SCADAPack 535E Hardware

Manual
 2 SCADAPack 535E Hardware Manual

Table of Contents

Part I SCADAPack 535E Hardware Manual 4

1 Technical
...................................................................................................................................
Support 5
2 Safety ...................................................................................................................................
Information 5
3 About this
...................................................................................................................................
Manual 9
4 About...................................................................................................................................
the SCADAPack 535E 11
5 Hardware
...................................................................................................................................
Overview 14
5.1 CPU, RAM and..........................................................................................................................................................
Storage 18
5.2 Pow er Supply..........................................................................................................................................................
and Back-Up Battery 19
5.3 Serial Ports .......................................................................................................................................................... 20
5.3.1 Serial1 and.........................................................................................................................................................
Serial2 Ports 21
5.3.2 Serial3 and.........................................................................................................................................................
Serial4 Ports 23
5.4 Ethernet Ports.......................................................................................................................................................... 26
5.4.1 Eth1, 2, 3 Ports
......................................................................................................................................................... 27
5.5 USB Ports .......................................................................................................................................................... 29
5.5.1 USB Host Port ......................................................................................................................................................... 30
5.5.2 USB Device.........................................................................................................................................................
Port 32
5.6 Inputs and Outputs .......................................................................................................................................................... 33
5.6.1 Digital Inputs ......................................................................................................................................................... 36
5.6.2 Counter Inputs ......................................................................................................................................................... 37
5.6.3 Digital Outputs......................................................................................................................................................... 38
5.6.4 Analog Inputs ......................................................................................................................................................... 39
5.6.4.1 Analog Input Range .........................................................................................................................................
and Resolution 40
5.6.5 Analog Outputs ......................................................................................................................................................... 43
5.6.5.1 Analog Output Range .........................................................................................................................................
and Resolution 44
5.6.5.2 Analog Output Load .........................................................................................................................................
Resistance Requirements 45
5.7 Ground Connectors .......................................................................................................................................................... 46
5.8 Isolation and Protection
..........................................................................................................................................................
Sum m ary 47
6 Installation
................................................................................................................................... 48
6.1 Mounting the ..........................................................................................................................................................
SCADAPack 535E 49
6.2 Pow er Supply..........................................................................................................................................................
Requirem ents 53
6.2.1 Analog Output .........................................................................................................................................................
Pow er Supply Configuration Options 55
6.3 Adding Inputs..........................................................................................................................................................
and Outputs 57
6.3.1 Intermodule.........................................................................................................................................................
Cabling 58
7 Addressing
...................................................................................................................................
and Startup Modes 62
7.1 Setting the RTU ..........................................................................................................................................................
Address for ES Rem ote I/O Operation 64
7.2 Starting in Run..........................................................................................................................................................
Mode 65
7.3 Starting in Service
..........................................................................................................................................................
Mode 66
7.4 Starting in Cold ..........................................................................................................................................................
Boot Mode 68
7.5 Starting in Factory
..........................................................................................................................................................
Boot Mode 70
8 Field ...................................................................................................................................
Wiring 72
8.1 Wiring Screw -Term
..........................................................................................................................................................
ination Connectors 73
8.2 Serial Port Wiring
.......................................................................................................................................................... 76
8.2.1 RS232 Pin .........................................................................................................................................................
Assignments and Cable Descriptions 77
8.2.2 RS232 Wiring
.........................................................................................................................................................
Examples 81
8.2.3 RS485 Wiring
......................................................................................................................................................... 83
 Contents 3

8.3 Ethernet Port ..........................................................................................................................................................

Wiring 84
8.3.1 Ethernet Pin.........................................................................................................................................................
Assignments and Cable Description 84
8.4 Digital Input Wiring.......................................................................................................................................................... 87
8.4.1 Controller Board
.........................................................................................................................................................
Digital Input Wiring Example 87
8.4.2 I/O Board Digital
.........................................................................................................................................................
and Counter Input Wiring Example 88
8.5 Digital Output ..........................................................................................................................................................
Wiring 90
8.5.1 Controller Board
.........................................................................................................................................................
Digital Output Wiring Example 91
8.5.2 Controlling .........................................................................................................................................................
Devices w ith the Controller Board Digital Output 92
8.5.3 I/O Board Digital
.........................................................................................................................................................
Output Wiring Examples 94
8.6 Analog Input Wiring .......................................................................................................................................................... 96
8.6.1 Analog Input .........................................................................................................................................................
Wiring Example 96
8.6.2 Supporting .........................................................................................................................................................
a Mix of Current and Voltage Inputs 98
8.6.3 Helping to .........................................................................................................................................................
Prevent Interruption of the Current Loop 103
8.7 Analog Output ..........................................................................................................................................................
Wiring 105
8.7.1 Analog Output
.........................................................................................................................................................
Wiring Example 105
8.7.2 Supporting .........................................................................................................................................................
Current and Voltage Outputs 108
9 Configuration
................................................................................................................................... 109
9.1 SCADAPack E..........................................................................................................................................................
Configurator 109
9.2 Reading and ..........................................................................................................................................................
Writing Data With Logic Program s 111
10 Diagnostics
................................................................................................................................... 112
10.1 LEDs .......................................................................................................................................................... 113
10.2 Accessing Diagnostics
.......................................................................................................................................................... 116
10.3 Startup Diagnostics
.......................................................................................................................................................... 118
10.4 Internal Tem..........................................................................................................................................................
perature Reading 119
10.5 Pow er Supply ..........................................................................................................................................................
and Battery Status 120
10.6 Com m unication ..........................................................................................................................................................
Statistics 121
10.7 Status Codes.......................................................................................................................................................... 122
10.7.1 System Status .........................................................................................................................................................
Codes 123
10.7.2 Communication .........................................................................................................................................................
and Device Status Codes 125
11 Maintenance
................................................................................................................................... 126
11.1 Calibration .......................................................................................................................................................... 127
11.2 Preventive Maintenance
.......................................................................................................................................................... 128
11.3 Routine Maintenance
.......................................................................................................................................................... 130
11.4 Replacing the..........................................................................................................................................................
Battery 133
11.5 Updating Firm ..........................................................................................................................................................
w are 135
12 Specifications
................................................................................................................................... 135
12.1 General .......................................................................................................................................................... 136
12.2 Pow er Supply .......................................................................................................................................................... 137
12.3 Controller Board .......................................................................................................................................................... 137
12.4 Data Capacity.......................................................................................................................................................... 139
12.5 Com m unications .......................................................................................................................................................... 140
12.6 Digital and Counter
..........................................................................................................................................................
Inputs 141
12.7 Digital Outputs .......................................................................................................................................................... 142
12.8 Analog Inputs .......................................................................................................................................................... 143
12.9 Analog Outputs .......................................................................................................................................................... 145
13 Standards
...................................................................................................................................
and Certifications 146

3
 4 SCADAPack 535E Hardware Manual

I SCADAPack 535E Hardware Manual

Copyright © 2014 Schneider Electric Canada Inc.

All rights reserved.

Version: 8.11.1
Date: November 2014

The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not intended
as a substitute for and is not to be used for determining suitability or reliability of these products for
specific user applications. It is the duty of any such user or integrator to perform the appropriate and
complete risk analysis, evaluation and testing of the products with respect to the relevant specific
application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be
responsible or liable for misuse of the information contained herein. If you have any suggestions for
improvements or amendments or have found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means, electronic or mechanical,
including photocopying, without express written permission of Schneider Electric.

All pertinent state, regional, and local safety regulations must be observed when installing and using this
product. For reasons of safety and to help ensure compliance with documented system data, only the
manufacturer should perform repairs to components.
 SCADAPack 535E Hardware Manual 5

1 Technical Support
Questions and requests related to any part of this documentation can be directed to one of the following
support centers.

Technical Support: Americas, Europe, Middle East, Asia

Available Monday to Friday 8:00am – 6:30pm Eastern Time

Toll free within North America 1-888-226-6876

Direct Worldwide +1-613-591-1943
Email [email protected]

Technical Support: Australia

Inside Australia 1300 369 233
Email [email protected]

2 Safety Information
Read these instructions carefully, and look at the equipment to become familiar with the device before
trying to install, operate, or maintain it. The following special messages may appear throughout this
documentation or on the equipment to warn of potential hazards or to call attention to information that
clarifies or simplifies a procedure.

The addition of this symbol to a Danger or Warning safety label

indicates that an electrical hazard exists, which will result in personal
injury if the instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
6 SCADAPack 535E Hardware Manual

WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can
result in death or serious injury.

CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can
result in minor or moderate injury.

NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, can
result in equipment damage.

PLEASE NOTE
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel.
No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this
material.

A qualified person is one who has skills and knowledge related to the construction and operation of
electrical equipment and the installation, and has received safety training to recognize and avoid the
hazards involved.

BEFORE YOU BEGIN

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective
point-of-operation guarding on a machine can result in serious injury to the operator of that machine.

CAUTION
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.
Before operational tests are performed, remove all blocks or other temporary
holding means used for shipment from all component devices.
Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in minor or moderate injury.

Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future reference.
 SCADAPack 535E Hardware Manual 7

Software testing must be done in both simulated and real environments.

Verify that the completed system is free from all short circuits and grounds, except those grounds
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to help prevent accidental equipment damage.

OPERATION AND ADJUSTMENTS

The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English version
prevails):

Regardless of the care exercised in the design and manufacture of equipment or in the selection and
ratings of components, there are hazards that can be encountered if such equipment is improperly
operated.
It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. Always use the manufacturer’s instructions as a guide for functional adjustments.
Personnel who have access to these adjustments should be familiar with the equipment
manufacturer’s instructions and the machinery used with the electrical equipment.
Only those operational adjustments actually required by the operator should be accessible to the
operator. Access to other controls should be restricted to help prevent unauthorized changes in
operating characteristics.

ACCEPTABLE USE
SCADAPack E Remote Terminal Units (RTUs) and input/output (I/O) modules are intended for use in
monitoring and controlling non-critical equipment only. They are not intended for safety-critical
applications.

WARNING
UNACCEPTABLE USE
Do not use SCADAPack E RTUs or I/O modules as an integral part of a safety
system. These devices are not safety products.
Failure to follow this instruction can result in death or serious injury.

CAUTION
EQUIPMENT OPERATION HAZARD
When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.

For safe and proper operating results, use only Schneider Electric software or
approved software with Schneider Electric hardware products.

Failure to follow these instructions can result in minor or moderate injury.

8 SCADAPack 535E Hardware Manual

Important Notices for Hazardous Locations

Class I Division 2, Groups A, B, C and D

Ex nA IIC T4 Gc

Class I Zone 2 AEx nA IIC T4 Gc

II 3 G

Applies to SCADAPack E products, models TBUP530, TBUP535 and TBUX (CSA Marked)
Those products are available for use in Class I, Division 2, Groups A, B, C & D and Class I Zone 2
Hazardous Locations. Such locations are defined in Article 500 and 505 of the US National Fire
Protection Association (NFPA) publication NFPA 70, otherwise known as the National Electrical Code,
in Section 18 of the Canadian Standards Association C22.1 (Canadian Electrical Code) and in IEC/EN
60079-10.
The products have been recognized for use in these hazardous locations by the Canadian Standards
Association (CSA) International.
CSA certification is in accordance with Standards CSA C22.2 No. 213, CSA C22.2 60079-0, CSA C22.2
60079-15, ANSI/ISA 60079-0, ANSI/ISA 60079-15, ANSI/ISA 12.12.01, FM 3600 and FM 3611 subject to
the following conditions of approval:
1. Install the product in a protective enclosure providing at least IP54 protection.
2. Confirm that the location is free from explosively hazardous gases before wiring, connecting or
disconnecting the product, using any USB connection or replacing any fuses.

WARNING EXPLOSION HAZARD

Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.
Substitution of components may impair suitability for
Class I, Division 2.
Refer to Articles 500 through 502 of the National Electrical
Code (NFPA 70) and Appendix J of CSA C22.1 for further
information on hazardous locations and approved Division
2 wiring methods.
Refer to Articles 505 of the National Electrical Code
(NFPA 70) and Section 18 of CSA C22.1 for further
information on hazardous locations and approved Zone 2
wiring methods.
 SCADAPack 535E Hardware Manual 9

3 About this Manual

Audience
This manual is written for people who need to install, troubleshoot or maintain the Remote Terminal Unit
(RTU) hardware. These individuals are typically:
Systems Engineers
Commissioning Engineers
Maintenance Technicians

Scope
This manual describes:
The physical design of the RTU, including detailed hardware specifications
The physical design of integrated inputs and outputs (I/O) and the basic requirements for adding I/O
expansion modules
Installation, wiring and addressing for the RTU
Diagnostics capabilities on the RTU
Maintenance recommendations for the RTU

Related Documents
Use this manual with other manuals included in your SCADAPack E documentation set. The table below
lists the main manuals for the tasks described. However, it is not a complete list of the manuals
available to you. Please see the SCADAPack E Reference Manual set for a complete listing of manuals.

For Information About See

The basic steps required to get your RTU up and The Quick Start Guide for your RTU
running

Configuring your RTU to communicate with other SCADAPack E Configurator User

SCADAPack E RTUs and with input and output (I/O) Manual
devices DNP3 Technical Manuals
Protocol Technical Manuals
Communication Interfaces Manual

Configuring security on your RTU Security Quick Start Guide

Security Administrator User Manual
Security Technical Reference Manual

Operating and troubleshooting your RTU SCADAPack E Operational Reference

Manual

Installing SCADAPack E Target 5 Workbench, using it SCADAPack Workbench Quick Start

to build custom applications for the RTU and Guide
downloading the applications to the RTU SCADAPack E Target 5 Technical
10 SCADAPack 535E Hardware Manual

Manuals

Installing ISaGRAF 3 Workbench, using it to build ISaGRAF 3 Quick Start Guide

custom applications for the RTU and downloading the ISaGRAF 3 Technical Manuals
applications to the RTU

Adding I/O expansion modules SCADAPack E I/O Expansion

Reference Manual
SCADAPack System Configuration
Guide
I/O Expansion Module Hardware
Manuals
 SCADAPack 535E Hardware Manual 11

4 About the SCADAPack 535E

The SCADAPack 535E Remote Terminal Unit (RTU) is a smart, microprocessor-based telemetry and
control device that can help to remotely monitor and control physical objects. For example, in a water
management environment, the SCADAPack 535E can be used to monitor and control the valves on flow-
monitoring devices at pumping stations. The RTU's 1 ms Sequence of Event (SOE) event monitoring
capability is well suited to telemetry applications that require high-speed time-stamping and data
capture.

SCADAPack 535E

Roles
The SCADAPack 535E can be configured to play one or more of the following roles in your Supervisory
Control and Data Acquisition (SCADA) environment:
RTU endpoint
DNP3 router between any combination of Ethernet and serial ports
DNP3 peer-to-peer communications device
Data concentrator for:
- Remote DNP3 and DNP3 IP slaves
- Local DNP3, DNP3 IP, Modbus RTU, Modbus TCP and DF1 serial slaves
- Local IEC 60870-5-103 protection relays
Protocol converter for:
12 SCADAPack 535E Hardware Manual

- Modbus RTU and Modbus TCP to DNP3 and DNP3 IP, and vice-versa
- Modbus RTU and Modbus TCP to IEC 60870-5-101/-104
- DF1 to DNP3 and DNP3 IP, IEC 60870-5-101/-104 or Modbus RTU and Modbus TCP
- IEC 60870-5-103 to DNP3/DNP3 IP, IEC 60870-5-101/-104 or Modbus RTU and Modbus TCP

The role your SCADAPack 535E plays in your SCADA environment determines how you should set up
communications to and from the RTU and how you should configure the RTU.

Communications
The SCADAPack 535E includes four serial ports and three Ethernet ports that are available for
communications with the SCADA master system, with other RTUs, with devices such as Programmable
Logic Controllers (PLCs), and with the local configuration software. It also includes a USB 2.0 device
port for local configuration and a USB 2.0 host port that supports plug-in media.

A socket modem port that supports GPRS, 3G or LTE communications with remote devices will be
available at a later date.

The SCADAPack 535E communicates using the Distributed Network Protocol (DNP) 3, IEC 60870-5 and
Modbus protocols.

Inputs and Outputs

The SCADAPack 535E provides 18 digital inputs, nine digital outputs and six analog inputs. Two analog
outputs are also available if the optional analog output module was purchased with the SCADAPack
535E.

I/O can be extended by adding up to 15 I/O expansion modules. The SCADAPack 535E supports the
6601 I/O expansion module which provides the following I/O:
16 digital inputs
8 digital outputs
6 analog inputs
2 analog outputs (this option is selected when the 6601 I/O expansion module is ordered)

Configuration
You can configure the SCADAPack 535E using three different methods:
Locally or remotely using SCADAPack E Configurator 109 , a software application that runs on a
desktop or laptop computer that is connected to the RTU through the USB device port or through any
of the available serial or Ethernet ports.
Remotely as part of an end-to-end SCADA system using the StruxureWare SCADA Expert
ClearSCADA software.
Locally using applications created in the SCADAPack Workbench or ISaGRAF 3 Workbench user
programming tools. Typically, applications created in these tools extend and enhance the functionality
provided by the RTU. However, you can also write applications that replace the configuration
functionality provided through the SCADAPack E Configurator software or the SCADA Expert
ClearSCADA software.

