Churchill Nano Link Series Manual de usuario

Nano_Link

TECHNICAL MANUAL

RADIO/LAND LINE TELEMETRY & TELECONTROL SYSTEM

WITH BATTERY-POWER OPTION

Churchill Controls Limited 2009

The contents of this document must not be disclosed to any third party without the written consent of Churchill

Controls Limited, nor are they to be used for any purpose other than to configure and maintain equipment supplied by

Churchill Controls Limited.

No part of this document can be reproduced, transmitted, transcribed, stored in a retrieval system or translated in any

way without the prior written consent of Churchill Controls Limited.

Whilst every attempt has been made to ensure the accuracy of this document, Churchill Controls Limited will not be

held liable for any errors or omissions.

As part of our policy of continuous improvement we would welcome any suggestions for changes to the document.

Churchill Controls Ltd.

30 Wellington Business Park

Dukes Ride

Crowthorne

RG45 6LS

Tel: 0118 9892200

Fax: 0118 9892007

e-mail: [email protected]

website: www.churchill-controls.co.uk

Issue Date Revision

1 05/05/99

2 20/10/00 Adds Exception Reporting

3 21/01/02 Enhances exception reporting and

adds 1 sec transducer warm-up

4 08/06/04 Adds 4 sec warm-up & new radio test

modes, plus various corrections

5 02/02/09 Adds rotation sensor and analogue

averaging modes

TABLE OF CONTENTS

1. PREFACE.........................................................................................................................................................3

2. COMMON FEATURES..................................................................................................................................4

2.1 Mechanical .........................................................................................................................................................4

2.1.1 Housing ..............................................................................................................................................................4

2.1.2 Nano_Link IP67 .................................................................................................................................................4

2.1.3 Polycarbonate Enclosures...................................................................................................................................4

2.2 Network Communications.................................................................................................................................. 5

2.2.1 Radio ..................................................................................................................................................................5

2.2.2 Leased Line ........................................................................................................................................................5

2.2.3 Private Wire .......................................................................................................................................................5

3. PRODUCT DESCRIPTION ...........................................................................................................................6

3.1 General ...............................................................................................................................................................6

3.2 Indicators............................................................................................................................................................7

3.3 Power Supply .....................................................................................................................................................7

3.3.1 Internal Batteries ................................................................................................................................................7

3.3.2 Universal Mains Power Supply.......................................................................................................................... 8

3.3.3 External 12/24VDC Source................................................................................................................................ 8

3.3.4 Solar Supply .......................................................................................................................................................8

3.3.5 External 5V Source ............................................................................................................................................9

3.4 Plant I/O ............................................................................................................................................................. 9

3.4.1 Digital Inputs......................................................................................................................................................9

3.4.1.1 Pseudo Digital Input 1 – Comms Fail alarm....................................................................................................................... 10

3.4.1.2 Pseudo Digital Input 2 – Battery Low alarm ...................................................................................................................... 10

3.4.2 Digital Outputs .................................................................................................................................................10

3.4.3 Analogue Inputs ...............................................................................................................................................11

3.4.3.1 Real Inputs: ........................................................................................................................................................................ 11

3.4.3.1.1 Potentiometer Interface..................................................................................................................13

3.4.3.1.2 Voltage Output Transducers ..........................................................................................................13

3.4.3.2 Pseudo Analogue Input 1 - Supply Volts............................................................................................................................ 14

3.4.3.3 Pseudo Analogue Input 2 - Radio Received Signal Strength Indicator (RSSI)................................................................... 14

3.4.4 Analogue Outputs............................................................................................................................................. 15

3.4.5 Expansion Capability .......................................................................................................................................15

3.4.5.1.1 7150-1 Digital Input Module .........................................................................................................16

3.4.5.1.2 7150-2 Digital Output Module ......................................................................................................17

4. INSTALLATION...........................................................................................................................................18

4.1 Mechanical .......................................................................................................................................................18

4.2 Aerials ..............................................................................................................................................................18

4.3 Surge Protection ...............................................................................................................................................19

