module description cpr-041

CPR-041 Module Description

Features

32 Bit Processor, 64 MHz

Ethernet Interface

4 Serial Ports

256 physical channel I/O processing capability

Designed for substation environment

Certified to Power Industry Standards

1 millisecond time Stamping

Flexible Communications: - Remote Communications - Local Serial Communications (IEDs)

- Local Diagnostics

XCell LAN Interface

20-72V DC Operation

CELL PROCESSOR MODULE

Contact:

[email protected]

www.microsol.com

No part of this document should be reproduced without the prior approval of Microsol

Introduction

The Cell processor is the core building block of the XCell product. It supports up to four I/O modules but can operate as a stand-alone module supporting serial communication and software applications. Its functions may include:

I/O Monitoring and Control IED Interfacing Control Applications SCADA Communications Protocol Conversion Cell processors may be networked using the onboard LAN to provide larger and more powerful systems.

4 Serial Ports

FrontPanel

Interface

BackplaneInterface

NetworkInterface

Processor

Flash andRAM

10/100 Mbit Ethernet

Fault Relay(Watchdog)

IsolatingDC/DC Converter

Battery Backed

Real Time Clock option

CPR-041 Module Description Rev 1.3

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Communications Interfaces The CPR-041 Cell Processor Module has excellent communications capabilities. It supports four serial communications ports, each utilizing an industry standard 9-way D-type connector, plus a 10/100 Base-T Ethernet port utilizing a standard RJ-45 connector.

The four serial ports support the RS-232 standard and port number four is software selectable between RS-232, RS422 and RS-485 standard.

All of the serial data ports can support bit rates of up to 115,200 bits per second.

Each port supports the standard modem signals, Transmit Data (TxD), Receive Data (RxD), Request to Send (RTS) and Clear to Send (CTS). Data Carrier Detected (DCD) is also supported on Ports 3 and 4. Rx and TX LEDs are provided for each serial port and located below the port as shown in the diagram below.

All 4 serial ports can be used for protocol communications; however, port 1 is usually reserved for diagnostics and configuration. The default usage of each port is as follows:

Connector 1 Monitor / Flash Download / Workbench Configuration / Protocol 1

Connector 2 Protocol 2 Connector 3 Protocol 3 Connector 4 Protocol 4

The diagram below shows the port designations on the CPR-041 front panel. The connections are summarized in the tables to the right.

All 4 ports have a +/-12V supply available for powering external communications devices such as line drivers or line isolators. Each port can provide 100mA at +12V DC and 100mA at 12V DC with overcurrent protection.

NOTE: As a +/- 12V DC supply is provided on each of the serial ports, particular care must be taken when making external connections to these pins.

LEDs are provided for the Ethernet interface with the following functionality:

LK Link Connected Act Rx/Tx Activity LED A 10Mbit / 100Mbit Mode (ON = 100Mbit; OFF = 10Mbit) B Unused

Connector 1 (Port 1)

Pin Function 1 2 RxD 3 TxD 4 5 GND 6 -12V 7 RTS 8 CTS 9 +12V


Pin Function 1 2 RxD 3 TxD 4 5 GND 6 -12V 7 RTS 8 CTS 9 +12V


Pin Function 1 DCD 2 RxD 3 TxD 4 5 GND 6 -12V 7 RTS 8 CTS 9 +12V


Pin Function* RS232 Function*

RS485 Function*

RS422 1 DCD 2 RxD Rx422A 3 TxD TRx485B Tx422B 4 5 GND GND GND 6 -12V -12V -12V 7 RTS TRx485A Tx422A 8 CTS Rx22B 9 +12V +12V +12V

* Note Connector 4 is software selectable between RS-232 and RS-485.

Figure 1 - CPR-041 Communications Ports

Connector 3

Connector 2

Connector4

Connector 1

Ethernet LEDs

RX/Tx LEDs Ports 1 and 2

RX/Tx LEDs Ports 3 and 4


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Communications Interfaces


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Power On Sequence Check Once the CPR-041 Processor Module has been inserted into the rack it may be switch on using the ON/OFF switch on the module front panel. When the processor module has been turned on it will quickly go through its Power On Self Test (POST) sequence.