Before you begin configuring the RTU, determine whether the ClearSCADA software will be used for any
configuration tasks. This documentation assumes you are using the SCADAPack E Configurator
software to configure the RTU. For information about using the ClearSCADA software, see the
ClearSCADA documentation.
 SCADAPack 535E Hardware Manual 13

Security
The RTU can communicate using the DNP3 protocol, which is level 4-compliant. The DNP3 protocol
supports the optional DNP3 Secure Authentication (SAv2) features and AGA-12 DNP3 Data Encryption
to help improve message confidentiality.
 14 SCADAPack 535E Hardware Manual

5 Hardware Overview
The figure below shows the locations of the inputs, outputs and ports on the SCADAPack 535E.

SCADAPack 535E Inputs, Outputs and Ports

Generally, power supply ports and input/output (I/O) terminals provide a level of protection against over-
voltages and other conditions. For ease of wiring and maintenance, external connections are terminated
on removable connectors. If you need to remove the RTU cover for any reason, first carefully consider the
following information.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
 SCADAPack 535E Hardware Manual 15

the RTU or the I/O expansion module before removing power.

Failure to follow these instructions can result in death or serious injury.
16 SCADAPack 535E Hardware Manual

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from the RTU before removing the RTU cover.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The electronics inside the RTU can be damaged by static electricity. If you need to
remove the RTU cover, wear an anti-static wrist strap that is connected to ground.
Failing to follow this simple step can cause intermittent or total loss of RTU
operation and will void the warranty.
Failure to follow these instructions can result in equipment damage.

This table below provides an overview of the major hardware components that comprise the RTU. For
complete hardware specifications, see the Specifications 135 section.

SCADAPack 535E Hardware Summary

Controller board

CPU 18 ST SPEAr 1380 32-bit, dual-core Cortex™ A9

microcontroller
Up to 600 MHz

Memory 18 128 MB NAND Flash

128 MB DDR3 RAM

Event logging Up to 40,000 events total

1 ms Sequence of Event (SOE) time stamping for digital
inputs
30 ms SOE time stamping for analog inputs

Database points Up to 20,000 points total

Power requirements SCADAPack 535E Controller with integrated I/O: 4.8 W

53 6601 I/O expansion module: 1.1 W
USB (5 V at 100 mA): 0.6 W
Serial port (5 V at 250 mA): 1.5 W

Environmental -40°C … 70°C (-40°F…158°F) operating temperature

 SCADAPack 535E Hardware Manual 17

requirements when mounted on a horizontally oriented DIN rail

-40°C … 65°C (-40°F…149°F) operating temperature
when mounted on a vertically oriented DIN rail
-40°C … 85°C (-40°F…185°F) storage temperature
5% to 95% relative humidity, non-condensing
Pollution Degree 2, Installation Category I, Indoor use
Inputs and outputs

Digital inputs 36 18, 8 of which have an associated counter

Digital outputs 38 9

Analog inputs 39 6

Analog outputs 43 2 (requires the optional analog output module)

Expansion I/O 6601 input/output module with optional analog output

module
support 57

Communications

Serial ports 20 2 RS232

2 RS232 or RS485

Ethernet ports 26 3 UTP 10/100BASE-T

USB ports 29 1 USB 2.0-compliant A-type receptacle

1 USB 2.0-compliant B-type receptacle

Socket modem 1 (not currently active)

ports

Serial protocols DNP3 level 4 in slave or master mode

IEC60870-5-101 in slave mode
Modbus RTU in slave or master mode
DF1 in master mode

IP protocols DNP3 level 4 in TCP slave or master mode

DNP3 level 4 in UDP slave or master mode
DNP3 in peer-to-peer mode
IEC60870-5-104 in slave mode
Modbus TCP in server or client mode
Modbus RTU in TCP client mode
 18 SCADAPack 535E Hardware Manual

5.1 CPU, RAM and Storage

CPU
The CPU executes a preemptive multitasking operating system, allowing simultaneous, real-time
provisioning of:
Communications protocols such as DNP3, TCP/IP, IEC 60870-5-101, IEC 60870-5-103, IEC 60870-5-
104 and Modbus
Time-stamped event processing
Configuration management
User-created sequence and control applications such as those created in SCADAPack Workbench or
ISaGRAF 3 Workbench

RAM
The onboard battery-backed RAM is used to store:
Configuration information such as point definitions and port configurations
User-created sequence and control applications such as those created in SCADAPack Workbench or
ISaGRAF 3 Workbench
Time-stamped event data

Storage
The RTU provides internal flash storage and support for USB storage media. The internal flash storage is
described here. For more information about support for plug-in storage media, see USB Ports 29 .

Operating System Flash

The operating system flash stores the RTU firmware. The firmware implements the communications
protocols — DNP3, TCP/IP, Modbus and others — the database of point configurations and the
SCADAPack Workbench or ISaGRAF 3 Workbench kernel that runs the user-created sequence and
control applications.

The use of flash memory chips allows you to transfer new firmware locally through a serial port and
remotely using command line instructions without removing the RTU front cover.

Boot Monitor Flash

The boot monitor firmware resides in a separate flash memory chip on the controller board. The boot
monitor firmware is the first code executed by the CPU when power is applied to the RTU. It configures
the RTU hardware then verifies, loads and executes the operating system firmware.

The boot monitor also provides facilities for reprogramming the operating system and boot monitor flash
memory.
 SCADAPack 535E Hardware Manual 19

5.2 Power Supply and Back-Up Battery

The RTU is powered by a 12...30 Vdc power supply that is connected to the power input connectors on
the RTU. The illustration below shows the location of the power input connectors.

Power Input Connectors

For details about power supply requirements, see Power Supply Requirements 53 .

A Tadiran TL-5186 3.6 V lithium battery installed on the RTU controller board provides back-up power to
the RTU's real-time clock and RAM memory. It also maintains the RTU configuration during a power-
supply interruption.
 20 SCADAPack 535E Hardware Manual

5.3 Serial Ports

The figure below shows the location of the four RS232 serial ports and the two RS485 terminal
connection points on the SCADAPack 535E.

SCADAPack 535E Serial Interfaces

Serial1 and Serial2 Ports 21

Serial3 and Serial4 Ports 23

 SCADAPack 535E Hardware Manual 21

5.3.1 Serial1 and Serial2 Ports

Serial1 and Serial2 are general-purpose serial data communications ports that can be used for RS232
communications with the SCADA master system, with other RTUs, with devices such as Programmable
Logic Controllers (PLCs), and with the SCADAPack E Configurator computer.

Serial1 and Serial2 can also be used for ES Remote I/O communications when the RTU is functioning
as a Main RTU in an ES Remote I/O configuration.

The figure below shows a close-up view of the RS232 serial ports and their LEDs.

Serial Ports

For information about Serial3 and Serial4, see Serial3 and Serial4 Ports 23 .

Configuration
Serial1 and Serial2 support RS232 with modem control.

Using the SCADAPack E Configurator software, you can configure Serial1 and Serial2 to define the port
function, mode, baud and data mode, as summarized in the table below.

Serial1 and Serial2 Configuration Parameters

Function Mode Baud Data Mode

ISaGRAF (default for RS232 (RTS On) 300 bps 8-bit No Parity 1 Stop Bit
Serial1) (default) 600 bps (default)
DNP3 (default for RS232 (RTS Keyed) 1200 bps 8-bit Even Parity 1 Stop Bit
Serial2) Hayes Modem 2400 bps 8-bit Odd Parity 1 Stop Bit
Cmd Line GPRS 4800 bps 7-bit Even Parity 1 Stop Bit
PLC Device 1xRTT 9600 bps (default) 7-bit Odd Parity 1 Stop Bit
ISaGRAF-User RS232 (RTS Off) 19200 bps 8-bit No Parity 2 Stop Bits
ES Remote I/O 38400 bps
PPP/TCPIP 57600 bps
TCP Service 115,200 bps
Modbus Slave
22 SCADAPack 535E Hardware Manual

DNP-VT Service
IEC-103 Master
IEC-101 Slave

For more information about configuring serial ports, see the SCADAPack E Configurator User Manual
and the Communication Interfaces Technical Reference Manual.

Cabling
Serial1 and Serial2 support RS232 serial cables with an eight-pin RJ45 Data Terminal Equipment (DTE)
connector. For more information, see:
RS232 Pin Assignments and Cable Descriptions 77

RS232 Wiring Examples 81

LEDs
The following table describes the Serial1 and Serial2 LEDs on the RTU front panel and on the physical
ports.

Serial1 and Serial2 LED Status Indications

LED Color Description

CTS Green Lit when the CTS input is active on this serial port.

DCD Green Lit when the DCD input is active on this serial port.

Left side of the Green Blinks when the port is transmitting data over the RS232 serial
physical port connection.

Right side of the Green Blinks when the port is receiving data over the RS232 serial
physical port connection.

For more information, see LEDs 113 .

HMI Power Control

Pin 1 of the RJ45 connector for Serial1 and Serial2 provides switched 5 V power for the SCADAPack
Vision or another human-machine interface (HMI). Use the Vision Power Pin Enabled check box on
the Controller Settings property page in SCADAPack E Configurator to enable and disable the voltage
output for pin 1.

Binary system point 50750 indicates the status of power to pin 1. The system point is set when the
power to pin 1 is on, and is cleared when the power to pin 1 is off.

For more information, see the SCADAPack E Configurator User Manual and the Configuration Technical
Reference Manual

Specifications
 SCADAPack 535E Hardware Manual 23

For serial port specifications, see Communications Specifications 140 .

5.3.2 Serial3 and Serial4 Ports

Serial3 and Serial4 are general-purpose serial data communications ports that can be used for RS232 or
RS485 communications with the SCADA master system, with other RTUs, with devices such as
Programmable Logic Controllers (PLCs), and with the SCADAPack E Configurator computer.

Serial3 and Serial4 can also be used for ES Remote I/O communications when the RTU is functioning
as a Main RTU in an ES Remote I/O configuration.

The figure below shows a close-up view of the serial ports and their LEDs along with the RS485 screw-
termination connectors for Serial3 and Serial4.

Serial Ports

For information about Serial1 and Serial2, see Serial1 and Serial2 Ports 21 .
Configuration
Serial3 and Serial4 are software configurable for three-wire RS232 communications or two-wire RS485
communications.

Using the SCADAPack E Configurator software, you can configure each of the serial ports to define its
function, mode, baud and data mode, as summarized in the table below.

Function Mode Baud Data Mode

ISaGRAF RS232 (default) 300 bps 8-bit No Parity 1 Stop Bit

DNP3 (default for Serial3) RS485 2w 600 bps (default)
Cmd Line (default for 1200 bps 8-bit Even Parity 1 Stop Bit
Serial4) 2400 bps 8-bit Odd Parity 1 Stop Bit
PLC Device 4800 bps 7-bit Even Parity 1 Stop Bit
ISaGRAF-User 9600 bps 7-bit Odd Parity 1 Stop Bit
ES Remote I/O (default) 8-bit No Parity 2 Stop Bits
TCP Service 19200 bps
Modbus Slave 38400 bps
24 SCADAPack 535E Hardware Manual

DNP-VT Service 57600 bps

IEC-103 Master 115,200 bps
IEC-101 Slave

For more information about configuring serial ports, see the SCADAPack E Configurator User Manual
and the Communication Interfaces Technical Reference Manual.

Cabling

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Serial3 and Serial4 support RS232 or RS485 operation, but not both at the same
time. If Serial3 or Serial4 is configured for RS485 operation, the port must remain
empty.
Do not insert an RS232 cable into Serial3 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial3+ and Serial3-.
Do not insert an RS232 cable into Serial4 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial4+ and Serial4-.
Failure to follow these instructions can result in equipment damage.

When configured as RS232, the Serial3 and Serial4 serial ports support RS232 serial cables with an
eight-pin RJ45 Data Terminal Equipment (DTE) connector. For more information, see:

RS232 Pin Assignments and Cable Descriptions 77

RS232 Wiring Examples 81

When configured as RS485, the Serial3 and Serial4 screw-termination connectors support wired
connections:

If Serial3 is configured as RS485, you can create a two-wire RS485 connection to the screw-
termination connectors labeled Serial3+ and Serial3-.
If Serial4 is configured as RS485, you can create a two-wire RS485 connection to the screw-
termination connectors labeled Serial4+ and Serial4-.

A maximum of 32 RTUs and other devices can be connected to any one RS485 network.

For more information, see:

Wiring Screw-Termination Connectors 73

RS485 Wiring 83

LEDs
The following table describes the Serial3 and Serial4 LEDs.

Serial3 and Serial4 LED Status Indications

 SCADAPack 535E Hardware Manual 25

LED Color Description

Left side of the Green Blinks when data is being transmitted over the RS232 or RS485
physical port serial connection.

If the port is configured for RS485, the LEDs on the empty port
indicate that data is being transmitted over the wired RS485
connection.

Right side of the Green Blinks when data is being received over the RS232 or RS485 serial
physical port connection.

If the port is configured for RS485, the LEDs on the empty port
indicate that data is being received over the wired RS485
connection.

For more information, see LEDs 113 .

HMI Power Control

Pin 1 of the RJ45 connector for Serial3 and Serial4 provides switched 5 V power for the SCADAPack
Vision or another human-machine interface (HMI). Use the Vision Power Pin Enabled check box on
the Controller Settings property page in SCADAPack E Configurator to enable and disable the voltage
output for pin 1.

Binary system point 50750 indicates the status of power to pin 1. The system point is set when the
power to pin 1 is on, and is cleared when the power to pin 1 is off.

For more information, see the SCADAPack E Configurator User Manual and the Configuration Technical
Reference Manual.

Specifications
For serial port specifications, see Communications Specifications 140 .
 26 SCADAPack 535E Hardware Manual

5.4 Ethernet Ports

The figure below shows the location of the three Ethernet ports on the SCADAPack 535E.

SCADAPack 535E Ethernet Ports

Eth1, 2, 3 Ports 27
 SCADAPack 535E Hardware Manual 27

5.4.1 Eth1, 2, 3 Ports

The three Ethernet ports are UTP 10/100BASE-T LAN ports that can be used for IP communications and
for ES Remote I/O communications when the RTU is functioning as a Main RTU in an ES Remote I/O
configuration. The Ethernet ports are typically used for point-to-point Ethernet connections and are
usually connected to an Ethernet hub or switch, although it is also possible to connect devices together
directly.

Each Ethernet port can run at 10 Mbps or 100 Mbps, at half or full duplex. The RTU automatically
detects an active Ethernet port and the supported speed of the connected device, giving preference to
100 Mbps full duplex connections.

The following figure shows a close-up view of the three Ethernet ports and their LEDs.

Ethernet Ports

Configuration
Using the SCADAPack E Configurator software, you can configure each of the Ethernet ports to define
its:
Function: TCP/IP + RemIO (default) or ES Remote I/O
IP Address
Subnet Mask

For more information about configuring Ethernet ports, see the SCADAPack E Configurator User Manual
and the TCP/IP Technical Reference Manual.

Cabling
The Ethernet ports support crossover or straight-through Ethernet cables with an eight-pin RJ45
connector. The RTU will automatically detect the interface used and serve the cable appropriately.

For more information, see Ethernet Pin Assignments and Cable Descriptions 84 .

LEDs
The following table describes the Ethernet LED status indications.

Ethernet LED Status Indications

28 SCADAPack 535E Hardware Manual

Location Color Description

Left side of the Green Activity LED.

physical port Lit when the Ethernet port is active.
Blinks when the port is transmitting or receiving data.
Right side of the Yellow Link LED.
physical port Lit when the 10/100 Ethernet link is active.

For more information, see LEDs 113 .

Specifications
For Ethernet port specifications, see Communications Specifications 140 .
 SCADAPack 535E Hardware Manual 29

5.5 USB Ports

The USB host and USB device ports on the RTU are USB 2.0-compliant ports that support 1.5 Mb/s and
12 Mb/s communications. The USB ports automatically detect and support the data rate of the
connected device. The two USB ports can be used simultaneously.

The figure below shows the location of the two USB ports on the SCADAPack 535E.

SCADAPack 535E USB Ports

USB Host Port 30

USB Device Port 32

 30 SCADAPack 535E Hardware Manual

5.5.1 USB Host Port

The USB host port is a USB series A receptacle that allows the RTU controller board to act as a host for
a plug-in USB drive. For bus-powered USB devices, the host port can provide up to 100 mA at 5 V.

The USB host port is not user configurable. It can be mounted and accessed through the RTU file
system at /usb0. For information about support for plug-in USB drives, see Data Capacity 139 .

WARNING
EXPLOSION RISK

Do not use USB ports in hazardous applications or hazardous locations.

Use USB ports only for non-hazardous applications in locations that are known to
be in a non-hazardous state.

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

WARNING
UNEXPECTED EQUIPMENT OPERATION

Verify that the data transfer between the RTU and the plug-in USB drive is complete
before removing the USB drive from the USB host port.

Removing a plug-in USB drive from the host port while the data transfer is in
progress can impact system performance and result in a system restart.