5. CONFIGURATION.......................................................................................................................................20

5.1 Switch S1 - Station Address.............................................................................................................................20

5.2 Switch S2 - Mode.............................................................................................................................................20

5.2.1 S2.1 ... S2.5 - Radio Versions – Set Channel ................................................................................................... 20

5.2.2 S2.1 ... S2.5 - Modem Versions – Set Data Rate.............................................................................................. 21

5.2.3 S2.6…S2.8 - Operating Mode..........................................................................................................................21

6. SPECIFICATIONS........................................................................................................................................22

7. NANO_LINK AS AN OUTSTATION..........................................................................................................23

7.1 Operating Modes ..............................................................................................................................................23

7.1.1 Continuous operation (S2.6…S2.8 = 001) .......................................................................................................23

7.1.2 Power-save mode with 250ms transducer settling time (S2.6…S2.8 = 000) ................................................... 23

Page 2

7.1.2.1 Sniff mode.......................................................................................................................................................................... 23

7.1.2.2 Receive Mode..................................................................................................................................................................... 23

7.1.2.3 Transmit Mode ................................................................................................................................................................... 23

7.1.2.4 Sleep Mode......................................................................................................................................................................... 24

7.1.3 Power-save mode with 1 second transducer settling time (S2.6…S2.8 = 110)................................................ 24

7.1.4 Power-save mode with 4 second transducer settling time (S2.6…S2.8 = 101)................................................ 24

7.1.5 Power-save mode with 30 second transducer settling time (S2.6…S2.8 = 100) .............................................. 24

7.1.6 Power-save mode, using digital outputs (S2.6…S2.8 = 010)...........................................................................24

7.1.7 Power-save mode, analogue averaging (S2.6…S2.8 = 011) ............................................................................ 25

7.1.8 Power-save mode, Rotation Sensor (S2.6…S2.8 = 111).................................................................................. 25

7.2 Outstation Alarm Handling ..............................................................................................................................26

8. NANO_LINK AS A BASE-STATION .........................................................................................................27

8.1 Operating Modes ..............................................................................................................................................27

8.1.1 Normal operation..............................................................................................................................................27

8.1.1.1 Continuous transmission (S2.6…S2.8 = 000) .................................................................................................................... 27

8.1.1.2 Slow Scan (S2.6…S2.8 = 010)........................................................................................................................................... 27

8.1.2 Radio Commissioning (S2.6…S2.8 = 001)......................................................................................................27

8.1.3 Radio Path Test Set (S2.6…S2.8 = 011) .......................................................................................................... 28

8.2 Base-station Alarm Handling ...........................................................................................................................29

9. SPECIAL FEATURES OF NANO_LINK...................................................................................................30

9.1 Rotation Sensor ................................................................................................................................................30

9.2 Shaft Encoder Interface....................................................................................................................................30

9.2.1 General .............................................................................................................................................................30

9.2.2 Implementation.................................................................................................................................................30

9.2.3 Hardware Configuration................................................................................................................................... 31

9.2.4 Software Configuration ....................................................................................................................................31

9.3 Exception Reporting.........................................................................................................................................32

9.4 Test Modes ....................................................................................................................................................... 33

9.4.1 Address 255 (S1 = 11111111) - Power down..................................................................................................33

9.4.2 Address 254 (S1 = 01111111) - Test Receiver................................................................................................33

9.4.3 Address 253 (S1 = 10111111) - Test Communications Device ......................................................................33

9.4.4 Address 252 (S1 = 00111111) – Calibrate Analogues / Test Hardware Outputs / Reset Counters .................. 34

10. ALPHANUMERIC DISPLAY MODULE...................................................................................................35

10.1 General .............................................................................................................................................................35

10.2 Operation..........................................................................................................................................................35

10.2.1 Update Number of Shaft Encoders................................................................................................................... 35

10.2.2 Zero Shaft Encoders ......................................................................................................................................... 36

10.2.3 Radio Path Test mode.......................................................................................................................................36

10.2.4 Update Radio Channel......................................................................................................................................36

Page 3

1. Preface

This manual is intended to give the installer, user and maintenance personnel all the information they are likely to need

for implementing telemetry systems from the Data_Link 2000 product range.