The Power On Self-Test sequence comprises three main segments, all of which MUST be successfully executed if the processor is to operate correctly.

1. A sequence of three character indications and three digit numbers are displayed on the processor 3-Character display starting with the characters CPU and finishing with the number 300. The following list is indicative of what is displayed. Other numbers may be seen on the display very briefly during the power up sequence but the following are the main points to be observed:

CPU BUG LD 100 FFS 105 200 300

2. The 128 LED Matrix cycles through all of the LEDs, ON and OFF.

3. Lastly a short sequence of 3 digit numbers are displayed finishing with the number 350 and reverting to the cell network number after a few seconds (the default cell network address is 001).

Please note it is VERY important that the cell processor displays the number 350 before displaying the unit number. If the number 350 is NOT displayed after the cycling of the LED matrix the cell has not started correctly.

Following a successful power up the following LEDs on the cell processor front panel should be active:

Active LED - Flashing while the processor is active

On Line LED

- Off if the processor is not communicating with other processors on the network

- On if the processor is communicating with other processors on the network

The 3-Character message display should be displaying the current unit number. Every unit on the XCell network must have a unique address. This address may be changed using the AUN menu option available from the Function Button immediately after startup. For further details refer to the AUN section under Function Menu below.

Operator Interface A number of important parameters must be set using the processor front panel Function Menu for correct system operation. The most important of these being the processor address / unit number. Other operating parameters are configured and downloaded from a PC using Microsols Workbench configuration tools. All front panel configuration options are described under the Function Menu options below.

XCell Operator Interface

The XCell Front Panel (Figure 2), has a number of different display sections:

Status LEDs 3 Character Display 128 LED Matrix Function Button


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Status LEDs

A pair of green status LEDs provides information about the state of the cell.

Active LED The software toggles this LED in normal operation to indicate that the processor is functioning.

On-Line LED This LED indicates that the processor is communicating with other active cells on the FieldNet network.

3-Character Display

This 3 x 7-segment display is used to display:

Unit Number Message Codes Function Menu options

- Unit Number In normal operation, the Cell address or unit number is displayed in this section.

- Message Codes Message codes are used to convey operational information to the user. They generally convey system or operational problems. They are displayed in place of the normal Cell address and will remain on display for approximately 1 minute unless canceled or replaced by another message.

- Function Menu The 3-Character display may also be used in conjunction with the Function Button to provide a Function Menu for a variety of user diagnostics and configuration parameters. Refer to the section on Function Menu for further details.

LED Matrix

This display, which comprises 128 LEDs, is used for a number of purposes as selected by the Function Button Menu. These include:

I/O Display Online Units Display Debug Display I/O Display Generally this LED matrix is used to display the status of the hardwired I/O. Each LED represents a physical hardware channel within that cell. For digital inputs and outputs the state of the LED indicates the state of the physical input or output. If the LED is ON, it indicates that the input or output is ON, and if the LED is OFF the input or output is OFF. For analogue input channels, the LEDs cycle through each of the channels indicating that the channels are being scanned. The cycle speed of the LEDs does not always correspond to the scan rate of the particular module. For HSC Counter modules, the LEDs cycle through the corresponding channel LEDs to indicate that the channels are present and being processed. The LED cycle on the HSC module is much faster than for analogues.

Online Units Display The LED Matrix can be used to display the active units communicating on the FieldNet LAN. Each LED represents an XCell Unit address. Note: For display purposes those units with addresses greater than 128 will have their LEDs overlap with those in the range 1-128.

Debug Display The matrix can also be used for specific application debug information. Some protocols update the Debug LEDs to provide user information on the current state of the protocol operation. Refer to the specific applications for further information on the use of the Debug Display.

Figure 2 - CPR-041 Operator Interface


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Function Menu

Function Button Operation

The function button drives the function menu. The function button is used to:

Move through the menus/sub menus Select an option Increment a value Exit an option Accept a setting Remove a system message

The message display shows the menu options and settings, which can be changed using the function button.