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

The following illustration shows the connections for the USB host port.

USB series “A”

receptacle

4 1. VBUS
3 2. D-
3. D+
2 4. GND
1

USB Host Port Connections

 SCADAPack 535E Hardware Manual 31

LEDs
The following table describes the USB host port LEDs on the RTU front panel.

USB Host Port LED Descriptions

LED Color Description

Status Green This LED is under the control of Binary System Point 50753. It can be
controlled by a SCADAPack Workbench or ISaGRAF 3 Workbench
application or through protocol control commands.

Store Green Flashes on and off alternately at a steady rate for five seconds when
data from the USB mass storage device is successfully loaded into
the RTU.
 32 SCADAPack 535E Hardware Manual

5.5.2 USB Device Port

The USB device port is a USB series B receptacle that provides DNP3 communications for local
connection to a local USB device, such as the computer running the SCADAPack E Configurator
software.

WARNING
EXPLOSION RISK

Do not use USB ports in hazardous applications or hazardous locations.

Use USB ports only for non-hazardous applications in locations that are known to
be in a non-hazardous state.

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

Configuration
Using the SCADAPack E Configurator software, you can configure the USB device port for DNP3
communications. This is the default configuration for the port. The USB device port is referred to as Port
0 in the SCADAPack E Configurator software and in SCADAPack E diagnostics.

The following illustration shows the connections for the USB device port.

USB Device Port Connections

 SCADAPack 535E Hardware Manual 33

5.6 Inputs and Outputs

The SCADAPack 535E provides a total of:
18 digital inputs
9 digital outputs
6 analog inputs
2 analog outputs (this option is selected when the SCADAPack 535E is ordered)

SCADAPack 535E Inputs and Outputs

34 SCADAPack 535E Hardware Manual

The following table describes the SCADAPack 535E input and output characteristics.

SCADAPack 535E Input and Output Characteristics

Location Name RTU Polarity Description

Label Sensitive

Controller Digital inputs Din1 Yes Digital inputs.

board 36 1-2 Din2 Not isolated from RTU logic.

Digital output Dout Yes Open drain.

38 1 Not isolated from RTU logic.

I/O board Digital inputs DI 1-8 Yes Digital inputs, the first eight (DI 1-8) of which
36 1-16 DI 9-16 have associated counters.
Counter inputs Organized into two groups of eight inputs:
37 1-8 DI 1-8 and DI 9-16.
Each group shares a common return.
The two groups are optically isolated from
one another and from the logic power.

Digital outputs DO 1-2 Yes Dry contact Form C mechanical relay

38 1-2 outputs.
Three voltage-free terminals for one relay
pole: Normally Open (NO), Normally Closed
(NC) and Common (COM).
Electrical isolation is provided between the
two digital outputs and between each digital
output and the device being controlled.

Digital outputs DO 3-8 Yes Dry contact Form A mechanical relay

38 3-8 outputs.
Voltage-free NO contacts that share a
common return.
Electrical isolation is provided between each
digital output and the device being
controlled.

Analog inputs AI 1+ - 6- Yes Analog inputs. Jumper configurable.

39 1-6 Electrical isolation is provided from each
channel to RTU logic and between
channels.
Analog outputs AO 1-2 Yes Analog outputs are provided by the optional
43 1-2 analog output module.
Electrical isolation is provided from each
channel to RTU logic, but not between
channels.
 SCADAPack 535E Hardware Manual 35

The inputs and outputs use 5 mm (.197 in.) pitch connectors. For information about wiring these
connectors, see Wiring Screw-Termination Connectors 73 .

The inputs and outputs on the RTU can be:

Monitored and controlled from a SCADA master station
Monitored and controlled from a remote outstation
Locally controlled using an application created in ISaGRAF 3 Workbench or SCADAPack
Workbench
Any combination of the above

Data that is received and sent through the inputs and outputs can be:
Transferred to an attached Programmable Logic Controller (PLC) for processing by that PLC
Time-stamped and stored locally for manual or automatic retrieval
These capabilities are provided by the RTU firmware. For more information, see the SCADAPack E
Technical Overview.
I/O can be extended by adding the 6601 I/O expansion module with the optional analog output module.
For details, see Adding Inputs and Outputs 57 .
 36 SCADAPack 535E Hardware Manual

5.6.1 Digital Inputs

Digital inputs are used to monitor the state of remote devices such as panel lamps, relays, motor
starters, solenoid valves and other devices.
Digital inputs are available for nominal 12...24 V operation. A current-limiting resistor on each input
determines the voltage range.
Wetting voltage for the volt-free contacts is usually provided by the DC power used with the RTU.
The digital inputs provide 1 ms Sequence of Event (SOE) time stamping to support Sequence Of Event
(SOE) applications.

The digital inputs also support state debouncing. If debouncing is enabled on a digital input channel,
then SOE time stamping on the digital point has the same resolution as the debounce resolution.

The LED for each digital input is lit when the input is active.
Configuration
Using the SCADAPack E Configurator software, you can configure each digital input to define its
characteristics, including:
DNP3 attributes
Alarm and trend attributes
Invert state
Remote control interlock attributes
Debounce time
For more information about configuring digital inputs, see the SCADAPack E Configurator User Manual
and the Configuration Technical Reference Manual.

Wiring
Digital inputs support solid or stranded wires from 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG). For more
information, see Wiring Screw-Termination Connectors 73 .

Specifications
For digital input specifications, see Specifications 135 .
 SCADAPack 535E Hardware Manual 37

5.6.2 Counter Inputs

For digital inputs that have an associated counter, the counter inputs are represented as 32-bit
counters.
The corresponding digital input invert settings are applied prior to counting transitions of the input.
If configured as non-inverting (default configuration), counter input points count OFF to ON
transitions.
If configured as inverted, ON to OFF transitions are counted on the corresponding counter channel.

The LED for each counter input is lit when the input is active.

Configuration
Using the SCADAPack E Configurator software, you can configure each counter input to define its
characteristics, including:
DNP3 attributes
Counter values
Alarm and trend attributes
Event attributes
Remote control interlock attributes
For more information about configuring counter inputs, see the SCADAPack E Configurator User Manual
and the Configuration Technical Reference Manual.

Wiring
Counter inputs support solid or stranded wires from 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG). For
more information, see Wiring Screw-Termination Connectors 73 .

Specifications
For counter input specifications, see Specifications 135 .
 38 SCADAPack 535E Hardware Manual

5.6.3 Digital Outputs

Digital outputs are used to control panel lamps, relays, motor starters, solenoid valves and other
devices. The relay outputs are well suited to applications that cannot tolerate any off-state leakage
current, that require high load currents, or that involve non-standard voltages or current ranges.
For Form A digital outputs that have a single Normally Open (NO) contact, loads can be connected to
either the high or the low side of the power source.
For Form C digital outputs that have an NO contact, a Normally Closed (NC) contact and a Common
(COM) contact, loads can be connected to either the NO or the NC terminal, and to either the high or the
low side of the power source. A signal from the second pole on each relay provides feedback to the
software to verify the correct relay activation for each operation.

The LED for each digital output is lit when the NO contact is closed, or activated, and the circuit is
continuous. For Form C digital outputs, this means the NC contact is open.

Configuration
Using the SCADAPack E Configurator software, you can configure each digital output to define its
characteristics, including:
DNP3 attributes
Alarm and trend attributes
Invert state
Remote control interlock attributes
Output pulse time

For more information about configuring digital outputs, see the SCADAPack E Configurator User Manual
and the Configuration Technical Reference Manual.

Wiring
Digital outputs support solid or stranded wires from 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG).For more
information, see Wiring Screw-Termination Connectors 73 .

Specifications
For digital output specifications, see Specifications 135 .
 SCADAPack 535E Hardware Manual 39

5.6.4 Analog Inputs

Analog inputs are used to monitor devices such as pressure, level, flow and temperature transmitters,
instrumentation such as pH and conductivity sensors, and other high-level analog signal sources.
Each analog input is individually configured for the input type — current or voltage — and range. The
SCADAPack 535E and the 6601 I/O expansion module use a 24-bit delta-sigma analog to digital (A/D)
converter.
The RTU is factory-calibrated for 0...20 mA and 4...20 mA current inputs and for 0...5 V and 1...5 V
operation. The mode of operation — current mode or voltage mode — is selected when the RTU or I/O
expansion module is purchased.
In current mode, a 250 ohm current sense resistor is used across each analog input channel. The
measurement range in current mode is 0...20 mA or 4...20 mA, selectable through the SCADAPack E
Configurator software. The 250 ohm resistor produces a voltage drop (input reading) of 5 V for 20 mA of
current flow. Loop current will only flow in analog inputs that have been configured for 20 mA.
In voltage mode, the analog inputs are high-impedance and single-ended with a measurement range of
0...5 V or 1...5 V, selectable through the SCADAPack E Configurator software.
The RTU also supports using a mix of current mode and voltage mode analog inputs if required. For
details, see Supporting Current and Voltage Inputs 98 .

Configuration
Using the SCADAPack E Configurator software, you can configure each analog input to define its
characteristics, including:
DNP3 attributes
Current values
Alarm and trend attributes
Scaling
Value deviation
For more information about configuring analog inputs, see the SCADAPack E Configurator User Manual
and the Configuration Technical Reference Manual.

Wiring
Analog inputs support solid or stranded wires from 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG). For more
information, see Wiring Screw-Termination Connectors 73 .

Specifications
For analog input specifications, see Specifications 135 .
 40 SCADAPack 535E Hardware Manual

5.6.4.1 Analog Input Range and Resolution

The analog inputs have a 24-bit, unipolar, analog to digital (A/D) converter that measures input voltages
from 0...5 V.
To assign RTU database points to the analog input channels, use the SCADAPack E Configurator to
select the signal range for each analog input channel. Each analog input channel can be configured for
one of the following signal ranges:
0...20 mA
4...20 mA
0...5 V
1...5 V
The signal range selected is scaled to the Raw Min. to Raw Max. values defined for each analog input
point when point integer values are used. The Eng. Min. to Eng. Max. values for the point are used to
scale the analog input Engineering Floating Point database value.
For example, if an analog input point's attributes are Raw Min. = 0, Raw Max. = 10,000 and the input
channel is selected for 4...20 mA:
A 20 mA input is 100% of the selected input signal range and corresponds to 10,000 counts.
A 4 mA input is 0% of the selected input signal range and corresponds to 0 counts.
 SCADAPack 535E Hardware Manual 41

The following tables show the over- and under-range status for current and voltage signals. Over- and
under-range status detection occurs when the measured input is outside of the specified range by more
than 0.2%.
Over- and Under-Range Status for Current Signals

Input 0...20 mA Range 4...20 mA Range

Current Point Coun Over- or Point Count1 Over- or

(mA) Database 1 Under-Range Database Under-Range
t
Value Status Value Status

RAW_MIN RAW_MIN
0.00 ENG_MIN 0 OFF ENG_MIN 0 ON

17.5% of RAW_MIN
3.50 range 1750 OFF ENG_MIN 0 ON

RAW_MIN
4.00 20% of range 2000 OFF ENG_MIN 0 OFF
8.00 40% of range 4000 OFF 25% of range 2500 OFF
12.00 60% of range 6000 OFF 50% of range 5000 OFF
16.00 80% of range 8000 OFF 75% of range 7500 OFF

RAW_MAX RAW_MAX
20.00 ENG_MAX 10000 OFF ENG_MAX 10000 OFF

RAW_MAX RAW_MAX
20.01 ENG_MAX 10000 ON ENG_MAX 10000 ON

Over- and Under-Range Status for Voltage Signals

Input 0...5 V Range 1...5 V Range

Voltage Point Coun Over- or Point Count1 Over- or
(Volts) Database 1 Under-Range Database Under-Range
t
Value Status Value Status

RAW_MIN RAW_MIN
0.00 ENG_MIN 0 OFF ENG_MIN 0 ON

17.5% of RAW_MIN
0.99 range 1980 OFF ENG_MIN 0 ON

RAW_MIN
1.00 20% of range 2000 OFF ENG_MIN 0 OFF
2.00 40% of range 4000 OFF 25% of range 2500 OFF
42 SCADAPack 535E Hardware Manual

3.00 60% of range 6000 OFF 50% of range 5000 OFF

4.00 80% of range 8000 OFF 75% of range 7500 OFF

RAW_MAX RAW_MAX
5.00 ENG_MAX 10000 OFF ENG_MAX 10000 OFF

RAW_MAX RAW_MAX
5.01 ENG_MAX 10000 ON ENG_MAX 10000 ON

1
Over- and under-range point status may also be asserted by SCADAPack E analog
input point configuration parameters. For more information see the SCADAPack E I/O
Expansion Reference Manual and the Data Processing Technical Reference Manual.
 SCADAPack 535E Hardware Manual 43

5.6.5 Analog Outputs

Analog outputs are used to control remote devices that require varying input information, rather than
simply on or off operations.
If the optional analog output module was selected when the SCADAPack 535E or the 6601 I/O
expansion module was ordered, two 20 mA analog outputs are available for use.
The analog output channels are powered with an external 12...30 Vdc (nominally 12 Vdc or 24 Vdc)
power supply. They can be configured for 4...20 mA current or 0...20 mA current. The outputs provide a
level of transient and over-voltage protection. Analog output resolution is 12 bits. The outputs share a
common return with each other and with the analog inputs.

Configuration
Using the SCADAPack E Configurator software, you can configure each analog output to define its
characteristics, including:
DNP3 attributes
Current values
Trend inhibit state
Scaling
Value deviation
For more information about configuring analog outputs, see the SCADAPack E Configurator User Manual
and the Configuration Technical Reference Manual.

Wiring
Analog outputs support solid or stranded wires from 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG).For
more information, see Wiring Screw-Termination Connectors 73 .

Specifications
For analog output specifications, see Specifications 135 .
 44 SCADAPack 535E Hardware Manual

5.6.5.1 Analog Output Range and Resolution

The optional analog output module, which is selected when the SCADAPack 535E or the 6601 I/O
expansion module is ordered, has a 12-bit, unipolar, digital to analog (D/A) converter.
You can select one of the following Output Type ranges on the SCADAPack I/O property page in the
SCADAPack E Configurator software. Both analog output channels use the same range:
0...20 mA
4...20 mA
The 0...20 mA output range resolution is 4.88 µA per D/A count.
Configuration for points attached to the analog output module channels uses the SCADAPack E Raw
Min. to Raw Max. and Eng. Min. to Eng. Max. parameters for integer and engineering scaling,
respectively.
These scaling ranges automatically apply to the analog input signal range selected in SCADAPack E
Configurator for the 6601 I/O expansion module analog Output Type (0...20 mA or 4...20 mA).
 SCADAPack 535E Hardware Manual 45

5.6.5.2 Analog Output Load Resistance Requirements

The load resistance for any given power supply voltage is limited:
On the high resistance end by the requirement for proper operation of the analog output circuit
On the low resistance end by the power dissipation in the analog output
The table below lists the analog output load resistance range. The operating range is within the area
defined as resistance limits.

Power Supply Voltage and Load Resistance Requirements

Power Supply Load Resistance Required

12 Vdc 0...475 ohms
24 Vdc 0...1075 ohms
30 Vdc 250...1375 ohms
 46 SCADAPack 535E Hardware Manual

5.7 Ground Connectors

The RTU provides two ground connectors labeled GND on the controller board I/O terminal block. The
ground terminals are typically used with connections to analog input and analog output devices.

RTU Ground Connectors

The GND connectors can be used in individual connections, or they can be connected to a terminal strip
that provides additional ground connection points.
 SCADAPack 535E Hardware Manual 47

5.8 Isolation and Protection Summary

The SCADAPack 535E provides isolation and protection from external connections as described in the
table below.

SCADAPack 535E Isolation and Protection

Location Connections Isolation Protection

Controller Digital inputs None High-resistance current-limiting

board resistor

Digital output None Over-voltage (TVS)

Serial ports None ESD

Ethernet ports Transformer None

USB ports None ESD

I/O board Digital inputs Optical Current-limiting resistor and

reverse polarity diode

Digital outputs Relay None

Analog inputs Optical (channel-to-channel and TVS diode

channel-to-RTU)

Analog outputs 1 Optical (channel-to-RTU) TVS diode

1
The optional analog outputs are selected when the SCADAPack 535E is ordered.
 48 SCADAPack 535E Hardware Manual

6 Installation
The SCADAPack 535E is factory-configured and under normal conditions does not require removal or
insertion of any peripherals or components. The configurations are stored in a combination of battery-
backed RAM and flash memory.
The lithium-powered RAM back-up battery has a shelf life of approximately two years when the RTU is
not connected to a power source. Battery life can be increased to more than eight years when the RTU
is permanently connected to a power source.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
RTU configuration information can be lost if the onboard RAM back-up battery goes
flat, is disconnected, if the RTU is damaged, or if there has been a firmware
upgrade.
Verify the voltage of the onboard RAM back-up battery before installing the RTU in
the field.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Installing the RTU in an environment where the electromagnetic compatibility (EMC)
rating exceeds the certified EMC rating for the RTU can lead to unpredictable
operation and unexpected results.
Failure to follow these instructions can result in equipment damage.