The Data_Link 2000 product is based on Nano_Link (which is a simple, low power, self-contained unit) and

Micro_Link (which is a more complex product with considerable expansion capacity and many configurable

functions). This manual concentrates on Nano_Link. If a system uses both Nano_Link and Micro_Link, this manual

should be read in conjunction with the ‘Data_Link 2000 Technical Manual’.

The Data_Link 2000 product range is subject to continuous evolution, so new features are constantly being added by a

combination of software enhancements and new hardware modules. This manual describes the features of Nano_Link

software version 2.24. Some of the features described may not be available, or may function slightly differently, in

earlier software versions. However, it is Churchill Control’s policy to ensure that wherever possible software is

backwards-compatible. This means that wherever possible the features described will be present in all future software

issues.

The software version fitted within Nano_Link can be found by removing the cover and examining the label on the

EPROM, or by connecting an alphanumeric display to it.

Every attempt has been made to lay out this manual in a logical sequence. Chapter 2 describes the features of

Nano_Link, and should be read before designing a system around Nano_Link.

Chapter 4 explains the method of installation.

Chapter 5 describes the method of configuring Nano_Link for each specific application, and chapters 6, 7, 8 and 9

describe the functionality in detail.

Chapter 10 describes the Alphanumeric Display Module, which provides a user interface if required.

Before shipping any Nano_Link system, Churchill Controls configure it to their best understanding of the specific

application requirements, and test it as a complete system. However, because the internal power supply has battery

back-up which would run down during shipping. To overcome this the configuration switches on each Nano_Link are

set to the power down mode immediately prior to shipping. After installation the system should begin operation

immediately if the user sets the switches to the position marked on the label attached to the unit.

Page 4

2. Common Features

2.1 Mechanical

2.1.1 Housing

All modules (except the Nano_Link IP67) are housed in plastic cases, which can be

clipped onto either G or ‘top hat’ DIN rails. The housings measure 125mm H x

125mm W x 110mm D (when mounted on a vertical surface). All electrical

connections are made through two part screw terminals along the top and bottom

edges. Connections between modules and with other devices are made through FCC68

RJ11 and RJ45 jacks. No internal circuitry is accessible without removing the top

cover.

The top cover is retained by internal clips, and can be removed by inserting a fingernail

or screwdriver into the centre of the gap at each side of the cover and pulling outwards.

Some modules also have screws.

To unclip modules from ‘top hat’ rails on a vertical surface, press down on the top of

the module and lift it out from the bottom.

2.1.2 Nano_Link IP67

This is a form of mechanical housing that can be used

when Nano_Link has no ancillary equipment around it. It

is a lower cost option than a conventional unit in a

polycarbonate enclosure.

As shown in the illustration, a leased line unit can also

incorporate a surge protection unit. All variants can also

include any of the power supply options and a rotation

sensor.

A label is attached to the inside of the lid to show the I/O

connections. It also identifies the type of power supply

fitted, and can be used to identify the required DIPswitch

settings.

2.1.3 Polycarbonate Enclosures

A range of polycarbonate enclosures is available for applications requiring wall-mounting. They range in size from

190mm x 190mm x 135mm (suitable for a single module) up to 380mm x 560mm x 135mm (for up to 4 modules). The

smallest enclosure is rated IP68 (submersible for 24 hours to a depth of 2m), whilst all others are IP67 (resistance to

temporary submersion to a depth of 1m). The enclosures are fitted with DIN rails to which the unit can be clipped and a

cable to extend the aerial connector to a TNC aerial socket on the top of the enclosure. It is assumed that the user will

fit any glands needed to bring plant I/O into the enclosure.

It should be noted that the IP rating is dependent on the lid being screwed down tightly, and all glands being correctly

fitted and secured.

Larger systems can be supplied in steel enclosures if required.