The function button should be pressed and held pressed for:

A count of one (1 seconds)

To remove a system message from the display When moving through the menus/sub menus When incrementing a value within a menu option e.g. AUN

A count of three (3 seconds)

When selecting an option from a function menu/sub menu When accepting a value while in an menu/sub-menu To exit a menu

Removing a Message from the Message Display

Message Codes may be displayed in the 3-character message display on the front panel of the processor. The Message Code is generally comprised of a three letter code and a three digit numeric code. The 3-character Display alternates every two seconds, between the alpha and numeric codes. The three letter alpha code identifies the software application that generated the message and the three digit numeric code identifies the exact message. Only the most recent message is displayed at any given time.

To remove a Message Code from the 3-Character Display:

Press the function button and hold for a count of two (2) before releasing it Wait for two (2) minutes and it will automatically be removed.

NOTE: Message Codes are also logged to an internal buffer that can be viewed using Workbench RTU Live option. These messages are stored in dynamic RAM and are not maintained during power down or reset.


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Function Menu Options

The following diagram shows the menu functions available for the CPR-041 cell processor and any limitation that may apply to the individual functions (many options, those inside the large rectangle, are only available during the first 10 seconds after the cell processor has rebooted).

Available for 10 seconds after boot

only.

These options are only used if the IEC-60870-5-

101 Master or Slave protocol named blocks are loaded into the cell

processor firmware

AUN

SCL

OR

DLT

CAL

HYS

TBL

RTU

C04

NET

SHC

LED

FSD

SAV

GPA

GPB

OLU

DBG

FFS

Figure 3 - CPR-041 Menu Option Tree

AUN Adjust Unit Number

This option is used to set the processor node address for FieldNet network communications. All units in a system must have unique numbers in order to communicate on the network. This is displayed by default on the 3-character display on the front of the processor.

The AUN option is only available from the function menu for 10 seconds after boot up. After this time the option is automatically removed from the menu.

On an XCell network, units can be numbered from 1 to 250. Unit numbers 251-254 are reserved for the Workbench configuration system and 255 is a broadcast address and must not be used.


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To change the unit number:

Select the AUN, (Alter Unit Number), option from the function menu. Each of the 3 digits in the unit number must be changed separately starting on the right

hand side.

Increment each digit in the message display until the desired value is displayed. Hold the function button to accept the required digit and then proceed to set the next digit. The unit number must be between 1 and 250, numbers 0 and 251-255 are reserved for system purposes.

Accepting the value on the third digit will save the new Unit Number and proceed to reboot the processor with the new network address accepted.

SCL Set Default Analogue Scaling

This menu option is only used in systems where no analog tables are downloaded from Workbench and therefore, is not generally used.

CAL Set Factory Analog Calibration Range

This defines the factory-calibrated range of the analogue input modules fitted in this unit. This is usually set to 021 (21mA). This, plus the OR (Over-range) value should equate to the maximum input range of the analog input module.

NOTE: This option is only relevant if the cell contains one or more Analog Input modules.

OR Over-range

This defines the percentage of over-range that will be included above the nominal maximum for analog values. This is generally set to 0%, 000.

DLT Set Analogue Delta Change as % of Scale

This menu option is only used in systems where no analog tables are downloaded from Workbench and therefore, is not generally used.

HYS Hysteresis

This menu option is used to specify the amount of hysteresis around the maximum and minimum configured analog range values for setting the out of configured range flag. This is to stop excessive change messages for inputs oscillating around the maximum or minimum end of the range. This hysteresis is applied to the out of configured range side of the analogue range. It is specified as a percentage of the configured range multiplied by 100 (i.e. 100 = 1%) and has a range of 0.00% to 9.99% (default = 100).

For example if an analogue channel has been set to a range of -10mA +10mA, and HYS set to 100 (or 1%). Then if the current is slowly decreased to -11mA we would get the out of range flag set at -10.2mA (range = 20mA) and if we increased the current again the flag would not be cleared until the value is increased to -10.0mA. Similarly the flag will be set as the current is increased to above +10.2mA and cleared when it is reduced below +10.0mA.

