacts
Isolation
500 V between channel groups
Omron G6B-2114P-US
Relay Part Number (G6B datasheet is available from
http://components.omron.eu/)
Yes. Module can be swapped while RTU is running. Hot
Hot Swap swap will not cause a Warm Start. Outputs will be restored
within 2 seconds once module is replaced.

CAUTION! Contacts should be protected with appropriate suppression devices when wired with
inductive loads to increase the service life of relays (please see the "Switching Inductive Loads"
section for more details). Contacts should also be protected with external fusing.
#Refer to the label on the side of the module which indicates the hardware version. If the version
number is not printed on the label then the module is v2.2 or older.

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12.3.4 DO-1 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Channel X LOAD X

Channel Y LOAD Y
_
Power
Supply
+
Common
Wiring Example
Notes:
1. Polarity can be reversed.
2. For safety reasons, do not connect more than one power source to a Digital Out Common
terminal.
3. If power supply voltage exceeds SELV levels (DC 60 V or AC 42 VPEAK relative to system earth
and/or ground) then all Common Terminals of the module must be connected to a single
power source and no other power sources can be connected to the same module.

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DO-2: 16 Channel Relay Output Module

12.4.1 Overview
• 16 SPST relay outputs
• One common per 8 channels
• 3 kV coil to contact isolation
• Can switch AC or DC voltages
The DO-2 provides 16 normally-open relay circuits for controlling output loads provided by
the user. The output points are arranged in two groups of eight. Each group shares a
common terminal. The relay outputs can be used to control a wide range of devices such as
motor starters, solenoids, and indicators.
Internal fuses protect the DO-2 relay contacts should ratings be exceeded.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Block-diagram of the DO-2 module is shown on the figure below.

DO-2 Block Diagram

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Electrical Hazards
Only appropriately qualified and trained personnel can install and
service this equipment.
Always power down input voltages exceeding Safety Extra Low
Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this
product, including field wiring.
Failure to do so may cause fire and may result in a serious
personnel injury or even death.

Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les
limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol)
avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves ou même la mort du personnel.

Electrical Hazards
If input voltage is expected to exceed Safety Extra Low Voltage
(SELV) levels (DC 60 V or AC 42 VPEAK relative to system earth
and/or ground) then all commons must be connected to a single
power source and no other power sources are allowed to be
connected to this module.

Risques Électriques
Si l’on prévoit que la tension d’entrée dépasse les limites de la Très
Basse Tension de Sécurité (TBTS) (DC 60V ou AC 42 Vcrête par
rapport à la terre du système et/ou au sol) alors les connexions
communes doivent être connectées à une seule source
d’alimentation et aucune autre source ne peut-être connectée au
module.

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12.4.2 DO-2 Module LEDs

LED State Description

OFF Module fault (no power)

OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail
OFF Digital output OFF (open)
1-16
ON Digital output ON (closed)

12.4.3 DO-2 Specifications

DO-2 16 Channel Digital Output Module Specifications
Outputs per Module 16
Commons 2 (each common supplies 8 outputs)
Relay Type SPST (Single Pole Single Throw, Normally Open)
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per common
Minimum Load 10 mA @ 5 VDC (wetting current)
Contact Resistance 100 mΩ maximum
-20 to +70 °C (v2.2 and below)
Operating Temperature
-40 to +85 °C (v2.3.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Altitude 2000 m max
Maximum working voltage in respect to system earth/ground
Isolation must not exceed 250 VAC / 130 VDC
Transient voltage: 3 kV
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Enabled when the common is wired to pins 10 and 20.
Fuse Monitor LED CAUTION! When wired, a maximum voltage of 30 V AC or DC
can be used to power the common.
Omron G6D-1A 12 VDC
Relay Part Number
(G6D datasheet is available from http://components.omron.eu/)
Yes. Module can be swapped while RTU is running. Hot swap will
Hot Swap not cause a Warm Start. Outputs will be restored within 2
seconds once module is replaced.

CAUTION! Contacts should be protected with appropriate suppression devices when wired with
inductive loads to increase the service life of relays (please see the "Switching Inductive Loads"
section for more details). Contacts should also be protected with external fusing.
#Refer to the label on the side of the module which indicates the hardware version. If the version
number is not printed on the label then the module is v2.2 or older.

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12.4.4 DO-2 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Note: Link terminals can be optionally connected to the adjacent Common terminals to enable the
Fuse Monitor LED (FU).
Caution: A maximum of 30 V (AC or DC) can be used to power the common if the link is installed.

Channel X LOAD X

Channel Y LOAD Y

Channel Z LOAD Z
_
Power
Supply
+
Common
Wiring Example
Notes:
1. Polarity can be reversed.
2. For safety reasons, do not connect more than one power source to a Digital Out Common
terminal.
3. If power supply voltage exceeds SELV levels (DC 60 V or AC 42 VPEAK relative to
system earth and/or ground) then both Common Terminals of the module must be
connected to a single power source and no other power sources can be connected to
the same module.

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DO-6: 16 Channel Open Drain Output Module

12.5.1 Overview
• 16 Open-drain outputs
• Designed to operate TEL REL 00x relay board
• DC Field Output (non-isolated)
The DO-6 provides 16 open drain N-FET outputs for controlling various loads including the
TELREL series of relay boards. Power for external loads can be provided from the modules
+12 VDC which is sourced from the backplane rail.
The DO-6 output channels are current limited and are protected from high levels of EMI that
may trigger false outputs.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Block-diagram of the DO-6 module is shown on the figure below.

DO-6 Block Diagram

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12.5.2 DO-6 Module LEDs

LED State Description

OFF Module fault (no power)
OK
ON Normal
OFF Digital output OFF (open)
A1-A16
ON Digital output ON (closed)

12.5.3 DO-6 Specifications

DO-6 Channel Open Drain Output Module Specifications
Outputs per Module 16
Commons 1
Rated Voltage 30 VDC maximum.
Output Type N-FET, Open Drain
Rated Load 70 mA per channel
Current Limit 90 mA per channel
12 VDC non-regulated, non-isolated (supplied by module directly from
Output Power
backplane), 1.6 A maximum
ON Response Time 15 ms maximum
OFF Response Time 15 ms maximum
-20 to +70 °C (v1.2 and below)
Operating Temperature
-40 to +85 °C (v1.2.A and above) #
Storage Temperature -40 to +85 °C
Operating Humidity 5 to 95 % RH (non-condensing)
Yes. Module can be swapped while RTU is running. Hot swap will not
Hot Swap cause a Warm Start. Outputs will be restored within 2 seconds once
module is replaced.
The DO-6 is functionally equivalent and pin compatible with the
Compatibility
superseded DO-5.
#Refer to the label on the side of the module which indicates the hardware version. If the version
number is not printed on the label then the module is v1.2 or older.