PRESS DOWN

PULL OUT

Page 5

2.2 Network Communications

2.2.1 Radio

Both Micro_Link and Nano_Link can be equipped with synthesised VHF or UHF transceivers which are approved to

ETSI standard EN 300 220-1 and can thus be used so can be used in all the European Community member states

(subject to national requirements). In the UK the de-regulated bands are designated MPT1328 (VHF) or MPT1329

(UHF) bands. Any of 32 channels can be selected to avoid conflict with other users.

The UHF MPT1329 band is the most popular, since it allows for transmit powers of up to 500mW ERP (Effective

Radiated Power), but doesn’t require a licence. There are 32 channels at 12.5KHz spacing, in the band 458.500MHz to

458.925MHz.

The radio range depends on the aerials used and the topography of the area, but will typically be up to 8Km in urban

environments and up to 25Km with elevated aerials.

There are two adjustments on the radio modules, Modulation Level and Transmit Power, both of which are factory set:

The Modulation Level trimmer sets the transmitter frequency deviation, and should never be changed.

The Transmit Power trimmer sets the output power in the range 20mW to 1W, and is pre-set to 500mW. It can only be

changed by qualified personnel equipped with a calibrated UHF power level meter. The output level can be set below

500mW to minimise power consumption and reduce potential interference with other users. It must be set below

500mW if the aerial has gain. It can only be set above 500mW if the aerial and/or aerial feeder has an overall gain of

less than unity, and then only to compensate for the losses. The ERP must never be set to more that 500mW when

using MPT1329.

Other versions can be supplied to operate within the regulated MPT1411 band of 457.5MHz to 458.5MHz and

463.0MHz to 464MHz at power levels up to 5W, or the unregulated MPT1328 band of 173.20MHz to 173.35MHz at a

power level of 10mW.

2.2.2 Leased Line

Nano_Link can alternatively be equipped with modems for use on leased telephone lines supplied by national network

providers such as BT and Mercury. The modems are approved for use through the European Union.

The modems are capable of operating with an end-to-end loss of up to 27dB, and provide correct impedance matching

in accordance with the regulations. Normal telephone wires have a loss of about 1.5dB per Km, giving a range of

typically 18Km. However, if more than one outstation is used, the line becomes mismatched, thus increasing the loss

and effectively reducing the maximum line length. This can be overcome by adding line amplification and/or

impedance matching pads. The network provider will normally arrange this.

2.2.3 Private Wire

Private wires are cable pairs similar to leased lines, but owned by the user. The user is thus responsible for

maintenance of the cable, but does not have to pay rental charges.

Over short distance the characteristics of the cable are unimportant. However, for distances greater than around 2Km

the cable should be matched to the terminating impedance of the modems, namely 600. The modems are capable of

operating with an end-to-end loss of up to 27dB. Normal telephone wires have a loss of about 1.5dB per Km, giving a

range of typically 18Km. However, if more than one outstation is used, the line would become mismatched, due to the

additional load impedance. This increases the loss and effectively reduces the maximum allowable line length. A high

impedance version of the modem is available to overcome this and allow large numbers of outstations to be connected

across a single pair of wires, with appropriate terminations at each end of the cable.

Page 6

3. Product Description

3.1 General

Nano_Link is housed in a compact plastic enclosure, which includes an internal power supply and radio or modem, and

can be clipped onto a standard DIN rail. It can be supplied in waterproof polycarbonate enclosures if required.

The internal power supply can be three ‘D’ alkaline batteries, a mains power supply with battery back-up or an external

12VDC source (such as a solar power supply). The module has been optimised for low power consumption, to the

extent that it will operate for over 2 years on low-cost Duracell batteries. Battery operation has the advantage of

significantly lower installation and running costs.

The internal communications device can be either a radio or a modem. The radio is normally operated on a de-

regulated UHF band, so doesn’t need a licence. The modem can use either a leased line (owned by a national network

provider) or a private wire (owned by the user). Nano_Link can also be used with external communications devices

connected to the Comms_Link port.