NOTE: This option is only relevant if the cell contains one or more Analog Input modules.

TBL Tables

This menu option and the RTU option below are used by processors with IEC-60870-5-101 Master or Slave protocol firmware installed. The TBL option allows the default IEC-60870-5-101 link configuration to be set from the front panel without downloading tables from Workbench. Refer to the IEC Master/Slave configuration Guide for further details.


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RTU RTU Number

This menu option and the TBL option above are used by processors with IEC-60870-5-101 Master or Slave protocol firmware installed. The RTU option allows the default Slave link-address to be set from the front panel. Refer to the IEC Master/Slave configuration Guide for further details.

CO4 Configure Serial Port 4 Physical Interface

The CO4 option allows the user to set the physical interface for serial port 4 on the CPR-041.

There are three options available:

232 - RS232 Interface 485 - 2 Wire RS485 Interface 422 - 4 Wire RS485 or RS422

NOTE: Even when the serial port is configured for RS422, the RTS line MUST be made active before packets can be sent out of the serial port. The protocol implementation must support RTS control.

NET Default Configuration of the TCP/IP stack

This option provides a way to enter a default TCP/IP configuration via the front panel without having to download a configuration table.

There are two sections to the NET configuration. These are:

BootP Default IP Address

BootP can either be turned ON or OFF, if it is turned ON, the units IP address is obtained from a Bootp/DHCP server automatically when the unit starts up. If BootP is turned OFF, then a default Class C IP address can be entered via the front panel.

The default IP address is split into 4 parameters:

IP1 - The first IP byte address IP2 - The second IP byte address IP3 - The third IP byte address IP4 - The fourth IP byte address

The configured default IP address, needs to be a valid Class C IP address, as the netmask is set internally by the processor.

SHC Show Hardware Configuration

The SHC option in the function menu allows the operator to view and save the type of I/O associated with the processor. Each processor module supports 4 Plant Interface modules located to the right of the processor. Some of these modules support two sub modules (daughter modules mounted on the main module). Therefore, the processor maintains 8 configuration definitions, one for each of the 8 possible hardware modules. The eight possible locations are shown in the following diagram. As most modules occupy two slot positions the same module type will be displayed for both locations.


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The SHC option displays the current hardware modules installed in the cell and the previously saved configuration. The processor operates with the saved configuration and assumes that this is the required configuration. If there is a mismatch between the saved configuration and the currently installed module it is assumed that the module is faulty and will report all associated channels as failed. It will also set a pseudo point indicating that the module is faulty and this can be transmitted to a Control Center. It is therefore very important to save the required configuration (using the SAV option at the end of the SHC display) before using the system. The required configuration should be saved for each cell as part of the initial system setup.

The SHC option in the function menu identifies the hardware in each half-card position (8 per cell) as shown above. These positions are referred to by their slot positions in the 3-character display panel (001 008). The majority of cards occupy a full card position and will therefore display the same module type for both half-card positions.

When the SHC option is selected the 3-character display shows the hardware installed in the first Slot position. It does this by toggling the display between the slot number 001 and the module type installed in that slot. For example it may toggle between 001 and DI6 to indicate that a 64 channel Digital Input module is present in slot position 1 (the top half card of the first board). Refer to the following table for abbreviations used for the various module types.

Type Description

UNC Unknown module or No module present in slot

DI6 High Density Digital Input module

DO4 High Density Digital Output module

AI3 High Density Analogue Input module

HSC High Speed Counter module

HA5 High Density Analogue Input Card (HAI-050)

AOI Isolated Analogue Output module

AOT Analogue Output Card

NOTE: This option is timed and it automatically exits if there is no button pressed for more than 30 seconds.

Using the function button the user can move through all 8 possible slot positions. If the cell hardware does not match the saved configuration then the SHC option will first display the current hardware for a particular slot followed by the saved configuration for the slot. The display of the current hardware will toggle between the hardware type and the slot number prefixed by the letter C. For example if the current hardware in slot 1 is an interrupting Digital Input module then the display will toggle between C01 and DI6. The saved hardware display is similar except that the letter S prefixes the slot number.