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12.5.4 DO-6 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Note: The +12 V Output is sourced from the backplane power rail and is not isolated.
Users should exercise caution to avoid shorting or overloading this output.

External DC power supply:

Load powered by module:

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13. RELAY EXPANSION BOARDS

Overview
The Kingfisher Plus+ Relay Expansion Boards are designed to be used in conjunction to the
DO-6 module. The relay boards allow much more flexible use of the DO-6 module due to the
wide range of relay types available.
Each relay board has unique internal wiring. Users should be mindful that they are not
completely pin-compatible. Please refer to individual wiring diagrams for details.

• 16 Channel Isolated Relay SPDT for DO-6-x complete with 1.5m cable
• Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel)
TEL REL 002 • Max Current 16 A @ 250 VAC resistive, 16 A @ 30 VDC resistive, 0.45 A @
125 VDC Inductive.
• 5 kV isolation (Coil to Contact)
• Omron G2R-1-E 12 VDC Relay

• Relay Board - 16 Channel Isolated Relay SPST for DO-6-x complete with
1.5m cable
• Max Voltage 380 VAC, 125 VDC, 16 commons (1 common per channel)
TEL REL 003 • Max Current 8 A @ 250 VAC resistive, 8 A @ 30 VDC resistive, 1 A @ 125 VDC
Inductive
• 5 kV isolation (Coil to Contact)
• Omron G2RG-2A4 12 VDC Relay

• Relay Board - 16 Channel Isolated Relay DPDT for DO-6-x complete with
1.5m cable
TEL REL 004 • Max Voltage 380 VAC, 125 VDC, 32 commons (2 common per channel)
• Max Current 5 A @ 250 VAC resistive, 5 A @ 30 VDC resistive
• 5 kV isolation (Coil to Contact)
• Omron G2R-2 12 VDC Relay

Electrical Hazards
Only appropriately qualified and trained personnel can install and
service this equipment.
Always power down input voltages exceeding Safety Extra Low
Voltage (SELV) levels (DC 60 V or AC 42 VPEAK relative to system
earth and/or ground) before performing any operation on this
product, including field wiring.
Failure to do so may cause fire and may result in a serious
personnel injury or even death.

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Risques Électriques
Seul le personnel qualifié et formé peut installer et entretenir cet
équipement.
Toujours mettre hors tension les tensions d’entrées dépassant les
limites de la Très Basse Tension de Sécurité (TBTS) (DC 60 V ou
AC 42 VPOINTE par rapport à la terre du système et/ou du sol)
avant d’effectuer toute opération sur ce produit, y compris le
câblage.
Ne pas le faire peut provoquer un incendie et peut entrainer
des blessures graves ou même la mort du personnel.

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TEL REL 002: SPDT Relay Board

13.2.1 Overview
• 16 SPDT Relay Outputs
• Common for each channel
• 5 kV coil to contact isolation
• Can switch AC or DC voltages
The TEL REL 002 is designed to accompany the DO-6 to provide 16 SPDT voltage free
output contacts.
Each relay consumes 43 mA @ +12 VDC from the backplane power supply. An external
supply can be connected to a screw terminal on the PCV is available (this is not the case if
the standard cable supplied with the DO-6 modules is utilized).
LED indicators are provided for each relay on the relay board. LED ON = relay active.

13.2.2 TEL REL 002 Specifications

TEL REL 002 SPDT Relay Boards Specifications
Outputs per Terminal Board 16
Commons 16# (1 common per channel)
Relay Type (per channel) SPDT (Single Pole, Double Throw)
16 A @ 250 VAC Resistive
Rated Load (per contact)
16 A @ 30 VDC Resistive
Maximum Operating Voltage 380 VAC, 125 VDC
16 A @ 30 VDC
Maximum Switching Power -
5 A @ 48 VDC
Resistive
0.6 A @ 125 VDC
16 A @ 12 VDC
Maximum Switching Power - 8 A @ 30 VDC
Inductive 0.7 A @ 48 VDC
0.45 A @ 125 VDC
Minimum Load 100 mA at 5 VDC
Contact Resistance 100 mΩ maximum
Relay Operations 100,000 minimum at 1800 operations per hour at rated load
Operating Temperature -20 to +70 °C (no icing)
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 43 mA
Coil Resistance 275 Ω @ 12 VDC

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253 mm(L) x 90 mm(W) x 70 mm(H)

Dimensions
(280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1500 mm (for connection to the DO-6 module)
Phoenix double height PCB terminal unit arranged in a dual three
Connection Terminals way terminal (please see wiring diagram). These terminals can
take wire sizes up to 4 mm2.
Omron G2R-1-E 12 VDC
Relay Part Number
(datasheet is available from http://components.omron.eu/)

CAUTION! Contacts should be protected with appropriate suppression devices when wired
with inductive loads to increase the service life of relays (please see the "Switching
Inductive Loads" section for more details). Contacts should also be protected with external
fusing.
#)
CAUTION! If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels
(DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons
must be connected to a single power source and no other power sources are allowed to be
connected to this module.

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13.2.3 TEL REL 002 Wiring Diagram

DO-6 to TEL REL 00x Interface Cable

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Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Colour Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 V D C Blue/Red 19
20 + 12 V D C Green/Red 20

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TEL REL 003: SPST Relay Board

13.3.1 Overview
• 16 SPST Relay Outputs
• Common for each channel
• 5 kV coil to contact isolation
• Can switch AC or DC voltages
• Higher inductive rating than other TEL REL 002
(1 A @ 125 V as opposed to 0.4 A @ 125 V)
The TEL REL 003 board is designed to be used in conjunction with the DO-6 (or superseded
DO-5) and provides superior inductive load rating than the TEL REL 002.
LED indicators are provided for each relay on the relay board. LED ON = relay active.

13.3.2 TEL REL 003 Specifications

TEL REL 003 SPST Relay Board Specifications
Outputs per Terminal Board 16
Commons 16# (1 common per channel)
Relay Type (per channel) SPST (Single Pole, Single Throw)
8 A at 250 VAC Resistive
Rated Load (per contact) 8 A at 30 VDC Resistive
1 A at 125 VDC Inductive
Maximum Operating Voltage 380 VAC, 125 VDC
Maximum Switching Power -
2000 VA, 240 W
Resistive
Contact Resistance 100 mΩ maximum
100,000 minimum at 1800 operations per hour at rated resistive
Relay Operations load
50,000 minimum at 360 operations per hour at rated inductive load
Operating Temperature -20 to +70 °C (no icing)
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 66 mA
Coil Resistance 180 Ω @ 12 VDC
253 mm(L) x 90 mm(W) x 70 mm(H)
Dimensions
(280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1.5 m (for connection to the DO-6 module)
Weidmuller single height PCB 3-way terminal unit (please see
Connection Terminals
wiring diagram). These terminals can take wire sizes up to 4 mm2.