Nano_Link has 4 digital inputs, which can each be used to monitor alarm or status conditions, and also to count pulses

from totalised flow transducers. Pseudo digital inputs flag communications fail alarm and battery low alarm

conditions. It also has 2 analogue inputs, which can be used with low-cost millivolt transducers or conventional current

loop transmitters. A pseudo analogue input monitors the battery voltage and another monitors the radio receive signal

strength.

Nano_Link can also be equipped with 4 digital outputs, each comprising a volt-free relay contact, and two 0…20mA

analogue outputs. The state of each output can be monitored by LED indicators located adjacent to the relevant

terminals.

The capacity can be increased by a further 16 digital inputs and/or 16 digital outputs by adding optional digital

expansion modules.

Although Nano_Link is intended primarily for use as an outstation or repeater, it can be configured as a base-station to

provide a simple point-to-point link to another Nano_Link, transferring up to 2 analogues and 20 digitals in both

directions.

However, to access pseudo inputs, use repeaters, or use more than one outstation, a Micro_Link base-station should be

used. This is described in the ‘Data_Link 2000 Technical Manual’

ano_Link

Aerial

Line

Comms_

Link

(TTL)

I/O_Link

85…265VAC

…

Hz 1

Internal battery

8…16VDC 0.5A

16…32VDC 0.5A

3…5.5VDC 1A

DIGITALS

OUTPUTS INPUTS

O/P

12341234

I/P

ANALOGUES

O/P INPUTS

1- 2- + 1- 1I 1+ 2- 2I 2+ -

12345678

Address

SWITCH 1

12345678

Channel Mode

SWITCH 2

Vin

+- I/O

Page 7

3.2 Indicators

All Nano_Link’s include four LED’s, designated RXD, TXD, Test and Heartbeat.

TXD and RXD monitor communications between the main processor and the radio or modem. It should be noted that

the radio acknowledges each character sent to it, so whenever the TXD LED flashes on a Nano_Link equipped with a

radio, the RXD flashes in sympathy. This does not happen on Nano_Link’s equipped with other communication

interfaces. In all cases incoming data will cause the RXD LED to flash on its own. Commands to the communications

interface (such as setting the radio channel or enabling the transmitter) are also sent on TXD and acknowledged

through RXD, although they may not result in any transmitted data.

The Test LED lights in normal operation whenever the transmitter is enabled. However, it is also used to indicate when

the unit is in test mode (see 9.3).

The Heartbeat LED flashes to indicate that Nano_Link is ‘alive’. The flashing sequence indicates its status:

When flicking on very briefly every second, Nano_Link is asleep, in its power-down mode.

When flashing continuously at the rate of 4 flashes per second, Nano_Link is awake, communicating correctly,

and its power supply is good.

When flashing three pulses out of every four, Nano_Link is awake, but has lost communication with the remote

device.

When flashing two pulses out of every four, Nano_Link is awake and has communication with the remote device,

but its battery is running low.

When flashing one pulse out of every four, Nano_Link is configured as a base-station, has communication with

the remote device, and its battery is good, but the remote outstation is reporting a low battery.

Nano_Link’s equipped with digital outputs also have 4 LED’s to monitor the state of these outputs. These LED’s are

located adjacent to the relevant terminals.

3.3 Power Supply

Nano_Link works from an input supply of 3.0…5.5VDC, which may be derived from a variety of sources via an

internal power supply unit.

The current consumption is less than 50A when asleep, increasing to about 20mA when awake, and about 1A when

the radio transmitter is active. Nano_Link incorporates is a power converter that generates a stable +5Vsupply when

required for the modem or radio receiver, expansion modules and other digital circuitry, and another that generates

+12VDC when required to power the radio transmitter, modem and/or external analogue transducers. If Nano_Link is

set to power save mode (see 7.1) both converters are disabled when not required to conserve power. However, in

constant power mode (see 7.1) they both remain active at all times.

The output of the internal power supply is accessible through the terminals marked ‘I/O’, which can also be used as the

power input if no internal supply is fitted. The input to the internal power supply is accessible through the terminals

marked ‘Vin’. The label is marked to indicate the type of supply fitted:

3.3.1 Internal Batteries

An internal battery pack can be fitted which holds three D alkaline cells (typically Duracell Procell batteries). These

have a capacity of 18 ampere-hours, which is sufficient to power the unit for at least two years if it is scanned every 15

minutes.