I/O Slots in a cell

S

L

O

T

1

S

L

O

T

2

S

L

O

T

3

S

L

O

T

4

S

L

O

T

7

S

L

O

T

8

S

L

O

T

5

S

L

O

T

6


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Following is an example of a saved configuration, which does not match the current hardware.

Current Hardware

Saved Hardware

Front Panel Displayed

Front Panel Displayed

DI6

HDO

HAI

DI6

HDO

HAI

DI6

DI6

Slot 1

Slot 2

Slot 3

Slot 4

Slot 5

Slot 6

Slot 7

Slot 8

C01 DI6

C02 DI6

C03 HDO

C04 HDO

C05 AI3

C06 AI3

007 DI6

008 DI6

S01 HDO

S02 HDO

S03 AI3

S04 AI3

S05 DI6

S06 DI6

007 DI6

008 DI6

Table 1 - Sample Hardware Configuration

To exit the SHC option or any other option, hold the Function Button for a count of five (5) or greater. Exiting the SHC option will present the SAV option and at this point the user may save the hardware configuration by holding the Function button or simply scroll back to the default display by briefly pressing the Function button.

The SAV (Save Hardware Configuration) option saves the current hardware modules as the required configuration. If one of these modules is subsequently removed then a fault will be generated. The cell will automatically reboot after the SAV option has been accepted.

NOTE: A Cell Processor can only interrogate slots within its own cell.

While the hardware configuration must be saved through the front panel on each processor individually before use, it can be viewed through Workbench for all processors.

NOTE: Workbench can be used to view the hardware configuration on all processors.

NOTE: This option is timed and it automatically exits if there is no button presses for more than 30 seconds.

LED LED Matrix Display Operations

This option (LED) allows the operator to select the 128 LED matrix on the front panel of the processor module for displaying the status of the I/O channels associated with the processor. The options are detailed in the following sections. GPA (Group A)

If GPA is selected, the LED matrix will represent the first 128 I/O channels (channels 0-127) on the cell. I/O channel 0 will be displayed using the top left LED of the matrix (1a) with the sequential channel numbers incrementing down and to the right (e.g. column a will display channels 0-15, column b, channels 16-31 etc). GPB (Group B)

If GPB is selected, the LED matrix will represent the second 128 I/O channels (channels 128-255) on the cell. I/O channel 128 will be displayed using the top left LED of the matrix with the sequential channel numbers incrementing down and to the right (e.g. column a will display channels 128-143, column b, channels 144-159 etc).


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FSD Field Service Data

The Field Service Data options (FSD) allows the operator to select the 128 LED matrix on the front panel of the processor module for displaying diagnostic information. The Field Service Data options are detailed in the following sections. OLU - On Line Units

If OLU is selected, the LED matrix will represent all units that can be seen on the FieldNet network. The LED corresponding to each unit number is illuminated if that unit is communicating on the network. As the LED matrix is limited to 128 LEDs, the unit numbers wrap around on the LED matrix at unit 129. The top left hand LED (LED [1a] in the matrix) is turned on by units 1, or 129. DBG - Debug

If DBG is selected the cell processor uses the LED matrix to display internal status information for a variety of software modules that may be loaded into the firmware. A mnemonic representing the module concerned is displayed on the message display and the individual LEDs in the matrix show specific status indicators for the module. FFS Flash File System

If FFS is selected the current contents, sector by sector, of the flash file system on the cell processor is displayed on the LED matrix. This is a map of the currently used flash memory area and includes both active and inactive files or data. Each sector (indicator LED) of the flash file system is 64k bytes in size.


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Monitor Port The CPR-041 has a realtime monitor program running on Port 1. This provides customers and field service personnel access to basic diagnostic information through a terminal interface. Detailed user instructions are contained in the CPR-041 Monitor Users guide. Further diagnostic functionality is available through the Workbench PC Application. Refer to the Workbench User Manual for more details.

Connecting to the Monitor/Workbench Serial Port

Connect to the XCell serial Port 1 using the following connections.