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Omron G2RG-2A4 12 VDC

Relay Part Number
(datasheet is available from http://components.omron.eu/)

CAUTION! Contacts should be protected with appropriate suppression devices when wired
with inductive loads to increase the service life of relays (please see the "Switching Inductive
Loads" section for more details). Contacts should also be protected with external fusing.
#) CAUTION!If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels
(DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons
must be connected to a single power source and no other power sources are allowed to be
connected to this module.

13.3.3 TEL REL 003 Wiring Diagram

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DO-6 to TEL REL 00x Interface Cable

Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 V D C Blue/Red 19
20 + 12 V D C Green/Red 20

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TEL REL 004: DPDT Relay Board

13.4.1 Overview
• 16 DPDT relay outputs
• 2 commons per channel
• 5 kV coil to contact isolation
• Can switch AC or DC voltages
The TEL REL 004 is designed to be used in conjunction with the DO-6 (or superseded
DO-5) and provides Double Pole Double Throw (DPDT) relays. This allows the user to utilize
both normally open and normally closed relay operation.
LED indicators are provided for each relay on the relay board. LED ON = relay active.

13.4.2 TEL REL 004 Specifications

TEL REL 004 DPDT Relay Board Specifications
Outputs per Terminal Board 16
Commons 32# (2 commons per channel)
Relay Type (per channel) DPDT (Double Pole, Double Throw)
5 A at 250 VAC Resistive
Rated Load (per contact)
5 A at 30 VDC Resistive
Maximum Current 5A
Maximum Operating Voltage 380 VAC, 125 VDC (2 A maximum)
Maximum Switching Power 750 VA, 90 W Resistive
Minimum Load 10 mA at 5 VDC
Contact Resistance 50 mΩ maximum
Relay Operations >10,000,000
Operating Temperature -20 to +70 °C (no icing)
Humidity 5 to 95 % RH (non-condensing)
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 44 mA per coil
Coil Resistance 275 Ω @ 12 VDC
253 mm(L) x 90 mm(W) x 70 mm(H)
Dimensions
(280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface Cable Length 1.5 m (for connection to the DO-5/6 module)
Omron G2R-2 12 VDC
Relay Part Number
(datasheet is available from http://components.omron.eu/ )

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CAUTION! Contacts should be protected with appropriate suppression devices when wired
with inductive loads to increase the service life of relays (please see the "Switching Inductive
Loads" section for more details). Contacts should also be protected with external fusing.
#)
CAUTION! If input voltage is expected to exceed Safety Extra Low Voltage (SELV) levels
(DC 60 V or AC 42 VPEAK relative to system earth and/or ground) then all used commons
must be connected to a single power source and no other power sources are allowed to be
connected to this module.

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13.4.3 TEL REL 004 Wiring Diagram

DO-6 to TEL REL 00x Interface Cable

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Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1 Channel 1 Black 1
2 Channel 2 White 2
4 Channel 3 Red 4
4 Channel 4 Green 4
5 Channel 5 Orange 5
6 Channel 6 Blue 6
7 Channel 7 White/Black 7
8 Channel 8 Red/Black 8
9 0 V Green/Black 9
10 0 V Orange/Black 10
11 Channel 9 Blue/Black 11
12 Channel 10 Black/White 12
13 Channel 11 Red/White 13
14 Channel 12 Green/White 14
15 Channel 13 Blue/White 15
16 Channel 14 Black/Red 16
17 Channel 15 White/Red 17
18 Channel 16 Orange/Red 18
19 + 12 V D C Blue/Red 19
20 + 12 V D C Green/Red 20

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14. COMBINATION IO MODULES

Combinational IO modules provide digital and analogue IO in a single module. They can be
installed in any 4, 6, or 12 slot backplane.

IO-2: Combinational Digital IO Module

14.1.1 Overview
• 8 SPST relay outputs
• Digital inputs
This module can be installed in any slot of a 4, 6 or 12 slot backplane.

Digital Inputs
The digital inputs are designed to be powered using an external power supply. A wide range
of digital input devices can be used such as push buttons, limit switches and electronic
proximity switches. Current through an input (in either direction) results in a logic 1 in the
status register. Power to operate the field devices must also be supplied by the user.

Digital Outputs
The output points are arranged in one group of eight points with one common. The output
switching capacity of each output is 2 amps. The relay outputs can control a wide range of
load devices such as motor starters, solenoids and indicators. Power for the internal relay
circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or
DC power to operate the field devices. An internal fuse protects the relay contacts should
ratings be exceeded.

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Block-diagram of the IO-2 module is shown on the figure below.

IO-2 Block Diagram

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14.1.2 IO-2 Module LEDs

LED State Description
OFF Module fault (no power)
OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail
OFF Digital input OFF
A1-A8
ON Digital input ON
OFF Digital output OFF (open)
B1-B8
ON Digital output ON (closed)

14.1.3 IO-2 Specifications

IO-2 Combinational IO Module Specifications
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Yes. Module can be swapped while RTU is running. Hot swap will
not cause a Warm Start. Outputs will be restored within 2
Hot Swap
seconds once module is replaced. Inputs will be cleared while
module is removed.

DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
Input Characteristics
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage
Isolation 3 kV between field and logic

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DIGITAL OUTPUTS
Outputs per Module 8
Commons 1 (common supplies all 8 outputs)
Relay T ype SPST (Single Pole Single Throw)
Maximum Switched
30 VDC, 42 VAC
Voltage
Maximum Switched
5 A per common
Current
Isolation 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Resistance 100 mΩ maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Omron G6D-1A 12 VDC
Relay Part Number
(G6D datasheet is available from http://components.omron.eu/)

CAUTION! Contacts should be protected with appropriate suppression devices when wired with
inductive loads to increase the service life of relays (please see the "Switching Inductive Loads"
section for more details). Contacts should also be protected with external fusing.

14.1.4 IO-2 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Digital Input Example:

(Note polarity can be
reversed on power supply)

Digital Output Example:

* Optional link for DC Supply only. Enables fuse fail LED ‘FU’ on module.
CAUTION: when the link is installed a maximum of 30 V (AC or DC) can be used to power
the common.
Note: DC powered inputs and low voltage AC inputs can both be used on the same module.