Mounting the SCADAPack 535E 49

Power Supply Requirements 53

Adding Inputs and Outputs 57

 SCADAPack 535E Hardware Manual 49

6.1 Mounting the SCADAPack 535E

The SCADAPack 535E mounts on a 7.5 mm x 35 mm (0.3 in. x 1.4 in.) DIN rail. The figures below show
the RTU dimensions when mounted.

SCADAPack 535E Dimensions

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the SCADAPack 535E before removing power.
Failure to follow these instructions can result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from the RTU before mounting it on a DIN rail.
Do not remove the RTU cover when mounting the RTU. The RTU is designed so
that it can be mounted on a DIN rail with the cover in place.
Failure to follow these instructions can result in death or serious injury.
50 SCADAPack 535E Hardware Manual

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The RTU can be mounted on a horizontally oriented DIN rail or on a vertically
oriented DIN rail.
The operating temperature for the RTU and the current rating for the digital outputs
are lower when the RTU is mounted on a vertically oriented DIN rail.
Read and understand the temperature specifications before mounting the RTU. See
the Specifications 135 for details.
Failure to follow these instructions can result in equipment damage.

To Mount a SCADAPack 535E

The illustrations below show how to mount the RTU on a horizontally oriented DIN rail. The steps to
mount the RTU on a vertically oriented DIN rail are the same.

1. With the lower part of the RTU tilted away from the DIN rail, position the mounting guide line on the
side of the RTU so that it is just above the edge of the DIN rail.

The springs on the back of the RTU should rest on the DIN rail and the edge of the DIN rail should be
under the support claws that are adjacent to the springs, as shown below.

DIN Rail Alignment for RTU Mounting

2. Push firmly on the RTU while tilting it toward the DIN rail until the DIN rail is positioned under both
 SCADAPack 535E Hardware Manual 51

the upper and lower claws on the back of the RTU.

3 Release the pressure on the springs so that the DIN rail is held firmly in place between the upper and
lower claws.

The mounting guide line should be aligned with the edge of the DIN rail.

The figure below shows a SCADAPack 535E with the DIN rail correctly positioned in the upper and
lower claws on the back of the RTU.

Rear View of a Correctly Mounted RTU

The figure below shows the front view of a SCADAPack 535E RTU that is mounted on a horizontally
oriented DIN rail.
52 SCADAPack 535E Hardware Manual

SCADAPack 535E on a Horizontally Oriented DIN Rail

 SCADAPack 535E Hardware Manual 53

6.2 Power Supply Requirements

The RTU is designed for 12...30 Vdc operating voltages and is powered through an 11-terminal
connector.
Power requirements are determined by a combination of factors, including the number of relays
energized, the number of LEDs activated, the number of Ethernet connections and the number of analog
outputs.
The table below summarizes the power requirements for the SCADAPack 535E, with and without the
6601 I/O expansion module.
SCADAPack 535E Power Requirements

Volts In SCADAPack SCADAPack 535E SCADAPack 535E SCADAPack 535E

535E Plus One 6601 I/O Plus Two 6601 I/O Plus Three 6601 I/O
Expansion Module Expansion Modules Expansion Modules

Volts (V) Power (W) Power (W) Power (W) Power (W)

11 4.1 5.2 6.3 7.4

13.8 4.1 5.2 6.3 7.4

24 4.5 5.6 6.7 7.8

30 4.8 5.9 7.0 8.1

WARNING
UNEXPECTED EQUIPMENT OPERATION
The input power supply must be a filtered DC supply.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Safety Extra Low Voltage (SELV) or Protective Extra Low Voltage (PELV) power
supplies are required on the power input and I/O points. Power supplies with
100...240 Vac inputs that comply with safety standard IEC/EN 60950 generally
have SELV outputs. Check with the manufacturer or the agency certification listing
to confirm that they have SELV outputs.
Failure to follow these instructions can result in death or serious injury.
54 SCADAPack 535E Hardware Manual

The following Schneider Electric power supply can be used:

Schneider Electric Phaseo regulated power supply, part number ABL 7RM24025, providing 100...240
Vac in and 24 Vdc, 2.5 A out.

Power Supply Wiring

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Install an external 1.6 A fast-acting fuse on the input voltage side of the power
supply connection.
Failure to follow these instructions can result in equipment damage.
The following figure illustrates power supply wiring. For details on wiring the power supply connectors,
see Wiring Screw-Termination Connectors 73 .

Power Supply Wiring

Analog Output Power Supply Requirements

If the optional analog output module was selected when the SCADAPack 535E was ordered, an
additional 24 Vdc power supply is required to power the field-side circuitry. Each analog output module
requires 50 mA current regardless of the system voltage. For information on the configuration options for
the analog output power supply, see Analog Output Power Supply Configuration Options. 55
 SCADAPack 535E Hardware Manual 55

6.2.1 Analog Output Power Supply Configuration Options

There are two configuration options for the external 24 Vdc power supply that is required when the
optional analog output module is installed:
The analog output module and the RTU can each have their own 24 Vdc power supply. In this
configuration, the analog outputs are isolated from the system logic.
The analog output module can share an external 24 Vdc power supply with the RTU. In this
configuration, the analog outputs are not isolated from the system logic.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Install an external 1.6 A fast-acting fuse on the input voltage side of the RTU power
supply connection.
Install an external 0.063 A fast-acting fuse on the input voltage side of the analog
output power supply connection.
Failure to follow these instructions can result in equipment damage.

The following figure illustrates the power supply configurations for isolated and non-isolated analog
outputs. For details on wiring the power supply connectors, see Wiring Screw-Termination Connectors
73 .
56 SCADAPack 535E Hardware Manual

Power Supply Configurations for Isolated and Non-Isolated Analog Outputs

 SCADAPack 535E Hardware Manual 57

6.3 Adding Inputs and Outputs

I/O expansion modules allow you to increase the number of inputs and outputs the RTU monitors and
controls.
The following table lists the I/O expansion modules that can be connected to the RTU.

I/O Expansion Module Support

I/O Expansion Type I/O Capacity

Module

6601 Composite I/O 16 digital inputs, 8 of which have an associated counter

8 digital (relay) outputs
6 analog inputs
2 analog outputs (this option is selected when the 6601
I/O expansion module is ordered)

For more information, see:

Intermodule Cabling 58
6601 Hardware Manual

Power Requirements
The 6601 I/O expansion module requires 5 V power, which is provided by the RTU. However, if the
analog output option was selected when the 6601 I/O expansion module was purchased, an additional
24 Vdc power supply is required to power the field-side circuitry. Each analog output module requires 50
mA current regardless of the system voltage.
For more information, see:
Power Supply Specifications 137
6601 Hardware Manual

Mounting and Addressing

I/O expansion modules are mounted on a 7.5 mm x 35 mm (0.3 in. x 1.4 in.) DIN rail then connected to
the RTU.
I/O expansion module addresses are configured using an onboard hex switch.
Up to 16 I/O expansion modules can be addressed on the RTU bus.
 58 SCADAPack 535E Hardware Manual

Configuration
Use the SCADAPack E Configurator software to configure the inputs and outputs on the I/O expansion
module.
For more information, see:
SCADAPack E Configurator User Manual
Configuration Technical Reference Manual
SCADAPack E I/O Expansion Reference Manual

6.3.1 Intermodule Cabling

SCADAPack E RTUs and 6601 I/O expansion modules are supplied with a short intermodule cable that
connects the unit to an RTU or to an I/O expansion module.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU or the I/O expansion module before removing power.
Failure to follow these instructions can result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from the I/O expansion module before removing the I/O expansion
module cover.
Remove power from the RTU before removing the RTU cover.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The electronics inside the I/O expansion module and the RTU can be damaged by
static electricity. If you need to remove the I/O expansion module or the RTU cover,
wear an anti-static wrist strap that is connected to ground.
Failing to follow this simple step can cause intermittent or total loss of I/O
expansion module and RTU operation and will void the warranty.
Failure to follow these instructions can result in equipment damage.

If you need to supply your own intermodule cable, follow these recommendations:
 SCADAPack 535E Hardware Manual 59

Use the shortest length intermodule cable possible.

The maximum total length of intermodule cables is 1.2 m (48 in.). This length restriction does not
include the short intermodule cable supplied with the I/O expansion module. The maximum number of
modules is 16.
Intermodule cables should not be located near any electrical noise sources such as inductive load
switching or variable frequency drives.
Intermodule cables should not be installed in the same cable tray or in parallel with field wiring.
Intermodule cables may cross field wiring at 90° if necessary.
60 SCADAPack 535E Hardware Manual

Connect the shielding wire on the intermodule cable to a convenient chassis ground point. There is a
small hole in the I/O expansion module for grounding the shielding wire.
Confirm that the power supply is rated for the total number of modules in the system.

For additional details, refer to the SCADAPack E I/O Expansion Reference manual.
The intermodule cable is connected from the SCADAPack E RTU to the 6601 I/O expansion module
connector as shown in the illustrations below.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
To help adequate air flow through the I/O expansion module, mount it upright on a
DIN rail in the position shown below. Mounting the I/O expansion module in other
positions can affect its operation at high temperatures, leading to unexpected
results.
Failure to follow these instructions can result in equipment damage.

6601 I/O Expansion Module Connected to a SCADAPack 530E

 SCADAPack 535E Hardware Manual 61

6601 I/O Expansion Module Connected to a SCADAPack 535E

 62 SCADAPack 535E Hardware Manual

7 Addressing and Startup Modes

Addressing
The SCADAPack 530E or SCADAPack 535E address only needs to be set when the RTU is replacing a
SCADAPack ES that was operating as a Main unit for ES Remote I/O units. For details, see Setting the
RTU Address for ES Remote I/O Operation in the SCADAPack 530E or SCADAPack 535E Hardware
Manual.

In every other configuration, the RTU address should remain at its default setting of 0. That means:
The physical hex switch on the RTU should remain at 0.
The read-only analog system point 50002 displays 0 in the SCADAPack E Configurator Point
Browser property page.

Startup Modes
By default, the RTU starts in Run mode when power is applied. Run mode is used for normal day-to-day
operations.
Holding down the Select button on the RTU front cover allows you to start the RTU in other modes of
operation. The startup mode is determined by the length of time the Select button is depressed when
power is applied to the RTU or a controller board reset occurs. The longer the Select button is
depressed, the more actions are applied to the RTU.
Because the startup mode is not determined until the Select button is released, you can cancel the
startup mode selection by removing power to the RTU while the Select button is depressed. This can be
a useful tactic to avoid starting up in modes where more actions are applied if you have held the Select
button down longer than your preferred startup mode requires.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
RTU prior to initializing it.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Starting the RTU in Cold Boot mode or Factory Boot mode returns RTU
configuration parameters to their default settings and erases applications created in
SCADAPack Workbench and ISaGRAF 3 Workbench. This information must be
reloaded into the RTU for correct RTU operation.
Before starting the RTU in Cold Boot mode or Factory Boot mode, save a copy of
the RTU configuration information, user-created applications, logs and other data to
an external drive so it can be reloaded when the procedure is complete.
Failure to follow these instructions can result in equipment damage.
 SCADAPack 535E Hardware Manual 63

The following tables describe the four RTU startup modes and the actions that are applied in each case.
Startup Modes

Start Mode Description

Run Automatically loads the RTU database
Executes SCADAPack Workbench and ISaGRAF 3 Workbench programs that are
in RTU memory
Communicates about the RTU interfaces and configuration
Start the RTU in Run mode for normal day-to-day operations.
Service Stops applications created in SCADAPack Workbench or ISaGRAF 3 Workbench
Overrides RTU ports with DNP3 communications at node address “0” so that the
RTU can be reprogrammed and initialized

Cold Boot Initializes the RTU controller board

Erases applications created in SCADAPack Workbench or ISaGRAF 3 Workbench

Factory Boot Reformats the flash file system

Initializes the RTU controller board
Erases any applications created in SCADAPack Workbench or ISaGRAF 3
Workbench

Startup Mode Actions

Run Service Cold Factory Action

Mode Mode Boot Boot
Mode Mode
X X X DNP node address set to zero (0)

X Serial port protocol set to DNP3

X X Serial port settings set to default

X X LED power set to default

X X Database initialized

X X SCADAPack Workbench and ISaGRAF 3 Workbench

applications erased

X Files erased

X Flash file system reformatted

X SCADAPack Workbench and ISaGRAF 3 Workbench

applications started

X Settings retained in non-volatile memory

X X SCADAPack Workbench and ISaGRAF 3 Workbench

applications in flash erased

X X Protocols set to defaults

 64 SCADAPack 535E Hardware Manual

7.1 Setting the RTU Address for ES Remote I/O Operation

If the SCADAPack 530E or SCADAPack 535E is replacing a SCADAPack ES that was operating as a
Main unit for ES Remote I/O units, you need to define the group number and the unit number for the
RTU:
The group number is defined by setting the Remote I/O Group parameter in SCADAPack E
Configurator, as described below.
The unit number is defined by setting the physical hex switch on the RTU. Because the unit number
for a Main RTU in an ES Remote I/O configuration is 0, the hex switch should remain at its default
setting of 0.

Analog system point 50017 reflects group number.

Analog system point 50002 reflects both the group number and the unit number. For example, if the
group number is 2, the hex value for analog system point 50002 will be displayed as 20 on the
SCADAPack E Configurator Point Browser property page. This is because the group number is set to 2
and the unit number for a Main RTU in an ES Remote I/O configuration is 0.
The hex value for analog system point 50002 is automatically updated in the RTU database. The updated
value is displayed on the SCADAPack E Configurator Point Browser property page the next time you
read the point information from the RTU.

To Set the ES Remote I/O Group Number

1. In SCADAPack E Configurator, select I/O > ES Remote I/O.
2. On the ES Remote I/O property page, set the value of the Remote I/O Group parameter in the
range 0-14.
This parameter sets the value of analog system point 50017. The value for analog system point
50017 is retained in non-volatile RAM, but is not saved as part of the RTU configuration. Changes to
the Remote I/O Group parameter take effect after the RTU is restarted.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU before restarting it.
Failure to follow these instructions can result in death or serious injury.

3. Restart the RTU when prompted.

4. In SCADAPack E Configurator, select Points > Point Browser.
5. On the Point Browser property page, click Read to read the updated Hex value for analog system
point 50002 and confirm that the first number reflects the correct value for the group number.
For more information about reading and writing system points in the SCADAPack E Configurator Point
Browser property page, see the SCADAPack E Configurator User Manual.
 SCADAPack 535E Hardware Manual 65

7.2 Starting in Run Mode

Run mode is the normal operating mode for the RTU. The RTU automatically starts in Run mode when
power is applied or when a board reset occurs. No action is required to select Run mode.
When the RTU starts in Run mode, it loads:
The defined serial and Ethernet communication parameters for every port.
The RTU database configuration and point attributes.
SCADAPack Workbench and ISaGRAF 3 Workbench applications then executes them. If there are
no user-created applications in RAM, but there are applications in flash ROM, then the flash ROM
program is loaded in RAM and executed.
When the RTU is operating in Run mode, the Run LED on the RTU front cover blinks approximately once
every three seconds.
 66 SCADAPack 535E Hardware Manual

7.3 Starting in Service Mode

Service mode is used for configuration, programming and maintenance work, usually when the
communication settings are unknown.
When the RTU starts in Service mode:
DNP3 node address zero (0) is set, enabling communications with SCADAPack E Configurator at a
known DNP address. Connect SCADAPack E Configurator to the USB device port or to a serial
communications port.
Any SCADAPack Workbench and ISaGRAF 3 Workbench applications that are running are
stopped.
Programs and configurations are retained in non-volatile memory.
Ethernet port parameters are unchanged.
Serial port parameters are set to the values listed in the table below. Serial1, Serial2 and Serial4
parameters are restored to their default values. Serial3 parameters remain at their pre-Service boot
settings.
Service Mode Serial Port Parameters

Serial Port Serial1 Serial2 Serial3 Serial4

(Port 1) (Port 2) (Port 3) (Port 4)
Function DNP3 DNP3 Unchanged Cmd Line
Mode RS232 (RTS On) RS232 (RTS On) Unchanged RS232
Baud 9600 bps 9600 bps Unchanged 9600 bps
Data Mode 8-bit No Parity 8-bit No Parity Unchanged 8-bit No Parity

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU before removing power.
Failure to follow these instructions can result in death or serious injury.

To Start the RTU in Service Mode

1. Remove power from the RTU.
2. Hold down the Select button.
3. Apply power to the RTU.
4. Continue holding the Select button down until the Status LED turns on.
To cancel the startup mode selection at this point, remove power from the RTU
before you proceed to step 5. This can be a useful tactic to avoid starting up in
modes where more actions are applied if you have held the Select button down
longer than this mode requires.
5. Release the Select button.
 SCADAPack 535E Hardware Manual 67

If you release the Select button before the Status LED turns on, the RTU will start in Run mode.
 68 SCADAPack 535E Hardware Manual

7.4 Starting in Cold Boot Mode

Cold Boot mode is used when you need to clear a configuration from the RTU. It is optional after
installing new SCADAPack E controller firmware.
Cold Boot mode does not format the flash file system. Start in Factory Boot mode to do this.
When the RTU starts in Cold Boot mode:
SCADAPack Workbench and ISaGRAF 3 Workbench applications are erased.
The RTU points database is cleared.
RTU configuration settings are returned to default.
The DNP3 Device Address is set to 0.
Serial and Ethernet port parameters are restored to the defaults listed in the table below.