XCell Port 1

Pin

PC Com Port Pin

2 - Rx 3 Tx

3 - Tx 2 - Rx

5 Signal Gnd 5 Signal Gnd

Ethernet Port Configuration

Configuration of the Ethernet port can be done using the NET option on the front panel Function Menu Options described previously or using the TCP/IP configuration table in Workbench, refer to the Workbench I/O Configuration Manual for further details.

Figure 5 PCXCell Cable

Figure 4 - Monitor Communications Port

Comm 1 - Monitor

Port

1 6 2 7 3 8 4

1 6 2 7 3 8 4

XCell DB-9 PC DB-9


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Technical Characteristics Data Acquisition and Processing No. of physical channels 256 Time stamping 1 ms Timer functions Real Time Clock, Calendar Clock (Battery backed up optional) Internal Clock Drift 8.64 s / day Internal Clock Drift with optional TCXO 0.173 s / day Fieldnet Network 5 Mbit / s Module Related Data Processor 32 bit, 64 MHz Motorola processor FLASH Up-to 16 Mbyte (standard 4 Mbytes) SRAM 32 MByte Battery backed up Expansion RAM 32 Kbytes (optional) Power Supply Nominal Input Voltages 24 V, 48 V, 60 V DC Supply Voltage Range 20 to 72V DC Output Power for entire cell 20 W @ 25 C CPR Power Consumption 5 W Supply type Positive or negative earth systems Isolation (supply to cell electronics) 2.5 kV Indications, Controls and Diagnostics Single LEDs Active (green), On Line (green) Seven segment displays (3) Cell Number, Cell Diagnostics 128 LED Matrix Status of associated Inputs and Outputs RS232 LEDs RX & Tx Ethernet LEDs 3 LEDs used - Link connected, Activity, 10/100MB operation On/Off Switch Power On/ Off to Cell Function Push Button Interrogate cell to determine status Watchdog / Fault Indication Output Contact opens on Fault, 150mA / 72 VDC Electrical Noise Immunity Electrostatic Discharge IEC 61000-4-2 15 kV RFI Susceptibility EMC Compliance Fast Transient disturbance High Frequency disturbance UK National Grid Company NGTS 2.13

IEC 61000-4-3, CISPR 22 10 volts/m 50 kHz to 1000 MHz IEC 60255-22-3, EN50082-2 IEC 61000-4-4 Class 4 and C.37.90.1 IEC 60255-22-1 Class 3 and C.37.90.1 Class Z

Environmental Conditions Temperature Continuous Operation Transportation and storage

IEC 60068-2-1 & IEC 60068-2-2 -10 to +60 C -40 to +70 C

Relative Humidity Vibration Drop & Topple

0 to 95% Non condensing in accordance with IEC 60068-2-3 & IEC 60068-2-30

IEC 60068-2-6 IEC 60068-2-31

MTBF MTBF for continuous operation at average temperature of 40C

127,998 hrs

Dimensions and Mass Dimensions (W * H * D) 8 hp x 6U (1.6 x 10.5 x 6.7 inches) / (40.6 x 266.7 x 170 mm) Weight Approx. 0.55 lbs / 250 grams Ethernet Speed Physical Interface

10 / 100 Mbit Ethernet 100 Base Tx

Serial Ports Number of Ports Speed Physical Interface Signals Supported

4 Up to 115200 3 x RS 232 only and 1 selectable RS 232/RS 422/RS 485 TxD, RxD, RTS, CTS, (DCD on last 2 serial ports only)


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Real Time Clock (optional) Expected Battery Life Accuracy Battery backed SRAM

10 years in the absence of power + 1 minute per month @ 25 degrees Celsius Note 1 32 KBytes

TCXO (optional) Accuracy +2 ppm over 10 to 60 degrees Celsius

Note 1 This clock is used during normal operation; the RTC is only used on startup for the startup time (only to 1 second resolution), after this time is maintained via software and regularly updated into the RTC

Email: [email protected] Web: www.microsol.com

Microsol Ltd. 2004 the information in this document is subject to change without prior notice. Microsol does not assume responsibility for any errors in fact or design in this publication. The publication is provided for general information only and shall not form part of any contract.

module description cpr-041

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baset ethernet port