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IO-3: Combinational Analogue/Digital IO Module

14.2.1 Overview
• 4 SPST relay outputs
• 4 analogue inputs
• 4 digital inputs
• 1 analogue output
This module can be installed in any slot of a 4, 6 or 12 slot backplane.

Analogue IO
The IO-3 provides two signal ranges: 0 to 20 mA and 4 to 20 mA. The default range is
4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O
for all channels.
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used
in the conversion process. All channels are updated four times per second (250 ms refresh
time). The placement of the bits within the data word is shown below.
MSB LSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

Scaling of the input is shown below:

All inputs share a single common and all outputs share a separate common at the zero volt
rail.
Input protection for the module is sufficient to guarantee operation with reduced performance
with up to 1500 V common-mode. The module provides electrical isolation of externally
generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be
wired using a good grade of twisted, shielded instrumentation cable. The shields can be
connected to E. The E connection provides access to the backplane (frame ground).

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Digital IO
Input characteristics are compatible with a wide range of user supplied input devices, such
as push buttons, limit switches and electronic proximity switches, whilst outputs can control a
wide range of user supplied load devices such as: motor starters, solenoids and indicators.
Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The
user must supply the AC or DC power to operate field devices. An internal fuse protects the
relay contacts should ratings be exceeded.

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Block-diagram of the IO-3 module is shown on the figure below.

IO-3 Block Diagram

14.2.2 IO-3 Module LEDs

LED State Description
OFF Module fault (no power)
OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail
A1-A4 - Not used
B1 - Not used
OFF Digital input OFF
C1-C4
ON Digital input ON
OFF Digital output OFF (open)
D1-D4
ON Digital output ON (closed)

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14.2.3 IO-3 Specifications

IO-3 Analogue/Digital Combinational IO Module Specifications
Supply Voltage (nominal) +5 VDC and +12 VDC from backplane
Isolation 5 kV Transient
Output Power 24 VDC / 100 mA max, Isolated
-20 to +70 °C (v1.3 and below)
Operating Temperature
-40 to +85 °C (v1.4.A and above) #
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Yes. Module can be swapped while RTU is running. Hot swap will
not cause a Warm Start. Outputs will be restored within 2
Hot Swap
seconds once module is replaced. Inputs will be cleared while
module is removed.
ANALOGUE INPUTS
Input Current Ranges 4 to 20 mA or 0 to 20 mA
Input Voltage Ranges * 1 to 5 V and 0 to 5 V *
Inputs per Module 4
Update Rate 2 ms (all four channels)
± 0.25% @ 25 °C
Accurac y
± 0.50% @ -20 to +70 °C
Resolution 12 bit (no sign bit)
Linearity < 1 Least Significant Bit
Isolation Transient voltage: 1 kV
Common Mode Rejection > 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection > 80 dB from DC to 1 kHz
250 Ω standard
Input Impedance 15 kΩ optional *. The internal load resistors can be factory
removed if high impedance voltage inputs are required.
Input Filter Cutoff Frequency 325 Hz @ -3 dB
ANALOGUE OUTPUT
Output Current Range 4 to 20 mA or 0 to 20 mA
Outputs per Module 1
250 ms (all channels)
Update Rate
Determined by I/O scan time and is application dependent
Accurac y ± 0.25% @ 25 °C
Resolution 12 bit (no sign bit)
User Load 0 to 850 Ω
Output Load Capacitance 2000 pF

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Output Load Inductance 1H

DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 4
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
Input Characteristics
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage

DIGITAL OUTPUTS
Outputs per Module 4
Commons 1 (common supplies all 4 outputs)
Relay T ype SPNO (Single Pole, Normally Open)
Maximum Switched
30 VDC, 42 VAC
Voltage
Maximum Switched 4 A per channel
Current 5 A per common
Minimum Load 10 mA @ 5 VDC (wetting current)
Contact Resistance 100 mΩ maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Omron G6D-1A 12 VDC
Relay Part Number
(G6D datasheet is available from http://components.omron.eu/)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with
inductive loads to increase the service life of relays (please see the "Switching Inductive Loads"
section for more details). Contacts should also be protected with external fusing.
#Refer to the label on the side of the module which indicates the hardware version. If the version
number is not printed on the label then the module is v1.3 or older.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the
complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any
combination of channels can be converted. It is recommended that modules be returned to Semaphore
for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to
boards during modification performed by clients. The circuit board resistors to change are: R39, R41,
R43 and R45 (channels 1 to 4 correspondingly).

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14.2.4 IO-3 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

Note: Link terminal can be optionally connected to the Digital OUT Common terminal to enable the
Fuse Monitor LED (FU).
CAUTION: when the link is installed a maximum of 30 V (AC or DC) can be used to power
the common.

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Note: DC powered inputs and low voltage AC inputs can both be used on the same module.

Analogue Input Examples

2 wire transmitter
(powered by module)

3 wire transmitter
(powered by module)

4 wire transmitter
(powered by module)

2 wire transmitter
(powered externally)

3 wire transmitter
(powered externally)

4 wire transmitter
(powered externally)

Analogue Output Example

Analogue load

Digital Input Example

Sensing the output form a field

contact

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Digital Output Example

Channel X LOAD X

Channel Y LOAD Y

Driving external load(s) from

digital output(s)
Channel Z LOAD Z
_
Power
Supply
+
Common
Notes:
1. Polarity can be reversed.
2. For safety reasons, do not connect more than one power source to a Digital Out Common
terminal.

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IO-4: Combinational Analogue / Digital IO Module

14.3.1 Overview
• 2 SPST relay outputs
• 2 analogue inputs
• 8 digital inputs
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.

Analogue IO
The IO-4 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is
4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O
for all channels.
Channel 1 can be utilized for a strain gauge input of range approximately 50 mV. 5 V
excitation voltage is supplied from this module (please refer to the wiring diagram for further
information).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used
in the conversion process. The placement of the bits within the data word is shown below.
MSB LSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

Scaling of the input is shown below:

All inputs share a single common and all outputs share a separate common at the zero volt
rail.
Input protection for the module is sufficient to guarantee operation with reduced performance
with up to 1500 V common-mode. The module provides electrical isolation of externally
generated noise between field wiring and the backplane through the use of optical isolation.

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To minimise the capacitive loading and noise, all field connections to the module should be
wired using a good grade of twisted, shielded instrumentation cable. The shields can be
connected to E. The E connection provides access to the backplane (frame ground).