Default Serial and Ethernet Port Parameters

Serial Port Serial1 Serial2 Serial3 Serial4

(Port 1) (Port 2) (Port 3) (Port 4)
Function ISaGRAF DNP3 DNP3 Cmd Line
Mode RS232 (RTS On) RS232 (RTS On) RS232 RS232
Baud 9600 bps 9600 bps 9600 bps 9600 bps
Data Mode 8-bit No Parity 8-bit No Parity 8-bit No Parity 8-bit No Parity

Ethernet Port Eth1 Eth2 Eth3

(Ethernet 1) (Ethernet 2) (Ethernet 3)
Function TCP/IP+RemIO TCP/IP+RemIO TCP/IP+RemIO

IP Address 0.0.0.0 0.0.0.0 0.0.0.0

Subnet Mask 0.0.0.0 0.0.0.0 0.0.0.0

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU before removing power.
Failure to follow these instructions can result in death or serious injury.
 SCADAPack 535E Hardware Manual 69

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Starting the RTU in Cold Boot mode returns RTU configuration parameters to their
default settings and erases applications created in SCADAPack Workbench and
ISaGRAF 3 Workbench. This information must be reloaded into the RTU for correct
RTU operation.
Before starting the RTU in Cold Boot mode, save a copy of the RTU configuration
information, user-created applications, logs and other data to an external drive so it
can be reloaded when the procedure is complete.
Failure to follow these instructions can result in equipment damage.

To Start the RTU in Cold Boot Mode

1. Remove power from the RTU.
2. Hold down the Select button.
3. Apply power to the RTU.
4. Continue holding the Select button down for 20 seconds until the Status LED begins blinking on
and off.
To cancel the startup mode selection at this point, remove power from the RTU before you
proceed to step 5. This can be a useful tactic to avoid starting up in modes where more
actions are applied if you have held the Select button down longer than this mode requires.
5. Release the Select button.
If you release the Select button before the Status LED begins blinking on and off, the RTU will start
in Service mode.
6. Reload the RTU configuration and user-created applications from back-up.
 70 SCADAPack 535E Hardware Manual

7.5 Starting in Factory Boot Mode

Factory Boot mode is used to reformat the flash file system and initialize the RTU to its factory default
settings.
When the controller board starts in Factory Boot mode:
SCADAPack Workbench and ISaGRAF 3 Workbench applications are erased.
The RTU points database is cleared.
RTU configurations are returned to their default settings.
The flash file system is reformatted.
Serial and Ethernet port parameters are restored to the defaults listed in the table below.

Default Serial and Ethernet Port Parameters

Serial Port Serial1 Serial2 Serial3 Serial4

(Port 1) (Port 2) (Port 3) (Port 4)
Function ISaGRAF DNP3 DNP3 Cmd Line
Mode RS232 (RTS On) RS232 (RTS On) RS232 RS232
Baud 9600 bps 9600 bps 9600 bps 9600 bps
Data Mode 8-bit No Parity 8-bit No Parity 8-bit No Parity 8-bit No Parity

Ethernet Port Eth1 Eth2 Eth3

(Ethernet 1) (Ethernet 2) (Ethernet 3)
Function TCP/IP+RemIO TCP/IP+RemIO TCP/IP+RemIO

IP Address 0.0.0.0 0.0.0.0 0.0.0.0

Subnet Mask 0.0.0.0 0.0.0.0 0.0.0.0

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU before removing power.
Failure to follow these instructions can result in death or serious injury.
 SCADAPack 535E Hardware Manual 71

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Starting the RTU in Factory Boot mode returns RTU configuration parameters to
their default settings and erases applications created in SCADAPack Workbench
and ISaGRAF 3 Workbench. This information must be reloaded into the RTU for
correct RTU operation.
Before starting the RTU in Factory Boot mode, save a copy of the RTU
configuration information, user-created applications, logs and other data to an
external drive so it can be reloaded when the procedure is complete.
Failure to follow these instructions can result in equipment damage.

To Start the RTU in Factory Boot Mode

1. Remove power from the RTU.
2. Hold down the Select button.
3. Apply power to the RTU.
4. Continue holding the Select button down for longer than 30 seconds until the Status LED stops
blinking on and off and remains lit.
To cancel the startup mode selection at this point, remove power from the RTU
before you proceed to step 5. This can be a useful tactic to avoid starting up in
modes where more actions are applied if you have held the Select button down
longer than this mode requires.
5. Release the Select button.
If you release the Select button while the Status LED is still blinking, the RTU will start in Cold
Boot mode.
The Factory Boot will take approximately 60 seconds to complete. During this time, the RTU may
appear unresponsive while the file system is being formatted. The Status LED will remain lit until
the Factory Boot has completed and the RTU restarts.
6. Reload the RTU configuration and user-created applications from back-up.
 72 SCADAPack 535E Hardware Manual

8 Field Wiring
The serial and Ethernet ports on the SCADAPack 535E can be connected to:
A SCADA master system such as StruxureWare SCADA Expert ClearSCADA
Other SCADAPack E RTUs
Devices such as Programmable Logic Controllers (PLCs)
The SCADAPack E Configurator computer

For information about cabling for serial and Ethernet ports, see:
Serial Port Wiring 76

Ethernet Port Wiring 84

The inputs and outputs on the SCADAPack 535E are connected to the device that you want to monitor
or control. In general, inputs are used to monitor devices, while outputs are used to control devices.

For information about wiring inputs and outputs see:

Wiring Screw-Termination Connectors 73

Digital Input Wiring 87

Digital Output Wiring 90

Analog Input Wiring 96

Analog Output Wiring 105

 SCADAPack 535E Hardware Manual 73

8.1 Wiring Screw-Termination Connectors

Screw-termination style connectors are provided to terminate wiring from:
Power supplies
RS485 devices
Input/output (I/O) devices

These 5 mm (0.197 in.) pitch connectors support solid or stranded wires from 3.3 mm2 to .08 mm2 (12
AWG to 28 AWG).

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU or the I/O expansion module before removing power.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Remove power from the RTU before servicing.
Failure to follow these instructions can result in equipment damage.
74 SCADAPack 535E Hardware Manual

To Wire a Connector
1. Use a slotted screwdriver to loosen the termination screw.

Loosening the Termination Screw

2. Insert the stripped wire into the connector so that the bared wire is located under the screw.
As illustrated below, the bared wire should be placed fully within the connector.
 SCADAPack 535E Hardware Manual 75

Inserting the Wire into the Connector

3. Apply 0.5 Nm (4.5 lb-in.) torque to tighten the screw so the wire is held firmly in place.
 76 SCADAPack 535E Hardware Manual

8.2 Serial Port Wiring

The topics in this section describe the wiring for the RS232 serial ports and RS485 screw-termination
connectors on the RTU.

SCADAPack 535E RS232 and RS485 Serial Interfaces

RS232 Serial Port Wiring

RS232 Pin Assignments and Cable Descriptions 77

RS232 Wiring Examples 81

RS485 Connector Wiring

Wiring Screw-Termination Connectors 73

RS485 Wiring 83
 SCADAPack 535E Hardware Manual 77

8.2.1 RS232 Pin Assignments and Cable Descriptions

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Serial3 and Serial4 support RS232 or RS485 operation, but not both at the same
time. If Serial3 or Serial4 is configured for RS485 operation, the port must remain
empty.
Do not insert an RS232 cable into Serial3 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial3+ and Serial3-.
Do not insert an RS232 cable into Serial4 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial4+ and Serial4-.
Failure to follow these instructions can result in equipment damage.

RS232 Pin Assignments

The serial ports on the RTU support serial cables with eight-pin RJ45 modular connectors. The
illustration and tables below show the pin numbers and assignments for the RJ45 connector.

RJ45 Connector Pin Number

RS232 Pin Assignments for Serial1 and Serial2

Pin No. Pin Function

1 +5V

2 DCD

3 DTR

4 GND

5 RxD

6 TxD
78 SCADAPack 535E Hardware Manual

7 CTS

8 RTS

RS232 Pin Assignments for Serial3 and Serial4

Pin No. Pin Function

1 +5V

4 GND

5 RxD

6 TxD

8
 SCADAPack 535E Hardware Manual 79

RS232 Cable Descriptions

The tables below describe the pin functions for the following connections:
RJ45 to DE-9S Data Terminal Equipment (DTE) for Serial1, Serial2, Serial3 and Serial4
RJ45 to DE-9P Data Communication Equipment (DCE) for Serial1 and Serial2

RJ45 to DE-9S DTE

This cable is used to connect from any of the four RS232 serial ports on the RTU to a DE-9S connector
on a DTE device, such as a PC. A 3 m (10 ft) long cable is available from Schneider Electric using part
number TBUM297217.

RJ45 to DE-9S DTE Cable Description

RJ45 RTU DTE DE-9S DTE DE-9S

8 Pins Function Function

Shield connects to shell

6 TxD RxD 2

5 RxD TxD 3

4 GND GND 5

1, 2, 3, 7 and 8 are Wires not connected at

not connected at this end.
this end.

RJ45 to DE-9P DCE

This cable is used to connect from the Serial1 or Serial2 RS232 port on the RTU to a DE-9P connector
on a DCE device such as a modem. A 38 cm (15 in.) cable is available from Schneider Electric using
part number TBUM297218.

RJ45 to DE-9P DCE Cable Description

RJ45 RTU DTE Function DE-9P DCE DE-9P

Function

Shield connects to shell

3 DTR DTR 4

6 TxD TxD 3

5 RxD RxD 2

2 DCD DCD 1

4 GND GND 5

7 CTS CTS 8

8 RTS RTS 7
80 SCADAPack 535E Hardware Manual

RJ45 RTU DTE Function DE-9P DCE DE-9P

Function

1 +5V +5V 9
 SCADAPack 535E Hardware Manual 81

8.2.2 RS232 Wiring Examples

The illustrations in this topic show different wiring options for the RS232 serial ports. The wiring options
you can use depend on the serial port signaling capabilities:
Serial1 and Serial2: TxD, RxD, CTS, RTS, DCD, DTR
Serial3 and Serial4: TxD, RxD

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from all devices before connecting or disconnecting inputs or
outputs to any terminal or installing or removing any hardware.
Failure to follow these instructions can result in death or serious injury.

DTE to DTE without Handshaking

This wiring option can be used with any of the four RS232 serial ports.

There are several methods for wiring an RS232 serial port to Data Terminal Equipment (DTE) and Data
Communications Equipment (DCE) devices. The simplest connection requires only three wires: RxD,
TxD and signal ground. The following diagram shows the wiring between two DTE devices when
handshaking is not required.
RS-232 COM port (DTE)
8 Pin connector DTE

DCD 2 DCD

RxD 5 RxD

TxD 6 TxD

DTR 3 DTR

GND 4 GND

RTS 8

CTS 7 RTS

+ 5V 1 CTS

See device
specifications
for pin numbers

RS232 DTE to RS232 DTE without Handshaking

DTE to DTE with Handshaking

This wiring option can be used with Serial1 and Serial2 RS232 ports.

Some DTE devices may require hardware handshaking lines. The CTS and RTS lines are commonly
used for handshaking. The DTR and DCD lines are less commonly used. The RTU does not require
these lines. Refer to the specifications for the external device for exact requirements. The following
diagram shows the wiring between two DTE devices when handshaking is required.
82 SCADAPack 535E Hardware Manual

RS-232 COM port (DTE)

8 Pin connector DTE

DCD 2 DCD

RxD 5 RxD

TxD 6 TxD

DTR 3 DTR

GND 4 GND

RTS 8

CTS 7 RTS

+ 5V 1 CTS

See device
specifications
for pin numbers

RS232 DTE to RS232 DTE with Handshaking

DTE to DCE with Handshaking

This wiring option can be used with Serial1 and Serial2 RS232 ports.

DCE devices require different wiring. The handshaking lines need to be connected. Many DCE devices
are half-duplex. Select half-duplex operation with these devices. The diagram below shows the wiring
between a DTE device and a DCE device with handshaking.
RS-232 COM port (DTE)
8 Pin connector DCE

DCD 2 DCD

RxD 5 RxD

TxD 6 TxD

DTR 3 DTR

GND 4 GND

RTS 8 RTS

CTS 7 CTS

+ 5V 1
See device
specifications
for pin numbers

RS232 DTE to RS232 DCE with Handshaking

 SCADAPack 535E Hardware Manual 83

8.2.3 RS485 Wiring

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from all devices before connecting or disconnecting inputs or
outputs to any terminal or installing or removing any hardware.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Serial3 and Serial4 support RS232 or RS485 operation, but not both at the same
time. If Serial3 or Serial4 is configured for RS485 operation, the port must remain
empty.
Do not insert an RS232 cable into Serial3 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial3+ and Serial3-.
Do not insert an RS232 cable into Serial4 if there is a two-wire RS485 connection
to the screw-termination connectors labeled Serial4+ and Serial4-.
Failure to follow these instructions can result in equipment damage.

The Serial3 and Serial4 RS485 screw-termination connectors support solid or stranded wires from 3.3
mm2 to .08 mm2 (12 AWG to 28 AWG). The table below describes the polarity assignment for these
connectors.

Connector Name Polarity Assignment

Serial3 Positive
+

Serial3 Negative
-

Serial4 Positive
+

Serial4 Negative
-

Either of the terminal connections labeled GND (ground) can be used with RS485 screw-termination
connections.

For instructions on inserting wires into the RS485 connectors, see Wiring Screw-Termination
Connectors 73 .
 84 SCADAPack 535E Hardware Manual

8.3 Ethernet Port Wiring

The topic in this section describes the wiring for the Ethernet ports on the RTU.

SCADAPack 535E Ethernet Ports

Ethernet Pin Assignments and Cable Description 84

8.3.1 Ethernet Pin Assignments and Cable Description

Ethernet Pin Assignments

The Ethernet ports on the RTU can be connected to an Ethernet wall jack or hub using standard RJ45
Category 5 patch cables. The illustration and table below show the pin assignments for the RJ45
modular connector.
 SCADAPack 535E Hardware Manual 85

RJ45 Connector Pin Number

Ethernet Pin Assignments

Pin No. Pin Function

1 +Tx

2 -Tx

3 +Rx

6 -Rx

8
86 SCADAPack 535E Hardware Manual

Ethernet Cable Description

Ethernet cables are used in 10/100 BASE-T LANs. These networks are also known as unshielded
twisted pair (UTP), copper wire, Category 3, 4 and 5 Ethernet wire or twisted pair.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The IEEE 802.3 10 BASE-T specification requires that 10 BASE-T and 100 BASE-T
devices support UTP 100-120 unshielded twisted pair cables of not less than 100 m
(328 ft) in length.
This requirement does not factor in losses due to connectors, patch panels, punch-
down blocks, or other cable management hardware, which introduce additional
loss.
For each connector or other intrusive cable management device in the total link,
subtract 12 m (39 ft) from the total allowable link length.

Failure to follow these instructions can result in equipment damage.

As long as specifications are met for the entire length of the cable, UTP cable segments can be run up
to a maximum allowable length of 200 m (656 ft).
The Ethernet ports on the RTU automatically configure themselves for Medium Dependent Interface
(MDI) or MDI-X. This means that either a crossover or a straight-through Ethernet cable can be used. The
RTU will automatically detect the interface used and serve the cable appropriately.
 SCADAPack 535E Hardware Manual 87

8.4 Digital Input Wiring

The topic in this section describes the wiring for the digital and counter inputs on the RTU.

SCADAPack 535E Digital Inputs

Digital Input Wiring Example 87

8.4.1 Controller Board Digital Input Wiring Example

NOTICE
 88 SCADAPack 535E Hardware Manual

UNEXPECTED EQUIPMENT OPERATION

When wiring digital inputs:
Confirm that the connection to the digital input does not exceed the ratings for
the digital input. See the specifications 135 section for details.
Confirm that the polarity of the connection is correct with the two positive
terminals wired together and the two negative terminals wired together.
Failure to follow these instructions can result in equipment damage.

The figure below shows a connection from Din 2 and a ground connector to a power supply or battery.

Controller Board Digital Input Wiring Example

8.4.2 I/O Board Digital and Counter Input Wiring Example

NOTICE
UNEXPECTED EQUIPMENT OPERATION
When wiring digital and counter inputs:
Confirm that the connection to the digital or counter input does not exceed the
ratings for the input. See the specifications 135 section for details.
Confirm that the polarity of the connection is correct with the two positive
terminals wired together and the two negative terminals wired together.
Failure to follow these instructions can result in equipment damage.
 SCADAPack 535E Hardware Manual 89

NOTICE
UNEXPECTED EQUIPMENT OPERATION
When the unit is operating in an electrically noisy environment use shielded wires
on connections to digital and counter inputs 1-4.
Failure to follow these instructions can result in equipment damage.

The figure below shows a shielded connection to DI 1 and an unshielded connection to DI 5. Both
connections are wired to the common for digital inputs 1-8 and to a power supply or battery.