When fitting new batteries, ensure that the negative end (flat) goes to the coil spring in the battery holder.

Battery power is only intended to be used for an outstation that is interrogated relatively infrequently (typically every

15 minutes) or uses exception reporting, and is not intended to support digital or analogue outputs. Furthermore it will

not support expansion modules.

Nano_Link monitors the battery voltage as an analogue value that can be read by the base-station. It also generates a

digital alarm if it drops below a defined level. The outstation should continue working for several days after generating

this alarm (assuming it is interrogated every 15 minutes).

Page 8

3.3.2 Universal Mains Power Supply

An internal mains power pack can be fitted, which derives a 5.3V supply from any input in the range 80…260VAC.

The supply includes rechargeable Ni-Cad batteries, which will support the unit in the event of a mains power failure.

Nano_Link monitors the battery voltage as an analogue value that can be read by the base-station, and generates a

digital alarm if it drops below a defined level. If a mains fail indication is required a mains-operated relay can be used

externally, with its contacts connected to one of Nano_Link’s digital inputs. The period for which the batteries will

support Nano_Link depends on the mode of operation, but will typically be at least 8 hours.

The power supply is double insulated, so does not require a safety earth. The power input is through a two-part screw

connector that is different both in size and colour from all other terminals, to ensure it cannot be incorrectly fitted.

Mains power should be used for any Nano_Link used as a base-station, a repeater or an outstation that is interrogated

continuously, used analogue or digital outputs or is fitted with expansion modules. It can also be used for an outstation

that is interrogated relatively infrequently.

3.3.3 External 12/24VDC Source

Two variants of this supply are available, one operating from a supply in the range 8…16VDC and the other for

16…32VDC. They are intended for operation from station supplies of nominally 12V and 24V respectively. If the

user wishes to monitor the battery voltage, and/or generate a battery low alarm, the 7041 Solar Power Controller

described below can be used by connecting the station battery to it and omitting the solar panel.

3.3.4 Solar Supply

Solar power requires an external solar panel, a solar controller and a lead-acid battery. The battery is required to

maintain the system overnight and during bad weather. Its size has to be calculated, along with that of the solar panel,

to ensure that the system continues operation throughout the year. Factors influencing the size of the panel and battery

include the electrical load, the location and the ambient temperature range. The controller ensures that the battery is not

overcharged during bright sunlight, and does not discharge into the panel at night.

Nano_Link ‘s supplied for solar operation are fitted with an internal 12VDC power supply, and use an external 7041

Solar Power Controller and battery. The controller is fitted in a small housing that clips onto DIN rail adjacent to

Nano_Link. The battery is normally fitted at the bottom of the enclosure. An important feature of the 7041 Solar

Power Controller is its very low internal power dissipation. Some commercially-available solar controllers are

designed for us with large solar panels and batteries, and consume more current than Nano_Link! They therefore

significantly reduce battery life when used on small systems.

As well as controlling charge to the battery, the 7041 Solar Power Controller also provides a digital Battery Low Alarm

output that can be connected directly to one of the digital inputs on Nano_Link. There is also a voltage monitor which

provides a level of 0…100mV for a battery voltage range of 0…20V. This output can be connected to one of the

analogue inputs on Nano_Link if required.

The 7041 Solar Power Controller has two LEDs, marked ‘Charging’ and ‘Charged’. The Charging LED flashes when

the battery is being charged by the solar panel. If the battery attains a fully-charged state the ‘Charged’ LED lights, and

the controller shorts out the solar panel to prevent further charging. In the quiescent state both LEDs will flash

alternately as a trickle charge is fed to the battery to maintain equilibrium.

Whenever the solar panel is not charging the battery (e.g. at night) the Charged LED will flash and the Charging LED

will remain off. If the battery voltage drops below 11V the flash rate will slow to about 1 pulse/second and the Battery

Low Alarm will be generated.

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