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Digital IO
Input characteristics are compatible with a wide range of user supplied input devices, such
as push buttons, limit switches and electronic proximity switches, whilst outputs can control a
wide range of user supplied load devices such as: motor starters, solenoids and indicators.
Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The
user must supply the AC or DC power to operate field devices. An internal fuse protects the
relay contacts should ratings be exceeded.
Block-diagram of the IO-4 module is shown on the figure below.

IO-4 Block Diagram

14.3.2 IO-4 Module LEDs

LED State Description

OFF Module fault (no power)

OK
ON Normal
OFF Fuse OK
FU
ON Fuse fail
OFF Digital input OFF
A1-A8
ON Digital input ON
OFF Digital output OFF (open)
B1-B2
ON Digital output ON (closed)

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14.3.3 IO-4 Specifications

IO-4 Analogue / Digital Combinational Module Specifications
Operating Temperature -20 to +70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Output Power 24 VDC / 100 mA max, Isolated
Yes. Module can be swapped while RTU is running. Hot swap will
not cause a Warm Start. Outputs will be restored within 2
Hot Swap
seconds once module is replaced. Inputs will be cleared while
module is removed.

ANALOGUE INPUTS
Input Current Ranges 4-20 mA and 0-20 mA
Input Voltage Ranges * 1-5 V and 0-5 V *
Inputs per Module 2
Update Rate 2 ms (all four channels)
± 0.25% @ 25 °C
Accuracy
± 0.50% @ -20 to +70 °C
Resolution 12 bit (no sign bit)
Common Mode Voltage 1500 V
Linearity <1 Least Significant Bit
Isolation 1000 VRMS between field and logic
Common Mode Rejection >70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection >80 dB from DC to 1 kHz
250 Ω standard
Input Impedance 15 kΩ optional *. The internal load resistors can be factory
removed if high impedance voltage inputs are required.
Input Filter
325 Hz @ -3 dB
Cutoff Frequenc y

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DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
ON-state Voltage 11.5 to 30 VDC maximum
OFF-state Voltage 0 to 4 VDC
ON-state Current 3.2 mA minimum
Input Characteristics
OFF-state Current 1 mA maximum
ON Response Time 10 ms typical
OFF Response Time 17 ms typical

Input Current 4 mA (typical) at rated voltage

Isolation 1000 VRMS between field and logic

DIGITAL OUTPUTS
Outputs per Module 2
Commons 1 (common supplies both outputs)
Relay Type SPST (Single Pole Single Throw)
Maximum Switched Voltage 30 VDC, 42 VAC
Maximum Switched Current 5 A per common
Isolation 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Resistance 100 mΩ maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Omron G6D-1A 12 VDC
Relay Part Number
(G6D datasheet is available from http://components.omron.eu/)

CAUTION! Contacts should be protected with appropriate suppression devices when wired with
inductive loads to increase the service life of relays (please see the “Switching Inductive Loads”
section for more details). Contacts should also be protected with external fusing.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or by the
complete removal) of the 250 Ω channel resistor. Each channel has its own resistor, so any
combination of channels can be converted. It is recommended that modules be returned to
Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for
damage caused to boards during modification performed by clients. The circuit board resistors to
change are: R85 and R41 (channels 1 and 2 correspondingly).

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14.3.4 IO-4 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

* Optional link for DC Supply only. Enables fuse fail LED ‘FU’ on module.
CAUTION! When the link is installed, a maximum voltage of 30 V (AC or DC) can be used to
power the common.

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Strain gauge input

(4 wire Wheatstone bridge)

2 wire transmitter
(powered by module)

3 wire transmitter
(powered by module)

4 wire transmitter
(powered by module)

2 wire transmitter
(externally powered)

3 wire transmitter
(externally powered)

4 wire transmitter
(externally powered)

Field contact input

(externally powered)

Driving digital load

(externally powered)

Passive field contact

(powered by module)

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IO-5: Combinational Analogue / Digital IO Module

14.4.1 Overview
• 4 analogue inputs
• 1 analogue output with open line detection
• 4 digital inputs
• 4 sinking solid state outputs
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.

Analogue IO
Input protection for the module is sufficient to guarantee operation with reduced performance
with up to 1500 V common-mode. The module provides electrical isolation of externally
generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be
wired using a good grade of twisted, shielded instrumentation cable. The shields can be
connected to E. The E connection provides access to the backplane (frame ground).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used
in the conversion process. The placement of the bits within the data word is shown below.
MSB LSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0

Scaling of the input is shown below:

All inputs share a single common and all outputs share a separate common at the zero volt
rail.
For analogue outputs, an Open Line Detection circuit will indicate whether current loop is
open or closed. Please note that open line detection circuit performance cannot be
guaranteed when AO value is set to less than 1% (328 decimal) of full scale in the 0-20 mA
range.

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The IO-5 provides two signal ranges, 0 to 20 mA and 4 to

20 mA. The default range is 4 - 20 mA. A link on the rear
of the module selects 4 - 20 mA (link installed) or
0 - 20 mA I/O for all channels.

Digital Inputs
For high speed isolated digital inputs are provided on the module. All four digital inputs share
on one common rail.
All channels can be configured as pulse counters that appear 16 bit unsigned integer values
in the analogue input registers of the RTU processor module. Because of processor module
limitations, only channels 1 and 2 can be configured as pulse counters when used with the
CP-11/12/21 and PC-1 processors (Toolbox 32). All four channels can be used as pulse
counters when used with CP-30 processor module (Toolbox PLUS).
Input characteristics are compatible with a wide range of user supplied input devices, such
as push buttons, limit switches, Hall sensors, proximity switches, etc.

Digital Outputs
The IO-5 provides 4 open-drain (sinking) outputs for controlling various loads. Power for the
loads can be provided from the on-board isolated +24 VDC power supply or from an external
power source.
The IO-5 output channels provide continuous protection from overloads.

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Block-diagram of the IO-5 module is shown on the figure below.

IO-5 Block Diagram

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14.4.2 IO-5 Module LEDs

LED State Description

OFF Module fault (no power)
OK
ON Normal
OFF Normal
RST
ON Module Reset in progress
OFF Field Power disabled
24Va
ON Field Power enabled
OFF Analogue input is less or equal to 1% of range
AI 1-4
ON Analogue input is greater than 1% of range
OFF Analogue output is set to less or equal to 1% of range
AO1
ON Analogue output is set to greater than 1% of range
OFF Analogue output line is closed (loaded)
OL
ON Analogue output line is open / loop current equal to zero
OFF Digital input OFF
DI 1-4
ON Digital input ON
OFF Digital output OFF (Output switch does not conduct)
DO 1-4
ON Digital output ON (Output switch conducts)

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14.4.3 IO-5 Specifications

IO-5 Analogue / Digital Combinational Module Specifications
Operating Temperature -40 to +85 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95 % RH (non-condensing)
Output Power 24 VDC / 100 mA max, Isolated
Maximum W orking
Voltage on any contact of 42.4 VPEAK / 60 VDC relative to system (backplane) ground
the field connector
Yes. Module can be swapped while RTU is running. Hot swap will
Hot Swap
not cause a Warm Start.