I/O Board Digital and Counter Input Wiring Example

 90 SCADAPack 535E Hardware Manual

8.5 Digital Output Wiring

The topics in this section describe the wiring for the digital outputs on the RTU.

SCADAPack 535E Digital Outputs

Controller Board Digital Output Wiring

Controller Board Digital Output Wiring Example 91

Controlling Grounded Devices with the Controller Board Digital Output 92

I/O Board Digital Output Wiring

I/O Board Digital Output Wiring Examples 94
 SCADAPack 535E Hardware Manual 91

8.5.1 Controller Board Digital Output Wiring Example

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Incandescent lamps and other loads may have inrush currents that will exceed the
rated maximum current of the relay contacts. This inrush current may damage the
relay contacts. Interposing relays need to be used in these situations.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
External lightning protection is required if the device being controlled is outside the
physical area (cubicle or building) in which the RTU is located.

Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
When controlling inductive loads, the relay contacts on digital outputs must be
protected. The energy stored in the coil can generate significant electrical noise
when the relay contacts are opened.
To suppress the noise in DC circuits, place a diode across the coil.
To suppress the noise in AC circuits, place a metal-oxide varistor (MOV) across
the coil.

Failure to follow these instructions can result in equipment damage.

The figure below shows a wiring example for the controller board digital output which provides an open
drain metal-oxide semiconductor field-effect transistor (MOSFET) for controlling loads such as relays or
lamps. See the specifications 135 for details about the power rating for this digital output.
For information about controlling devices with this digital output, see Controlling Devices with the
Controller Board Digital Output 92 .
 92 SCADAPack 535E Hardware Manual

Wiring Examples for the Controller Board Digital Output

8.5.2 Controlling Devices with the Controller Board Digital Output

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Incandescent lamps and other loads may have inrush currents that will exceed the
rated maximum current of the relay contacts. This inrush current may damage the
relay contacts. Interposing relays need to be used in these situations.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
External lightning protection is required if the device being controlled is outside the
physical area (cubicle or building) in which the RTU is located.

Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
When controlling inductive loads, the relay contacts on digital outputs must be
 SCADAPack 535E Hardware Manual 93

protected. The energy stored in the coil can generate significant electrical noise
when the relay contacts are opened.
To suppress the noise in DC circuits, place a diode across the coil.
To suppress the noise in AC circuits, place a metal-oxide varistor (MOV) across
the coil.

Failure to follow these instructions can result in equipment damage.

The single digital output on the controller board does not include an internal relay. As a result, this digital
output needs an external interposing relay to control devices.

Add the external interposing relay between the digital output and the device that you want to control. The
example below shows the wiring needed to control a grounded device, such as a radio.

See the specifications 135 for details about the power rating for this digital output.

Positioning of External Interposing Relay

 94 SCADAPack 535E Hardware Manual

8.5.3 I/O Board Digital Output Wiring Examples

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Incandescent lamps and other loads may have inrush currents that will exceed the
rated maximum current of the relay contacts. This inrush current may damage the
relay contacts. Interposing relays need to be used in these situations.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
External lightning protection is required if the device being controlled is outside the
physical area (cubicle or building) in which the RTU is located.

Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
When controlling inductive loads, the relay contacts on digital outputs must be
protected. The energy stored in the coil can generate significant electrical noise
when the relay contacts are opened.
To suppress the noise in DC circuits, place a diode across the coil.
To suppress the noise in AC circuits, place a metal-oxide varistor (MOV) across
the coil.

Failure to follow these instructions can result in equipment damage.

Form A Digital Output Wiring

The figures below show wiring examples for the I/O board Form A digital outputs (DO 3-8).
 SCADAPack 535E Hardware Manual 95

Wiring Examples for I/O Board Form A Digital Outputs

Form C Digital Output Wiring

The figure below shows a wiring example for the I/O board Form C digital outputs (DO 1-2).

Wiring Example for I/O Board Form C Digital Outputs

 96 SCADAPack 535E Hardware Manual

8.6 Analog Input Wiring

The topics in this section describe the wiring for the analog inputs on the RTU.

SCADAPack 535E Analog Inputs

Analog Input Wiring Example 96

Supporting Current and Voltage Inputs 98

Helping to Prevent Interruption of the Current Loop 103

8.6.1 Analog Input Wiring Example

The analog inputs support loop-powered and self-powered transmitters.

NOTICE
 SCADAPack 535E Hardware Manual 97

UNEXPECTED EQUIPMENT OPERATION

If a transducer or transmitter connected to an analog channel is placed outside of
the building or structure where the RTU or I/O expansion module that provides the
analog inputs is installed, there is an increased possibility of extremely severe
power surges caused by lightning. In these cases, additional surge protection must
be supplied by the user.

Failure to follow these instructions can result in equipment damage.

Loop-powered transmitters are two-terminal devices that are connected between a power supply and
the analog input. The loop current from the power supply passes through the transmitter and returns to
the power supply through a 250 ohm resistor in the 20 mA input circuit.
Self-powered transmitters have three terminals:
Power In connects to a power supply
Signal Out connects to the analog input channel
Common connects to COM
Self-powered transmitters can have a current or voltage output.

In the wiring example below, Transmitter 1 is grounded and connected to AI 1-. Transmitter 6 is
connected to the positive power supply and to AI 6+. These two connections are possible because the
analog inputs are isolated.

Analog Input Wiring Example

 98 SCADAPack 535E Hardware Manual

8.6.2 Supporting a Mix of Current and Voltage Inputs

Overview
The unit is shipped with the six analog inputs operating either in DC current mode or in DC voltage
mode. However, you can change the input mode for individual analog inputs to support a mix of current
and voltage analog inputs if needed.
The unit is factory-calibrated for 0...20 mA and 4...20 mA current inputs and for 0...5 V and 1...5 V
operation so there is no need to adjust the calibration when you change the input mode for an analog
input.
Changing voltage inputs to current inputs
If the analog inputs are operating in DC voltage mode, there are two ways to support DC current input:
Add an external resistor to convert the current input to voltage input. This is the recommended
approach because:
You do not need to remove the unit from the DIN rail or disconnect the wiring.
The current loop can be configured so it is not interrupted if you need to service the unit.
For details, see Converting Current Input to Voltage Input 98 .
Move the appropriate analog input dip switches from the voltage position to the current position. This
approach is not recommended because:
In most situations you need to remove the unit from the DIN rail and disconnect the wiring.
The current loop is interrupted if you need to service the unit.
If you choose this approach, carefully consider the precautions below before proceeding. For details,
see Moving the Analog Input DIP Switch to Change the Input Mode 100 .
Changing current inputs to voltage inputs
If the analog inputs are operating in DC current mode, you can move the appropriate analog input dip
switches to the voltage position to support DC voltage inputs. Carefully consider the precautions below
before proceeding. For details, see Moving the Analog Input DIP Switch to Change the Input Mode 100 .

Converting Current Input to Voltage Input

In the following illustration, the analog inputs are configured to operate in voltage mode and an external
resistor is used to convert current input to voltage input where necessary. This wiring approach allows
you to configure the current loop so it is not interrupted if the unit requires servicing. For details, see
Helping to Prevent Interruption of the Current Loop 103 .
 SCADAPack 535E Hardware Manual 99

Wiring to Support a Mix of Current and Voltage Inputs

100 SCADAPack 535E Hardware Manual

Moving the Analog Input DIP Switch to Change the Input Mode
The procedure below describes how to move the dip switches on the back of the unit to change the
analog input mode from DC voltage mode to DC current mode, or from DC current mode to DC voltage
mode.
If you have open access to the back of the unit, where the dip switches are located, you do not need to
remove the unit from the DIN rail or the wiring from the unit to access the dip switches. In this case, skip
to step 4 in the procedure below.
If you do not have open access to the back of the unit, you will need to remove the unit from the DIN rail
and you will likely need to remove the wiring from the unit to access the dip switches. In this case, follow
the procedure below from step 1. Carefully consider the precautions below before proceeding.
To change the operating mode for an analog input

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the SCADAPack E RTU and the I/O expansion module before removing power.
Failure to follow these instructions can result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from all devices before connecting or disconnecting inputs or outputs
to any terminal or installing or removing any hardware.
Failure to follow these instructions can result in death or serious injury.

1. Remove power from the unit.

2. Disconnect all power, I/O and serial port wiring.
3. Remove the unit from the DIN rail.
To remove the unit from the DIN rail, press down on the top of the unit to compress the mounting
springs while tilting the bottom of the unit toward you. When the DIN rail is free of the lower claws
on the back of the RTU, gently lift the unit away from the DIN rail.
4. On the back of the unit, locate the dip switch for the analog input that you want to reconfigure.
The dip switch numbers correspond to the analog input numbers. For example, to change the input
mode for analog input 1, move dip switch 1. The figure below shows the six dip switches set for DC
current mode.
 SCADAPack 535E Hardware Manual 101

Analog Input Dip Switches Set for Current Mode

5. Move the dip switch to the alternate mode of operation:
For DC current (mA), slide the dip switch to the lower position.
For DC voltage (V), slide the dip switch to the upper position.
In the figure below, analog inputs 2, 3 and 6 are configured for DC voltage while analog inputs 1, 4
and 5 are configured for DC current.

Analog Inputs Configured for a Mix of Current and Voltage Inputs

6. Remount the unit on the DIN rail.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Do not connect I/O devices that exceed the maximum current or voltage for an
analog input.
The maximum DC current for an analog input is 20 mA.
102 SCADAPack 535E Hardware Manual

The maximum DC voltage for an analog input is 5 V.

Failure to follow these instructions can result in equipment damage.

7. Reconnect the inputs and outputs.

8. Reconnect the power connectors and reapply power to the unit.
9. In SCADAPack E Configurator, go to the SCADAPack IO property page and change the Input
Type for the analog inputs that were reconfigured.
 SCADAPack 535E Hardware Manual 103

8.6.3 Helping to Prevent Interruption of the Current Loop

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from all devices before connecting or disconnecting inputs or
outputs to any terminal or installing or removing any hardware.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Do not exceed the maximum voltage specified for each analog input.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The RTU or I/O expansion module must be the only loop current measurement
device in the loop when using the analog inputs in the 20 mA measurement
mode. If power to the module is removed, the module reverts to voltage mode
and results in an open current loop. Applications that cannot tolerate this
possibility need to utilize external current sense resistors with the module input
range set to voltage.
Failure to follow these instructions can result in equipment damage.

Add 250 ohm external resistors to the current loop at the terminal strip to help prevent interruption of the
current loop if the RTU or I/O expansion module is being serviced. The physical wiring of the external 250
ohm external resistors at the terminal strip is illustrated below.
104 SCADAPack 535E Hardware Manual

Wiring to Help Prevent Interruption of the Analog Input Current Loop

As illustrated below, the RTU or I/O expansion module providing the analog inputs does not need to be
the last device in the current loop.

Valid SCADAPack E RTU Positions in the Current Loop

 SCADAPack 535E Hardware Manual 105

8.7 Analog Output Wiring

The topics in this section describe the wiring for the analog outputs on the RTU.

SCADAPack 535E Analog Outputs

Analog Output Wiring Example 105

Supporting Current and Voltage Outputs 108

8.7.1 Analog Output Wiring Example

The figure below shows loads connected to the two analog outputs.

NOTICE
106 SCADAPack 535E Hardware Manual

UNEXPECTED EQUIPMENT OPERATION

Install a 0.063A fast-acting fuse on the input voltage side of the analog output power
supply connection.
Failure to follow these instructions can result in equipment damage.

Analog Output Wiring Example

The analog output circuitry is configured internally to receive power from an external power supply on
pins 1 and 2 of the removable terminal block. Pin 5 (Com 1-2) and pin 2 (power input –) are connected
internally. As illustrated in the following figure, the two analog outputs are not isolated from each other,
but are isolated from the RTU logic.
 SCADAPack 535E Hardware Manual 107

Analog Output Internal Wiring

 108 SCADAPack 535E Hardware Manual

8.7.2 Supporting Current and Voltage Outputs

The analog outputs can be configured for 4...20 mA current or 0...20 mA current.

If a voltage output is required (1...5 V, for example), run the 4...20 mA or 0...20 mA signal to the device
that requires voltage input and place a 250 ohm resistor across the input terminals on the device. With
this resistor in place, the analog output is electrically isolated from the rest of the RTU, but is not
isolated from the power supply.

The table below lists resistance values and output range settings for common voltage ranges. The
resistance value listed is the parallel resistance of the device and the load resistor.

Resistance Values and Output Ranges

Resistance Output Range Voltage Range

250 ohm 0...20 mA 0...5 V

4...20 mA 1...5 V

500 ohm 0...20 mA 0...10 V

 SCADAPack 535E Hardware Manual 109

9 Configuration
The RTU can be configured:
Locally or remotely using SCADAPack E Configurator 109 , a software application that runs on a
desktop or laptop computer.
Remotely as part of an end-to-end SCADA system using the StruxureWare SCADA Expert
ClearSCADA software.
Locally using applications created in SCADAPack Workbench or ISaGRAF 3 Workbench. 111

Before you begin configuring the RTU, determine whether the SCADA Expert ClearSCADA software will
be used for any configuration tasks. This documentation assumes you are using the SCADAPack E
Configurator software to configure the RTU. For information about using the ClearSCADA software, see
the ClearSCADA documentation.

9.1 SCADAPack E Configurator

The SCADAPack E Configurator software provides a graphical user interface that allows you to configure
the RTU settings and to load those settings into the RTU. It also integrates with SCADAPack
Workbench and ISaGRAF 3 Workbench so you can build and diagnose IEC 61131-3 sequences that
extend the RTU capabilities.
If you begin RTU configuration in the SCADAPack E Configurator software, you cannot switch to the
StruxureWare SCADA Expert ClearSCADA software. Similarly, if you begin RTU configuration in the
SCADA Expert ClearSCADA software, you cannot switch to the SCADAPack E Configurator software.
The following table summarizes where in the SCADAPack E Configurator software you will find the
configurable attributes for each hardware element on the SCADAPack 530E and SCADAPack 535E.

Configuration Parameters in SCADAPack E Configurator

Hardware Label SCADAPack E SCADAPack E SCADAPack E

Configurator Folder Configurator Configurator Label
Property Page(s)
Serial1 Ports Ports 0-4 Port 1
Serial2 Port 2
Serial3 Port 3
Serial4 Port 4
Eth1 TCP/IP TCP/IP Ethernet 1
Eth2 Ethernet 2
Eth3 Ethernet 3
USB Device Ports Ports 0-4 Port 0
DI Points Binary Points Binary Points
DO Counter Points 1 Counter Points 1
AI1 Analog Points 1 Analog Points 1
AO1

1 The SCADAPack 530E does not provide counter inputs, analog inputs or analog outputs. Add the 6601
I/O expansion module if you need these input or output types.
110 SCADAPack 535E Hardware Manual

The figure below illustrates the Ports 0-4 property page for the SCADAPack 530E and SCADAPack
535E and shows the location of the other property pages listed in the table. For details about using
SCADAPack E Configurator, refer to the SCADAPack E Configurator User Manual.

SCADAPack E Configurator User Interface

 SCADAPack 535E Hardware Manual 111

9.2 Reading and Writing Data With Logic Programs

IEC 61131-3 applications use I/O connections to the SCADAPack E RTU point database to access
physical I/O points and derived data.

Reading and Writing Digital I/O Data

SCADAPack Workbench applications can read digital data, including digital input/output points:
Use SCADAPack Workbench RTU_BIN_READ I/O devices to read digital input points.
Use SCADAPack Workbench RTU_BIN_READ_OUTPUT I/O devices for reading digital output point
states.

To write digital data, including digital output points, use SCADAPack Workbench RTU_BIN_WRITE I/O
devices.

To read or write data to the digital inputs or outputs in ISaGRAF 3 Workbench applications, use rtuxxdi,
rtuxxdo or rtuxxdos I/O boards.

Reading and Writing Analog Input Data

SCADAPack Workbench applications can read analog data, including analog input points, using
RTU_RAW_READ or RTU_ENG_READ I/O devices.
For ISaGRAF 3 Workbench applications, use rtuxxai I/O boards to read the analog inputs.
Configuration for points attached to the analog input channels uses the SCADAPack E RAW_MIN,
RAW_MAX and ENG_MIN, ENG_MAX parameters for integer and engineering scaling, respectively.
These scaling ranges apply to the analog input signal range selected in SCADAPack E Configurator for
each analog input channel.

Reading and Writing Analog Output Data

The I/O board includes two analog output channels if the optional analog output module was ordered with
the unit.
SCADAPack Workbench applications can write analog data, including analog input points, using
RTU_RAW_WRITE or RTU_ENG_WRITE I/O devices. They can also can read analog outputs using
RTU_RAW_READ_OUTPUT and RTU_ENG_READ_OUTPUT I/O devices.

For ISaGRAF 3 Workbench applications, use rtuxxao I/O boards to write to the analog inputs and
rtuxxaos I/O boards to read analog outputs.