ANALOGUE INPUTS
Input Current Ranges 4 - 20 mA or 0 - 20 mA
Input Voltage Ranges * 1 - 5 V or 0 - 5 V *
Inputs per Module 4
Resolution Unsigned 12 bit
Accurac y
± 0.25% @ 25 °C
(includes Gain, Linearity
± 0.50% @ -40 to +85 °C
and Offset errors)
Update Rate 120 ms
Cross-Channel Rejection > 115 dB from DC to 1 kHz
250 Ω standard
Input Impedance 1 MΩ optional *. The internal load resistors can be factory
removed if high impedance voltage inputs are required.
Input Filter
7 Hz @ -3 dB
Cutoff Frequenc y
16 dB @ 50 Hz
AC noise attenuation
18 dB @ 60 Hz
Output Field Power 24 VDC / 80 mA Isolated
Isolation 5 kV Transient

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ANALOGUE OUTPUT
Output Current Range 4 - 20 mA or 0 - 20 mA
Outputs per Module 1
Output Type Isolated, Sourcing
Resolution Unsigned 12 bit
250 ms
Update Rate
Determined by I/O scan time and is application dependent
Accurac y (includes Gain, ± 0.25% @ 25°C
Linearity and Offset errors) ± 0.50% @ -40 to +85 °C
User Load 0 to 850 Ω
Isolation 5 kV Transient

DIGITAL INPUTS
Inputs per Module 4 with one common
Input Type Optically isolated, Sinking
Maximum Input Voltage 30 VDC
Guaranteed ON-state Voltage 10 VDC minimum
Guaranteed OFF-state Voltage 4.0 VDC maximum
Counters Type Pulse, Unsigned 16-bit (all channels)
Maximum Counters Speed 10 kHz
Approx. (VIN / 4.7) mA:
Input Current
2 mA @ 9.4 VIN; 6.4 mA @ 30 VIN
Isolation 5 kV Transient

DIGITAL OUTPUTS
Outputs per Module 4 with one common
Output Type Optically isolated, Solid State, Sinking
Maximum Switched Voltage 30 VDC
Maximum Switched Current 2 A per channel
Isolation 3 kV Transient
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one pin (or
by the complete removal) of the 250 Ω channel resistor. Each channel has its own resistor,
so any combination of channels can be converted. It is recommended that modules be
returned to Semaphore for factory conversion if required. No responsibility will be taken by
Semaphore for damage caused to boards during modification performed by clients. The
circuit board resistors to change are:
• Ch.1: R81 (or R85+R86);
• Ch.2: R82 (or R87+R88);
• Ch.3: R83 (or R89+R90);
• Ch.4: R84 (or R91+R92).

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14.4.4 IO-5 Wiring Diagram

The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit
identification information can be recorded on the outside surface of the insert.

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Analogue Input Examples

2 wire transmitter
(powered by module)

3 wire transmitter
(powered by module)

4 wire transmitter
(powered by module)

2 wire transmitter
(powered externally)

3 wire transmitter
(powered externally)

4 wire transmitter
(powered externally)

Analogue Output Example

Analogue load

Digital Input Example

Sensing the output form a field

contact

Digital Output Example

Driving external load from digital

output

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15. ADAPTORS AND CABLES

Overview
A range of adaptor and cable accessories are available for the Kingfisher Plus+ range to
allow for communications interfacing. The adaptor plugs universally adapt to RJ45 to allow
standard CAT5/6 cabling to be used between RTUs, PLCs and communications devices.

Connectivity Example

Reference:

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Summary of available adaptors and cables

Part Number Description
ADP-04 Maxon and Tait radios (DB9F to RJ45 Adaptor) for 'R' option
ADP-05 PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options
DB9 port saver. Used with ADP-05 for concealed PC serial ports
ADP-N
(e.g. Current HP Notebooks)
ADP-05-N PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver.
PSTN modem external 25 pin (DB25M to RJ45 Adaptor) for 'S' options,
ADP-07
confirm PSTN pin-outs
ADP-08 RJ45 to DB9 Female Converter (Straight Connect)
RJ45 to DB9 Male Converter (Straight Connect) for Serial Port to MaxStream
ADP-08 M
External Spread Spectrum Radio
ADP-16 Trio "D" and "E" Series Radio (DB9M to RJ45 Adapter) for 'S' options
Uni-Op Display Model - MD02R-04-00A5 (DB15M to RJ45 Adapter) for 'S'
ADP-25
options
ADP-28 Trio "H" series Spread Spectrum Radio (DB9M to RJ45 Adapter) for 'S' options
ADP-29 Trio "M" series Radio (Modem fitted) (DB9M to RJ45 Adapter) for 'S' options
ADP-31 Trio "M" series Radio (DB9M to RJ45 Adapter) for PC-1 'R' option
RJC-05 Cable RJ45 Plug both ends "1:1" - 0.5 meters
RJC-10 Cable RJ45 Plug both ends "1:1" - 1.0 meter
RJC-20 Cable RJ45 Plug both ends "1:1" - 2.0 meters
RJC-30 Cable RJ45 Plug both ends "1:1" - 3.0 meters
RJC-50 Cable RJ45 Plug both ends "1:1" - 5.0 meters
RJC-100 Cable RJ45 Plug both ends "1:1" - 10.0 meters
Wavecom GSM Cable (RJ45 to HD15) for 'S' options, to suit Fastrack Xtend
RJC-ADP-22B
FXT009, and superseded 1205-1306, Supreme 10
RJC-ADP-26 Maxon MM-6280IND 3G Cable (RJ45 to DB15) for 'S' options
RJC-ADP-27 Motorola Satellite Series 9522 L-Band Cable (RJ45 to DB25) for 'S' options
RJC-ADP-30 Trio "M" series radio Cable (RJ45 to DB15) for 'L' option
RJC-45/12 RJ45 to RJ12 Phone Lead - 2.0meters
RJC-X-OVER Serial RJ45 to RJ45 cross over cable - 1.5 meters
RJC-ETHER-X-OVER Ethernet RJ45 to RJ45 cross over cable - 2.0 meters
CAB-OPTION-J Image Capture Option cable - SMB to BNC female - 2.5m
CAB-IO-1 External I/O cable - 1m
CAB-IO-2 External I/O cable - 2m
CAB-IO-5 External I/O cable - 5m
CAB-FO-PATCH-1 Patch Cable for A3 Ethernet Option Board (MTRJ to ST)
CAB-FO-PATCH-2 Patch Cable for A3 Ethernet Option Board (MTRJ to SC)

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RTU Test Cables

RJC-X-OVER: Kingfisher Plus+ RJ45 to RJ45 RS-232 Null Modem Cable (serial
crossover)

RJ45 to Kingfisher RTU Serial Port RJ45 to Kingfisher RTU Serial Port

RJC-ETHER-X-OVER: Kingfisher Plus+ RJ45 to RJ45 Ethernet Crossover Cable

RJ45 to Kingfisher RTU Ethernet Port RJ45 to Kingfisher RTU Ethernet Port

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Device Cables and Adaptors

ADP-04: PC-1/MC-1 Radio Port to Tait T2010 or Maxon RDM-01 Radio (SD125)

RJ45 to Kingfisher RTU Radio Port To Tait 2010 or Maxon RDM-01 radio

ADP-05: RTU Serial Port to PC Serial Port (creates a null modem cable)

To Kingfisher Serial Port To PC Serial Port

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ADP-07: RTU Serial Port to External PSTN Modem

To Kingfisher Serial Port To PSTN Modem

ADP-08: RJ45 to DB9 Female Converter (Straight Connect)

(Note: when coupled with an ADP-05 forms a null modem cable DB9 female to DB9 female)

To Kingfisher Serial Port To External Device

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ADP-08-M: Serial Port to Digi External Spread Spectrum Radio

For Digi XTend-PKG or XStream-PKG, and other 3rd party radios.

To Kingfisher Serial Port To External Radio

ADP-09: Serial Port to HITECH or Nematron Display Panel

To Kingfisher Serial Port To Operators Panel

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ADP-16: Serial Port to Trio D-Series Radio or Trio E/K/M Series Radio
Hardware flow control supported.

To Kingfisher Serial Port To Trio Radio

RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio

For TC-450SR, TC-900SR or RTU Serial Port to Trio S-Series Radio with 24/48SR modem.

To Kingfisher Serial Port To Trio Radio

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RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125)

To Kingfisher Serial Port To Maxon Radio

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RJC-ADP-20: CP-xx Line Option Board to Trio S Series Analogue Radio

For use with TC-450SR or TC-900SR.

To Kingfisher Serial Port To Maxon Radio

RJC-ADP-21: CP-xx Line Option Board to Tait T2010 Analogue Radio

To Kingfisher Serial Port To Tait Radio

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RJC-ADP-22B: Serial Port to Wavecom GSM

For use with the WM02-G900, Fastrack, Fastrack Supreme, or Fastrack Xtend.
Note: Adds a RTS/DTR link to the previous RJC-ADP-22 cable. Link required for Fastrack
Supreme. Link will also work with the older WM02-G900 and Fastrack modems.

To Kingfisher Serial Port To GSM or GPRS Modem

RJC-ADP-23: PC-1/MC-1 Radio Port/Serial Port to Trio S- Series (SB) Repeater

To Kingfisher Serial Port To GSM or GPRS Modem

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RJC-ADP-26: Serial Port to Maxon MM-6280IND 3G Data Modem

(previously used for the Maxon MM-5100 CDMA Modem)

To Kingfisher Serial Port To 3G Data Modem

RJC-ADP-27: RTU Serial Port to Motorola 9522 Satellite Transceiver

To Kingfisher Serial Port To Satellite Transceiver

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ADP-28: RTU Serial Port to Trio H–Series Spread Spectrum Radio

To Kingfisher Serial Port To Trio Radio

ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR450
For hardware flow control see the ADP-16.

To Kingfisher Serial Port To Trio Radio

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RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio (no modem
fitted) E.g. MR450

To Kingfisher Serial Port To Trio Radio

ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g.
MR450

To Kingfisher Serial Port To Trio Radio

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CAB-FO-PATCH-1: A3 Ethernet MTRJ Fibre Optic to 2 × ST adaptor cable

To Kingfisher A3 Option Board To external Device

CAB-FO-PATCH-2: A3 Ethernet MTRJ Fibre Optic to 2 × SC adaptor cable

To Kingfisher A3 Option Board To external Device

Maxon Intermax: Serial Modem to Kingfisher Serial Port

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16. ACCESSORIES
Accessories are available that can ease the installation of your RTU. These include
rack mounting hardware and battery carrier mounts.

MBR-3: 19” Rack Mounting for BA-12-PLUS

A 12 slot backplane (BA-12-PLUS) is mounted in a 19 inch rack using two MBR-3 mounting
brackets. The MBR-3 brackets replace the surface mount brackets supplied with BA-12-
PLUS backplanes. Each pair of MBR-3 brackets is supplied with four M4 x 6 mm pan head
screws.

Installation Note
The holes in the MBR-3 brackets that are used to attach the brackets to the back of the
backplane are drilled oversize to accommodate slight variances in racking equipment. By
loosening these screws, pushing the brackets toward the centre of the backplane and then
re-tightening the screws, the unit will fit freely into any correctly sized 19-inch rack.

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TEL-RAK-002: 19” Rack Mounting for BA-4/6/40

A four slot backplane (BA-4 or BA-40) or a six slot backplane (BA-6-PLUS) is mounted in a
19 inch rack using a TEL-RAK-002 mounting bracket. One BA-6-PLUS or two BA-4/BA-40
backplanes can be attached to the TEL-RAK-002 using the surface mount brackets supplied
with each backplane. The TEL-RAK-002 is supplied with eight M3 x 5 mm screws for
attaching the backplane(s).

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Battery Bracket: 7 Ah Battery Mounting Bracket

When using a 7 Ah backup battery, a standard battery holder is available for mounting on an
enclosure gear plate. The bracket supports the battery and allows a General Power Outlet
(GPO) to be mounted on the front using M3 x 10 mm pan head screws. The battery holder
also allows an ISB50LN lightning arrester to be mounted underneath.

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17. GLOSSARY
Terms and Abbreviations

Analogue Input, Analogue Output, Digital Input and Digital Output

AI, AO, DI, DO
respectively

A group of 8 bits. Each bit can be a 0 (off) or a 1 (on) allowing up to 256

Byte
combinations.

Comms Communications

Current Sinking Current is supplied into the RTU’s IO terminal.

EMI Electro-magnetic interference

Functional Earthing of a point in a system, which is necessary for a purpose other

Earthing than safety.