More Information
Refer to the SCADAPack E Target 5 Technical Reference Manuals, ISaGRAF 3 Technical Manuals, or
the SCADAPack E Configurator User Manual for information about how to assign RTU points.
 112 SCADAPack 535E Hardware Manual

10 Diagnostics
The RTU provides a number of capabilities that can help you monitor RTU operations and perform
troubleshooting tasks. They include:
LEDs that indicate the status of RTU ports and communications
Diagnostics for several aspects of RTU communications and exceptional RTU operating conditions
System points that measure internal RTU temperature and provide power supply and battery status
System points that provide communications status information
Status codes that provide information about system, communication and device status

The following topics provide an overview of the diagnostics capabilities on the RTU:
LEDs 113
Accessing Diagnostics 116
Startup Diagnostics 118
Internal Temperature Reading 119
Power Supply and Battery Status 120
Communication Statistics 121
Status Codes 122
 SCADAPack 535E Hardware Manual 113

10.1 LEDs
The front panel for the SCADAPack 530E and SCADAPack 535E provides 16 LEDs to indicate hardware
status. The figure below shows the RTU front panel LEDs.

SCADAPack 530E and SCADAPack 535E Front Panel LEDs

In addition to the front panel LEDs, the serial and Ethernet ports and the digital inputs and outputs on
the RTU include LEDs to indicate status. The following table describes the LEDs on the SCADAPack
530E and SCADAPack 535E.

SCADAPack 530E and SCADAPack 535E LED Descriptions

Type Name or Color Description

Location

General Power Green Lit when correct voltage is applied to the power
terminals. Does not indicate whether the CPU is
running.

Run Green Blinks when the CPU is running.

Status Red Blinks to indicate a new status code has been

generated.

To view the status code and its description, go to

the General > Controller Status property page in
the SCADAPack E Configurator software.

The status code is also available through analog

system point 50020.

Force Red Lit when an I/O point is being forced into a state that
does not represent its actual state. This typically
114 SCADAPack 535E Hardware Manual

occurs during debugging exercises or when a

SCADAPack Workbench or ISaGRAF 3 Workbench
application locks the I/O point for its own use.

Input and Digital input Green Lit when the digital input is active.
Output Blinks when pulses are applied if the digital input is
configured to be a counter (SCADAPack 535E only).

Digital output Green Lit when the digital output is active.

USB Host Status Green This LED is under the control of Binary System Point
50753. It can be controlled by a SCADAPack
Workbench or ISaGRAF 3 Workbench application or
through protocol control commands.

Store Green Blinks when automatic loading of security files from

the USB mass storage device into the RTU is
successfully completed.
Eth1, Eth2, Left side of the Green Activity LED.
Eth3 physical port Lit when the Ethernet port is active.
Blinks when the port is transmitting or receiving data.
Right side of Yellow Link LED.
the physical Lit when 10/100 Ethernet link is active.
port

Modem1 TxD Green Lit when the (optional) cellular modem is transmitting
data.

RxD Green Lit when the (optional) cellular modem is receiving

data.

Link Green Lit when the (optional) cellular modem has an active
network connection.

Serial1 and CTS Green Lit when the CTS input is active on the port.
Serial2
DCD Green Lit when the DCD input is active on this serial port.

Left side of the Green Blinks when the port is transmitting data over the
physical port RS232 serial connection.

Right side of Green Blinks when the port is receiving data over the RS232
the physical serial connection.
port

Serial3 and Left side of the Green Blinks when data is being transmitted over the
Serial4 physical port RS232 or RS485 serial connection.

If the port is configured for RS485, the LEDs on the

empty port indicate that data is being transmitted
 SCADAPack 535E Hardware Manual 115

over the wired RS485 connection.

Right side of Green Blinks when data is being received over the RS232 or
the physical RS485 serial connection.
port
If the port is configured for RS485, the LEDs on the
empty port indicate that data is being received over
the wired RS485 connection.

1 The cellular modem is expected to be available in a future release.

 116 SCADAPack 535E Hardware Manual

10.2 Accessing Diagnostics

The RTU provides diagnostics for several aspects of RTU communications and exceptional operating
conditions. The following operational diagnostics are specifically supported:
DNP3 diagnostics at each protocol layer, including network routing.
TCP/IP diagnostics including DNP3 over IP, IP servers and TCP service ports.
PLC communication diagnostics including protocol packet displays, communication status and
device status for serial and network PLC services.
RTU system diagnostics.
The operational information provided during a diagnostic display session can assist in troubleshooting.
To sort these diagnostics from normal operational messages, it may be advantageous to disable DNP,
TCP/IP, PLC and system diagnostics using the DNPDIAG, TCPDIAG, PLCDIAG and SYSDIAG
commands from the command line. Other RTU diagnostics use the following format to assist in
identifying messages from various RTU tasks:
Task-name>>diagnostic text

To Access Diagnostics
Use a command line in a diagnostic display session to query the RTU's operational status. The
commands available are detailed in the SCADAPack E Operational Reference Manual.
There are three main ways to access command line diagnostics:
Using an ASCII terminal connected to any RTU serial port configured for the Cmd Line function. This
is the method used to display startup diagnostics. For details, see Startup Diagnostics 118 . To access
a diagnostic display session, use the DIAG command as described in the SCADAPack E Operational
Reference manual.
Using an ASCII terminal connected to any RTU serial port configured for the ISaGRAF function.
Enable the SCADAPack Workbench or ISaGRAF 3 Workbench functionality to enter command line
mode through an ISaGRAF port. To access the command line, press the Enter key three times. To
return to SCADAPack Workbench or ISaGRAF 3 Workbench debugging mode, type the BYE
command.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The BYE command should be issued prior to disconnecting the ASCII terminal for
correct SCADAPack Workbench or ISaGRAF 3 Workbench operation.
Failure to follow these instructions can result in equipment damage.

Using Telnet over TCP/IP links. Multiple Telnet sessions may be established with the RTU on the
same TCP/IP interface, or multiple sessions may be simultaneously established on multiple TCP/IP
interfaces.
 SCADAPack 535E Hardware Manual 117

Where a direct serial connection or Telnet is not available, diagnostics can be directed to an RTU file.
This is achieved using the FILEDIAG command described in the SCADAPack E Operational Reference
Manual. This diagnostics log file can then be retrieved for analysis using DNP3 file transfer.
You can also use the Transfer > Remote Command Line menu option in SCADAPack E Configurator
to access the command line interface for remote SCADAPack ES units through a virtual terminal window
over DNP3 links. The RTU does not need to be configured with a Cmd Line or ISaGRAF port to access
this functionality.
 118 SCADAPack 535E Hardware Manual

10.3 Startup Diagnostics

At startup, the RTU displays information about its startup sequence and configuration in ASCII text
format through any port configured for the Cmd Line function. By default, Serial4 (Port 4) on the RTU is
configured for the Cmd Line function.
Once startup is complete, the RTU terminates the diagnostic session and enters command mode
unless you have configured the RTU to remain in the diagnostic display session. Use the SYSDIAG
OVERRIDE command described in the SCADAPack E Operational Reference Manual to configure the
RTU to remain in the diagnostic display session when startup is complete.
To access command line mode from a diagnostic display session, press the Esc (Escape) key on your
keyboard.
 SCADAPack 535E Hardware Manual 119

10.4 Internal Temperature Reading

Analog system points are used to measure RTU input supply voltage and the ambient temperature of the
RTU controller board. Use the SCADAPack E Configurator software to add the system points you want
to measure to the RTU points database.
Once defined, system points can be accessed directly from a user application program or through
remote RTU communications.

Internal Temperature oC
Analog System Point 50062
This analog system point measures the ambient temperature at the controller board in degrees Celsius.
It is useful for measuring the operating environment of the controller board and returns an integer value in
the range –40°C to 75°C. Temperatures outside this range cannot be measured.
Use the system point directly by defining an analog system point with the point number 50062 in the
RTU points database.
Read the system point into a user-created SCADAPack Workbench or ISaGRAF 3 Workbench
application as an Integer or Real variable from an input board connection.

Internal Temperature oF
Analog System Point 50063
This analog system point measures the ambient temperature at the controller board in degrees
Fahrenheit. It is useful for measuring the operating environment of the controller board and returns an
integer value in the range –40°F to 167°F. Temperatures outside this range cannot be measured.
Use the system point directly by assigning an analog system point with the point number 50063 in
the RTU points database
Read the system point into a user-created SCADAPack Workbench or ISaGRAF 3 Workbench
application as an Integer or Real variable from an input board.
 120 SCADAPack 535E Hardware Manual

10.5 Power Supply and Battery Status

Internal binary system points are used to indicate the status of the RTU power supply and the onboard
back-up RAM battery. These can be accessed from a user-created application or through remote RTU
communications.
Use the SCADAPack E Configurator software to add the system points you want to measure to the RTU
points database.
Local Input Power Supply Low

Binary System Point 50206

An internal binary point indicates the condition of the input power supply. It compares the Supply
Voltage System Analog Point 50060 with the low voltage notification level set in SCADAPack E
Configurator General>Controller Settings property page. If the input power supply is lower than the low
voltage notification level then this Binary System Point is activated.

Use the system point directly by assigning a binary point to this point number (50206) in the RTU
database.
For SCADAPack Workbench and ISaGRAF 3 Workbench applications, read the status point through
an input board connection.

Local On Board Battery Low

Binary System Point 50207

An internal binary point indicates the condition of a monitor on the lithium battery that maintains the non-
volatile RAM in the controller. If active, the point indicates that the onboard controller battery needs
replacement.

Use the system point directly by assigning a binary point to this point number (50207) in the RTU
database.
For SCADAPack Workbench and ISaGRAF 3 Workbench applications, read the status point through
an input board connection.
 SCADAPack 535E Hardware Manual 121

10.6 Communication Statistics

The RTU provides three types of communication statistics through analog system points:

SCADAPack E (global) communication statistics

Port communication statistics
TCP/IP communication statistics
The analog system points for communication statistics can be read from the RTU using specific DNP3
point range read requests. Alternatively, they can be read into a SCADAPack Workbench or ISaGRAF 3
Workbench user-created application through input boards or function blocks.
Communication statistics point values can be reset at any time by controlling the relevant system point
value and setting it to 0. This may be done by a SCADAPack Workbench or ISaGRAF 3 Workbench
application or through DNP3 point controls.
The communication statistics analog system points cannot be directly added to the RTU points
database and returned in DNP3 Class data polls. To map communication statistics points to a SCADA
master, the values can be imported into a SCADAPack Workbench or ISaGRAF 3 Workbench
application, manipulated if required, then exported to a derived point, which can be configured for access
by a SCADA master.
Communication statistics analog system points can be accessed as 16-bit or 32-bit analog input points.
For details, see the SCADAPack E Operational Reference Manual.
 122 SCADAPack 535E Hardware Manual

10.7 Status Codes

This section describes the following RTU status codes
System Status Codes 123
Communication and Device Status Codes 125
 SCADAPack 535E Hardware Manual 123

10.7.1 System Status Codes

SCADAPack E RTUs provide system status codes through analog system points. The latest status is
retained as the value of the system status. DNP3 event reporting may be configured for the system
status point to provide a time-stamped history of status codes.
User-defined status codes may be generated through SCADAPack Workbench or ISaGRAF 3
Workbench using the RTUPARAM function block with the SYS_ERR_CODE parameter.
The status of SCADAPack Workbench and ISaGRAF 3 Workbench applications are reported:
To the SCADAPack Workbench or ISaGRAF 3 Workbench Debugger if connected locally or
remotely
Through the SCADAPack E System Error Point
Through a SCADAPack E diagnostic display session

SCADAPack E System Status Codes

Status Name Description

Code

0 Normal Normal status on the RTU.

1-100 ISaGRAF Target Status See the SCADAPack E ISaGRAF Technical Reference
Manual and the SCADAPack E Target 5 Technical
Reference Manual.

100-999 User Defined Status For SCADAPack Workbench, see the RTUPARAM
function block in the SCADAPack E Target 5 Function
Block Reference Manual.
For ISaGRAF 3 Workbench, see the RTUPARAM function
block in the ISaGRAF Function Blocks Reference Manual.

1001-1009 ISaGRAF Application Load Did not load SCADAPack Workbench or ISaGRAF 3
Status Workbench application files or memory application for
targets.

1010-1019 Configuration Status Configuration file status codes.

1020-1029 Profile Status Profile configuration status codes.

1030-1039 Event & Trend Status Event storage threshold status codes.

1040-1049 Data Processing Status Run-time data processing status codes.

1050-1059 Remote I/O Status Firmware mismatch status codes.

1400-1401 Mounting Status Root folder mounting status codes.

2000-2999 TCP/IP Status TCP/IP configuration and run-time status.

See the SCADAPack E TCP/IP Technical Reference
Manual for details.

3000-3099 Extended Status Additional configuration file and firmware update status
codes.
124 SCADAPack 535E Hardware Manual

For details about SCADAPack E system status codes, see the SCADAPack E Operational Reference
Manual.
 SCADAPack 535E Hardware Manual 125

10.7.2 Communication and Device Status Codes

DNP3 Communication Status

DNP3 communication status is reported by the RTU through a diagnostic display session as DNP3
driver diagnostic information. These status codes are also reported through the SCADAPack Workbench
or ISaGRAF Workbench Peer Communication function blocks in the output STATUS variable.
DNP3 communication status is not reported through the RTU System Error Point.
See the SCADAPack E DNP3 Technical Reference Manual for a complete list of DNP3 communication
status codes.

TCP/IP Status
TCP/IP communication and configuration status is reported by the RTU through a diagnostic display
session as TCP/IP diagnostic information. These status codes are also reported through the
SCADAPack Workbench or ISaGRAF Workbench TCP/IP function blocks in the output STATUS
variable.
TCP/IP status is reported through the RTU System Error Point for incorrect TCP/IP configuration.
See the SCADAPack E TCP/IP Technical Reference Manual for a complete list of TCP/IP
communication status codes.

PLC Device Communication Status

Status codes from PLC device drivers on the RTU are reported through analog system points. These
analog system points represent the status of communications between a SCADAPack Workbench or
ISaGRAF Workbench PLC device I/O board and a PLC device.
PLC device communication status is not reported through the SCADAPack E System Error Point.
PLC device communication status codes are detailed in the following manuals:
SCADAPack E ISaGRAF Technical Reference Manual
SCADAPack E Target 5 Technical Reference Manual
SCADAPack E Modbus Communication Interfaces Manual
 126 SCADAPack 535E Hardware Manual

11 Maintenance
The following sections describe the recommended maintenance activities for the RTU:

Calibration 127
Preventive Maintenance 128
Routine Maintenance 130
Replacing the Battery 133
 SCADAPack 535E Hardware Manual 127

11.1 Calibration

The RTU is electronically calibrated at the factory during the manufacturing process and after any repair
procedures.

There are no user calibration procedures.

 128 SCADAPack 535E Hardware Manual

11.2 Preventive Maintenance

Keep circuit boards free from contaminants such as dust and moisture.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU or the I/O expansion module before removing power.
Failure to follow these instructions can result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from the RTU before removing the RTU cover.
Remove power from the RTU before servicing.
Failure to follow these instructions can result in death or serious injury.

Battery Handling Procedures

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Treat batteries with care.
Follow the manufacturers’ instructions concerning battery storage, use and
disposal.
Keep batteries clean and free from contaminants or other materials that could
short the terminals.
Connect new batteries using the correct polarity.
Replace batteries with new units of the same chemistry, capacity and make.
Observe the manufacturers’ instructions regarding disposal of batteries.
Considerable energy remains in the battery.
Failure to follow these instructions can result in equipment damage.
 SCADAPack 535E Hardware Manual 129

Electrostatic Discharge (ESD) Procedures

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The electronics inside the RTU can be damaged by static electricity. If you need to
remove the RTU cover, wear an anti-static wrist strap that is connected to ground.
Failing to follow this simple step can cause intermittent or total loss of RTU
operation and will void the warranty.
Failure to follow these instructions can result in equipment damage.
 130 SCADAPack 535E Hardware Manual

11.3 Routine Maintenance

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU or the I/O expansion module before removing power.
Failure to follow these instructions can result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK
Remove power from the RTU before removing the RTU cover.
Remove power from the RTU before servicing.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The electronics inside the RTU can be damaged by static electricity. If you need to
remove the RTU cover, wear an anti-static wrist strap that is connected to ground.
Failing to follow this simple step can cause intermittent or total loss of RTU
operation and will void the warranty.
Failure to follow these instructions can result in equipment damage.

Primary Power Supply

The primary power for the RTU is a DC power supply. If this is a mains-operated power supply charger
with battery backup, replace the batteries every 36 months or earlier if necessary.
 SCADAPack 535E Hardware Manual 131

Real-Time Clock and Onboard RAM Back-up Battery

The RTU includes a lithium-powered back-up battery on the controller board. The main task of the
battery is to back-up the microprocessor RAM chips and the real-time clock. However, the back-up
battery also maintains the RTU configuration during a power-supply interruption.

NOTICE
LOSS OF DATA
RTU memory contents are lost when:
The onboard RAM back-up battery goes flat.
The onboard RAM back-up battery is replaced while power to the RTU is
disconnected.
When memory contents are lost, RTU configuration information and user-created
applications must be reloaded for correct RTU operation.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Before replacing the onboard RAM back-up battery, save a copy of the RTU
configuration information, user-created applications, logs and other data to an
external drive so it can be reloaded when the procedure is complete.
Failure to follow these instructions can result in equipment damage.