IO Input / Output

LED Light-emitting diode

N-FET N-channel Field Effect Transistor

Port A physical connection or socket on an RTU used for communications

Processor Module Processor module containing a CPU (Central Processing Unit)

Refers to the format of messages that may be passed to, from and
through an RTU in communication with local and remote devices.
Protocol Communications may use one or more RTU ports.
Examples of protocols used within telemetry include Kingfisher, Modbus
and DNP3.

Remote Terminal Unit. Describes a group of processor, communications

RTU and IO modules that comprise a device for monitoring and control of
equipment in remote locations.

Transfer Control Protocol / Internet Protocol. Commonly used for

TCP/IP
Ethernet communications.

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Symbols

The module can only be used in not-tropical climate regions.

The module can only be used at altitude not exceeding 2000 metres above
sea level.

This point can be used for Functional Earthing connection.

The module is Class II Equipment

The module is Class II Equipment with Functional Earthing

DANGER.
Failure to follow these instructions could result in death or serious injury.

WARNING.
Failure to follow these instructions could potentially result in personal injury or
death.

CAUTION.
Failure to follow these instructions could potentially result in product damage.

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18. APPENDIX A: SYSTEM INSTALLATION

Superseded items are not present in this hardware manual.
For information regarding any modules not present in this document please refer to the
Superseded Products Manual available on Semaphore Helpdesk.
To avoid fire hazards and exposure to electrical shock and other safety hazards, all
instructions listed below must be followed.

Enclosure Requirements
All components of a Kingfisher Plus+ RTU shall be installed inside of an enclosure providing
safety and environmental protection as required. The enclosure shall be made from metal or
other material with a flammability rating of V-0 or better in accordance with the requirements
of the IEC 60950-1 standard for a fire enclosure. An enclosure not required to prevent a fire
hazard if the RTU is installed above concrete or another non-combustible surface.
An RTU shall be mounted with all modules in a vertical position as illustrated below. The
enclosure must provide sufficient clearances for conventional air cooling, with a minimum
clearance of 100 mm between the RTU modules and the top and bottom of the enclosure:

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RTU Installation Example

1. Vent must be installed if enclosure has a battery.
Install a second vent in lower right corner if battery capacity exceeds 26 Ah or if
environmental conditions require greater airflow.
2. Install Backplane low enough to allow for airflow through modules.
3. Radio or Modem.
Note: Radio or Modem can be mounted on rear of door by using DIN rail. Ensure that
the radio is mounted on the top left corner of the door to allow radio to clear the RTU
modules when the door is closed.
4. Gear plate.
5. PSU-x AC Power Supply Unit.
6. Power cable strain relief.
Note: Kingfisher Plus+ modules do not specifically allow for wire strain relief, however,
cable ties can be attached to the enclosures of the modules via the venting slots, or a
self-adhesive cable tie mount can be affixed onto the housing frame.
7. Slotted duct (20 × 60 mm).
8. IO wiring terminal.
9. Double GPO.
One outlet for the RTU and a spare for a laptop. When 7 Ah battery is used, DGPO is
mounted on side of battery bracket (available from your supplier).
10. Lightning arrester. Install high enough to allow easy access for antenna lead connection.
11. Battery bracket. Can rest on front lip of enclosure.
12. Earthing stud. Ensure GPO, Backplane and lightning arrester are connected to this point
using appropriate earthing methods.

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13. Leave at least 30 mm clearance to allow room for glands and cables.
14. Cable glands mounted through gland plate.
15. Enclosure must not contain openings in this area to avoid fire risk to external
environment.

Mains Power Connection

Only appropriately qualified and trained personnel can install and service this equipment.
Mains Power must be connected in accordance with local national wiring rules and
regulations. Building installation shall provide appropriate short-circuit backup protection
rated not higher than 20 A and with a breaking capacity of at least 1500 A.
Always remove input mains voltage (by disconnecting power cord from the mains power
outlet or by switching off an external circuit breaker, depending on installation) before
performing any operation on this product. Failure to do so may cause fire and may result in a
serious personnel injury or even death.
Disconnect power cord from the Power Supply Module and wait for its LEDs on the front
panel to go OFF before wiring, removing or servicing.

Warning
For PERMANENTLY CONNECTED EQUIPMENT, a readily
accessible disconnect device shall be incorporated in the building
installation wiring.
For PLUGGABLE EQUIPMENT, the socket-outlet shall be installed
near the equipment and shall be easily accessible.

Earth / Ground Conductors

Earth / Ground conductors should be connected in a tree fashion with branches routed to a
central earth ground point. This ensures that no ground conductor carries current from any
other branch. This method is shown in the following figure.

PROGRAMMING RTU CABINET MOTOR DRIVES MACHINERY

AND OTHER
DEVICE
BACKPLANE ELECTRICAL
CONTROL
BACKPLANE EQUIPMENT

NOTE: SIGNAL AND POWER

CONNECTIONS NOT SHOWN CENTRAL GROUND POINT

EARTH GROUND

Recommended System Grounding

Earth / Ground conductors should be as short and as large in size as possible. Braided
straps or ground cables (typically green insulation with a yellow tracer - AWG #12 / 5 mm2 or
larger) can be used to minimise resistance. Conductors must always be large enough to
carry the maximum short circuit current of the path being considered.

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Protective Earth / Ground

Although safety of the Power Supply Module and other modules with the potentially
hazardous voltage levels have been assessed and found to be in compliance with the
appropriate requirements, an additional level of protection from a potential electrical shock
can be provided by connecting the RTU backplane to the Protective Earth / Ground.
The Earth / Ground rail of the backplane PCB can be grounded by mounting screws to the
metal back-plate of the backplane when properly installed. Additional grounding wire straps
should be used in case reliable screw connections cannot be assured. Earth / Ground
connections should be made from one of the PCB mounting tabs to a system earth / ground
terminal (usually a threaded stud) using a minimum AWG#12 wire and ring terminals. Use of
a nut and star washer for each wire on the ground connection lug is recommended to ensure
adequate grounding. Ensure the paint coating is removed under the lug to make good
electrical contact.
All backplanes grouped together in a RTU system must have a common ground connection.
This is especially important for backplanes that are not mounted in the same enclosure.
The best way to provide proper ground connections is to ensure that the RTU backplane
metal frame is directly connected to the mounting panel (or rear plate) by connecting a
ground strap from one of the ground lugs on either side of the backplane to the mounting
panel or cabinet in accordance with local safety requirements.

Functional Earth / Ground

Yellow / Green wire in the mains power cord provides only Functional (NOT Protective)
Earth / Ground connection and cannot be relied upon for safety purposes.

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