The onboard RAM back-up battery will retain the RTU configuration for at least two years if the unit is not
powered. Replace the battery after every five years of continuous use, or earlier if necessary.
RAM back-up batteries are not rechargeable.

Power Supply Notifications

The RTU provides notifications for the following:

Onboard lithium battery low

Input power supply low
If an Input Power Supply low notification is generated, it may be due to power supply interruption, and/or
low voltage on primary DC backup batteries.

Cleaning
There are no special cleaning instructions for this product.
132 SCADAPack 535E Hardware Manual

Routine Maintenance Schedule

The frequency of routine maintenance depends on the specific piece of equipment and the environment
in which it is installed. Routine maintenance is recommended at two time-intervals:
Every three years
Every five years
The following table summarizes the recommended frequency for maintenance procedures. In some
cases, the period stated is the maximum interval between maintenance activities. Experience, or the
high usage of a particular piece of equipment, may determine that maintenance procedures need to be
performed more frequently than indicated in the table
Items requiring re-calibration may not be suitable for user servicing. Contact Schneider Electric for advice
5 .

Routine Maintenance Schedule

Component Every Three Years Every Five Years

Connections and ground points CR

Power supply units CR

Modems CR

RAM back-up battery CR R

R=Replace CR=Check and replace if necessary

 SCADAPack 535E Hardware Manual 133

11.4 Replacing the Battery

A flat-package lithium battery located on the controller board provides back-up power to the RTU's real-
time clock and RAM memory.
Replace this battery with a Tadiran TL-5186 3.6V lithium battery as soon as possible after the RTU
reports that the RAM battery status is low and at the intervals recommended in the Routine Maintenance
130 section.

The RAM battery status is provided on the Controller Status property page in the SCADAPack E
Configurator software. Take care not to confuse this status with an external power supply low condition.
The following procedure requires the RTU to be powered off briefly. It also requires restarting the RTU in
Cold Boot mode. As a result, the following precautions should be carefully considered before proceeding.

Back-Up Data Before Replacing the Battery

NOTICE
UNEXPECTED EQUIPMENT OPERATION
RTU memory contents are lost when:
The onboard RAM back-up battery goes flat.
The onboard RAM back-up battery is replaced while power to the RTU
disconnected, as required in the procedure below.
The RTU is started in Factory Boot mode or in Cold Boot mode. Starting in Cold
Boot mode is required in the procedure below.
When memory contents are lost, RTU configuration information and user-created
applications must be reloaded for correct RTU operation.
Failure to follow these instructions can result in equipment damage.

NOTICE
UNEXPECTED EQUIPMENT OPERATION.
Before replacing the onboard RAM back-up battery or starting the RTU in Factory
Boot mode or Cold Boot mode, save a copy of the RTU configuration information,
user-created applications, logs and other data to an external drive so it can be
reloaded when the procedure is complete.
Failure to follow these instructions can result in equipment damage.
134 SCADAPack 535E Hardware Manual

NOTICE
UNEXPECTED EQUIPMENT OPERATION
The electronics inside the RTU can be damaged by static electricity. If you need to
remove the RTU cover, wear an anti-static wrist strap that is connected to ground.
Failing to follow this simple step can cause intermittent or total loss of RTU
operation and will void the warranty.
Failure to follow these instructions can result in equipment damage.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment being monitored or controlled by
the RTU before removing power.
Failure to follow these instructions can result in death or serious injury.

To Replace the Onboard RAM Back-up Battery

1. Remove power from the RTU.

2. Put on an anti-static wrist strap and verify that it is connected to ground.
3. Remove the RTU cover.
4. Cut the tie wrap on the battery and carefully remove it from its socket on the controller board.
5. Insert the new Tadiran TL-5186 3.6V lithium battery. The tie wrap is intended to keep the battery in
place during shipping and does not need to be replaced.
6. Reattach the RTU cover.
7. Apply power to the RTU and start it in Cold Boot mode by holding the Select button down for 20
seconds until the Status LED begins blinking on and off.
8. In SCADAPack E Configurator, use the Transfer > Set RTU time to reset the time on the RTU.
9. Reload the RTU configuration and user-created applications from back-up.
 SCADAPack 535E Hardware Manual 135

11.5 Updating Firmware

On the SCADAPack 535E, you can update:
Controller board operating system firmware in offline or online mode
Controller board boot monitor firmware in offline or online mode
I/O board firmware

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Before you install any firmware updates, check the Release Notes for the firmware
update to determine the most suitable firmware versions for the functionality you are
using and to confirm version compatibility.
Failure to follow these instructions can result in equipment damage.

For the procedures to update firmware, see the SCADAPack E Firmware Update User Manual.

12 Specifications
The following topics provide detailed hardware specifications for the RTU, its ports and its inputs and
outputs.
General 136
Power Supply 137
Controller Board 137

Data Capacity 139

Communications 140
Digital and Counter Inputs 141
Digital Outputs 142
Analog Inputs 143
Analog Outputs 145
 136 SCADAPack 535E Hardware Manual

12.1 General
Environment -40°C … 70°C (-40°F…158°F) operating temperature when
mounted on a horizontally oriented DIN rail
-40°C … 65°C (-40°F…149°F) operating temperature when
mounted on a vertically oriented DIN rail
-40°C … 85°C (-40°F…185°F) storage temperature
5% to 95% relative humidity, non-condensing
Pollution Degree 2, Installation Category I, Indoor use
Elevation 3,000 m (9,842 ft)

Terminations 3.3 mm2 to .08 mm2 (12 AWG to 28 AWG), solid or stranded

Packaging Corrosion-resistant and RoHS-compliant clear zinc-plated steel

with black enamel paint

SCADAPack 535E 151 mm (5.9 in.) wide

Dimensions 182 mm (7.2 in.) high
87 mm (3.4 in.) deep

SCADAPack 530E 151 mm (5.9 in.) wide

Dimensions 135 mm (5.3 in.) high
75 mm (3.0 in.) deep

6601 I/O Expansion Module 151 mm (5.9 in.) wide

Dimensions 182 mm (7.2 in.) high
47 mm (1.9 in.) deep

Shock IEC 61131-2

½ sine, 15 ms, 15 g

Vibration IEC 61131-2

5 – 8.4 Hz: Amplitude controlled, 7.0 mm (0.28 in.) peak-to-peak
8.4 – 150 Hz: Acceleration controlled, 1.0 g peak
 SCADAPack 535E Hardware Manual 137

12.2 Power Supply

Input Voltage Rated voltage: 12…30 Vdc
Limit voltage: 11.5...32 Vdc
Turn-on voltage: 10…11.5 Vdc
Turn-off voltage: 9..10 Vdc
Maximum Power SCADAPack 530E plus 4 6601 I/O expansion modules
plus USB: 8.6 W
Power Requirements SCADAPack 530E: 3.7 W
SCADAPack 535E with integrated I/O: 4.8 W
6601 I/O expansion module: 1.1 W
USB (5 V at 100 mA): 0.6 W
Serial port (5 V at 250 mA): 1.5 W
Also see Power Supply Requirements 53
Maximum System SCADAPack 535E plus 3 6601 I/O expansion modules
Configuration SCADAPack 530E plus 4 6601 I/O expansion modules
SCADAPack 535E plus 2 6601 I/O expansion modules
plus serial port 5 V
SCADAPack 530E plus 3 6601 I/O expansion modules
plus serial port 5 V
USB 5 V at 100 mA permissible in any configuration
Isolation Controller power input, USB and serial communication
ports are not isolated from the enclosure
See the relevant specifications for I/O point isolation
information
Protection Protected up to 60 Vdc for over-voltages and reverse
polarity voltages
Inrush current limited
Cable Length Maximum: 30 m (98.4 ft)

12.3 Controller Board

Processor ST SPEAr 1380 32-bit, dual-core Cortex™ A9 microcontroller

Floating Point Integrated Hardware Floating Point Unit

CPU Speed Up to 600 MHz

Memory 128 MB NAND Flash

128 MB DDR3 RAM
Non-volatile RAM Non-volatile CMOS SRAM with lithium battery retains content for up to
two years when not connected to an active power source

Internal Analog Inputs Power input: 37 V full scale. Accuracy is 0.5% of full scale.
Onboard lithium battery: 4 V full scale. Accuracy is 0.5% of full scale.
5 V power supply: 6 V full scale. Accuracy is 0.5% of full scale.
3.3 V power supply: 4 V full scale. Accuracy is 0.5% of full scale
Internal Temperature Monitor Controller temperature: -40°C…75°C (-40°F...167°F)
138 SCADAPack 535E Hardware Manual

Clock Calendar ±15 seconds per month at -15°C…60°C (5°F...140°F)

 SCADAPack 535E Hardware Manual 139

12.4 Data Capacity

Maximum Database Points Approximately 20,000
Reduced if event pool increased above approximately
7,000 events

Maximum DNP3 Events 40,000

Reduced if database points increased above
approximately 10,000 points

Maximum Data Concentrator Approximately 15,000

points

Maximum Data Concentrator Approximately 100

Devices

File System Typical Storage 10 MB

Maximum Trend Sample Files 400 (when no user programming used)

Remote Upload Trend Data: 100,000

Integers

Remote Upload Trend Data: 50,000

Floats

Trend Aggregation Up to 10 MB with Restart History used in ISaGRAF 3 or

SCADAPack Workbench
See the SCADAPack E Trend Sampler Technical
Manual for details

Local Access Aggregated 2,500,000

Trend Data: Integers

Local Access Aggregated 1,250,000

Trend Data: Floats

USB Host Storage Single-partition plug-in USB mass storage devices up to

32 GB
 140 SCADAPack 535E Hardware Manual

12.5 Communications
Serial1, 2 RS232 signals: TxD, RxD, CTS, RTS, DCD, DTR

Serial3, 4 RS232 signals: TxD, RxD

RS485: 2-wire half-duplex operation

Serial1…4 5 V at 250 mA available

8-pin modular jack connector (RJ45)
Baud rates up to 115,200 bps
Cable Length RS232: Maximum 15 m (50 ft)
RS485: Maximum 1200 m (3937 ft)

Protection RS232 ports are rated to ±15kV (IEC 61000-4-2, Air

Discharge) static protection
Ethernet 1, 2, 3 10/100 Mbps UTP (10/100Base-T) transformer isolated

USB Host Port USB 2.0-compliant A-type receptacle

Supports USB mass storage devices up to 32 GB
USB Device Port USB 2.0-compliant B-type receptacle

I/O Bus I/O expansion module bus. The RTU supports the 6601
I/O expansion module which provides:
16 digital inputs, 8 of which have an associated counter
8 digital (relay) outputs
6 analog inputs
2 analog outputs (this option is selected when the 6601
I/O expansion module is ordered)
Maximum Modbus/TCP Server Fixed: 20
Connections
 SCADAPack 535E Hardware Manual 141

12.6 Digital and Counter Inputs

Controller Board
Digital Inputs
Turn-on Voltage Minimum: 8 Vdc

Turn-off Voltage Maximum: 4 Vdc

Input Voltage Maximum: 36 V

Input Resistance 30 kohms

Isolation Ground return connected to chassis ground

Cable Length Maximum: 3 m (9.84 ft)

I/O Board
Digital Inputs
Normal Operation Range 12…24 Vdc

Turn-on Voltage Minimum: 9 Vdc

Turn-off Voltage Maximum: 4 Vdc

Over-Voltage Tolerance 150% sustained over-voltage without foreseeable damage

DC Input Current 0.9…1.2 mA at 12 Vdc

2.1…2.4 mA at 24 Vdc

Isolation Isolation is in 2 groups of 8

Isolation from RTU logic and chassis
1000 Vac/1500 Vdc

Time Stamping 1 ms Sequence of Event (SOE)

Counter Inputs
Electrical Characteristics Shared with digital input channels

Reporting 16-bit and 32-bit counters

Deviation
Time-stamped events
Polled, unsolicited reporting

Frequency Up to 8 channels:
DI 1 to 4: 0...1.5 kHz
DI 5 to 8: 0...150 Hz
 142 SCADAPack 535E Hardware Manual

12.7 Digital Outputs

Controller Board
Description Sinking MOSFET output

Power Rating 30 V, 0.5 A

Isolation Ground return connected to chassis ground

Cable Length Maximum: 3 m (9.84 ft)

I/O Board
Type 2 Form C SPDT relays available to the application
Separate Normally Open/Normally Closed/Common

6 Form A relays available to the application

Normally Open, one Common
Isolation 500 Vac minimum to RTU logic

Maximum Switching Voltage 30 Vdc or 25 Vac

Maximum Switching Load 60 W or 50 VA per relay

2 A per relay
2 A per common on digital outputs 1-2
12 A per common on digital outputs 3-8
Status and Reporting Individual relay pole feedback to software
Output state poll
Temperature De-rating Horizontally oriented DIN rail mounting:
- 2 A maximum per relay at 60°C (140°F)
- De-rate by 0.1 A per 1°C to 1 A maximum per relay at
a maximum ambient temperature of 70°C (158°F)

Vertically oriented DIN rail mounting:

- 2 A maximum per relay at 60°C (140°F)
- De-rate by 0.1 A per 1°C to 1.5 A maximum per relay
at a maximum ambient temperature of 65°C (149°F)
Controls Direct Operate
Select Before Operate
Trip/Close
Latch
Pulse
 SCADAPack 535E Hardware Manual 143

12.8 Analog Inputs

Type Uni-polar, differential, voltage or current

Resolution (filtered) 24-bit conversion yields an effective 19 bits of resolution during

filtered conversions
10 uV on the 5 V range
40 nA resolution on the 20 mA range
Resolution (fast) 24-bit conversion yields an effective 13 bits of resolution during
unfiltered conversions.
0.6 mV resolution on the 5 V range
2.4 uA resolution on the 20 mA range
Accuracy ±0.1% of full scale at 25ºC (77ºF)
±0.2% over-temperature range

Isolation 250 Vac from RTU logic and chassis

60 Vdc between inputs
Transformer
Input Resistance 250 ohms
800 kohms in current/voltage configurations

Ranges Input Type: 4...20 mA, 0...20 mA, 1...5 V, or 0...5 V

Under-range: 4...20 mA measures to 0 mA
Individual inputs are current or voltage jumper selectable.
Calibration in voltage mode 1...5 V is available as an option.
Contact factory for custom calibrations
Sampling Rate Filtered: 500 ms per 6 channels
Fast: 30 ms per 6 channels

Common Mode Rejection 80 dB

Normal Mode Rejection Filtered: 86 dB (50/60 Hz)

Fast: Not applicable

Status ADC reference check

Reporting Deviation
8 alarm limits
Under- and over-range events
Quality flags
Integer/floating point
Time-stamped events
Polled, unsolicited reporting on deviation and per alarm limit
144 SCADAPack 535E Hardware Manual

Time Stamping 30 ms Sequence of Event (SOE)

Cable Length Maximum: 30 m (98.4 ft)

 SCADAPack 535E Hardware Manual 145

12.9 Analog Outputs

Type Uni-polar

Resolution 12-bit over 0...20 mA range

Accuracy ±0.15% at 25°C (77ºF)

±0.35% of full scale over-temperature range
Response Time Less than 10 µs for 10% to 90% signal change

Power Supply (External) 12…30 Vdc

Power Supply Cable Length Maximum: 30 m (98.4 ft)

Power (Current) Requirements 10 mA plus up to 20 mA per output

Isolation Transformer
500 Vdc maximum to RTU logic and chassis
Range 0...20 mA
4...20 mA
Voltage output may be accomplished with external
precision resistor
Status & Reporting Power missing
Temperature too high
Open loop detected
Values out of range
ADC reference check
Controls Direct Operate
Select Before Operate
Load Range 12 Vdc: 0…475 ohms
24 Vdc: 0…1075 ohms
30 Vdc: 250…1375 ohms
 146 SCADAPack 535E Hardware Manual

13 Standards and Certifications

Introduction
SCADAPack E RTUs have been designed to comply with the relevant standards and rules for electrical
equipment in an industrial automation environment.

Industrial Standards
Requirements specific to the PAC functional characteristics, immunity, robustness, and safety:
IEC/EN 61131-2
CSA 22.2 No.142 completed by CSA-E 61131-2
UL 508

European Directives for EC Marking

Low voltage: 2006/95/EC (not applicable)
Electromagnetic compatibility: 2004/108/EC

Installation in Classified Ex Area

Hazardous locations class I, division 2, groups A, B, C, and D and class I, zone 2 according to CSA
C22.2 No. 213, CSA C22.2 60079-0, CSA C22.2 60079-15, ANSI/ISA 60079-0, ANSI/ISA 60079-15,
ANSI/ISA 12.12.01, FM 3600 and FM 3611
EC ATEX (european directive 94/9/EC) in defined atmosphere zone 2 according to EN 60079-0 and EN
60079-15

Specific Countries
For Australia and New Zealand: ACMA requirements for RCM marking
For United States: FCC Part 15 Subpart B Class A

More details on certifications are available on the Schneider Electric website: www.schneider-electric.
com.