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User Guide
Version 2.01
1 Introduction
1.1 Safety & Handling
DANGER
Keep Away from Live Circuits
Operating personnel must not remove product covers. Qualified maintenance personnel must
make internal adjustments. With certain products such as power supplies, dangerous
voltages may exist when the equipment is live. Always disconnect input voltages and
discharge circuits before touching them to avoid injuries.
Do not operate in an Explosive Environment
Do not operate the product in the presence of flammable gases or fumes unless with a
suitable enclosure. Operation of any electrical apparatus in such an environment exposes the
user to the risk of fire or explosion.
Do Not Operate a Damaged Product
If the safety or protection features of this product have been compromised, either through
physical damage, excessive moisture, or any other reason, remove power and do not use the
product until safe operation can be verified by trained service personnel. If necessary, return
the equipment to the supplier for service and repair to ensure that safety features are
maintained.
Do Not Substitute Parts or modify this Product
Do not install unauthorised substitute parts/components or perform any unauthorised
modification to the equipment. Return the equipment to the supplier for service and repair to
ensure that safety features are maintained.
Ground the Product
To avoid risk of electric shock and to provide protection against induced surges, each rack
must be connected to an electrical ground and all modules secured into the rack with the
securing screws supplied.
Operate within the Specified Limits
Operate this product within its specified limits only. Operating the product outside its limits
may cause product failure and may pose a safety risk.
Page ii of 3
1.2 Confidentiality
This document contains proprietary information of Microsol Limited. The information and
designs in the document are covered by international copyright and a number of international
patents existing and pending. Microsol, and its legally appointed licensees, reserve the right
to seek full redress in the case of any infringement.
The information in this document is subject to change without prior notice. Microsol does not
assume responsibility for any errors in fact or design in this publication. Specifications can
and do vary in different applications. The publication is provided for general information only
and shall not form part of any contact.
1.3 Warranties
Unless otherwise stated this product is warranted against defects in materials and
workmanship for a period of one year from date of shipment. During the warranty period, the
supplier will, at its option, either repair or replace products that are proven to be defective.
For warranty service or repair, this product must be returned to a local service centre. The
Buyer shall prepay shipping charges to the service centre. The service centre shall pay
shipping charges to return the product to the Buyer. However, the Buyer shall pay all
shipping charges and taxes for products returned to the supplier from another country.
The Manufacturer warrants that its firmware designated for use with specific equipment will
execute its programming instructions when properly installed on that equipment. The
Manufacturer does not warrant that the operation of the equipment or firmware will be
uninterrupted or error-free.
1.3.1
Limitation of Warranty
The foregoing warranty shall not apply to defects resulting from improper or inadequate
maintenance by the Buyer, Buyer-supplied software or interfacing, unauthorised modification
or misuse, operation outside of the environmental specifications for the product, or improper
site preparation or maintenance.
No other warranty is expressed or implied. The Manufacturer and/or Supplier specifically
disclaim the implied warranties of merchantability and fitness for a particular purpose.
1.3.2
Exclusive Remedies
The remedies provided herein are the Buyers sole and exclusive remedies.
The
Manufacturer and/or supplier shall not be liable for any direct, indirect, special, incidental, or
consequential damages, whether based on contract, tort, or any other legal theory.
1.3.3
Claims
The customer must notify the Supplier in writing of any warranty claim not later than thirty (30)
days after the expiration of the warranty period. For assistance, contact the Supplier office or
representative.
Page iii of 3
Table of Contents
1
Introduction .......................................................................................................ii
1.1
1.2
Confidentiality ............................................................................................iii
1.3
Warranties..................................................................................................iii
1.3.1
1.3.2
1.3.3
Claims ..................................................................................................iii
2.2
2.3
Inter-Cell Communication............................................................................ 2
2.3.1
Network ............................................................................................... 2
2.3.2
2.3.3
Unique Address.................................................................................... 3
2.3.4
2.3.5
Applications ......................................................................................... 3
3.1.2
3.2
Earthing...................................................................................................... 6
3.2.1
3.2.2
Earthing an enclosure........................................................................... 7
3.3
Power......................................................................................................... 8
3.3.1
3.3.2
3.3.3
3.3.4
3.4
Rack........................................................................................................... 4
3.1.1
3.4.1
3.4.2
3.4.3
3.4.4
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
Data Quality........................................................................................ 22
3.6.5
3.6.6
Page iv of 2
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.4.1
4.5
4.5.1
5
5.1.1
Status LEDs....................................................................................... 32
5.1.2
3-Character Display............................................................................ 32
5.1.3
LED Matrix.......................................................................................... 33
5.2
5.2.1
5.2.2
5.3
5.4
Installing/Updating Firmware........................................................................... 39
7.1
7.2
Time Management..................................................................................... 39
7.3
Redundancy ............................................................................................. 40
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.5
Ethernet Interface..................................................................................... 44
7.6
Diagnostics............................................................................................... 44
Page v of 2
Cell
processor
Up to four
plant
interface
modules
Serial
ports
Copper LAN
Figure 1 A cell
Page 1 of 44
Distributed cells are generally connected using fibre optic cable and associated fibre optic
communications modules to avoid any electrical interference that may occur within a substation environment.
2.3.1
Network
The communications used for data transmission between XCell units is a high-speed
Local Area Network capable of supporting simultaneous communications between
XCell units on the LAN. It is a token passing network and is therefore deterministic in
nature. It is a communication platform capable of supporting the real-time information
needs of a Power Utility now and into the future.
Unlike products that utilise a high-speed I/O bus, the XCell LAN can transport any
type or size of data. The LAN is independent of the data that it transports and can
therefore carry I/O data, fault files, configuration data, diagnostic data, display data,
etc.
It supports peer-to-peer communications between XCell units and this provides a
powerful and flexible communications structure for the site. All units communicate on
an equal basis and therefore they are not dependent on a master unit for system
communications.
2.3.2
Distributed Data
Each cell forms part of the real-time distributed database that is accessible to all cells
in the system. All cells operate on an equal basis sharing information between each
other. There is no master cell distributing or polling data. All cells co-operate on an
equal basis with complete access to all system data. With the appropriate software
and the required memory, any cell can run any application, from sequential logic,
mathematical expressions, communication protocols, data servers, web servers or
any other form of data manipulation or display.
Data gathered by each cell is available through the LAN to all other cells on a
publisher/subscriber basis. All cells have complete access to the entire system data
on the network. Applications residing in any cell can use data from all other cells.
Communication protocols residing in any cell have access to all system data and can
transmit all or part of the data, via the communications link, to multiple destinations.
Page 2 of 44
2.3.3
Unique Address
Each cell within a multi-cell network must have a unique address so that the data
collected by that cell can be identified within the global distributed database. This
address has a maximum value of 249 (the addresses 0 and 250-255 are reserved),
however other further limitations may apply to this value depending on any external
communications protocols being used.
2.3.4
Plant I/O
Although each cell must contain a processor module it may also contain up to four plant
interface modules. These modules provide access to a variety of I/O including digital
inputs/outputs, analogue inputs/outputs and high speed pulse counters.
2.3.5
Applications
In addition to the standard plant I/O modules the XCell processor module has the ability
to run additional application software onboard.
2.3.5.1 eXpress
The eXpress application provides the facility for users to develop their own applications
to run on the XCell target system. These applications can range from mathematical
calculations to interlocking logic and control applications (e.g. load shedding, AVC Tap
Changer, Transformer Paralleling, Capacitor Bank control, Switching Sequences).
Applications are developed on a PC platform using the eXpress development
workbench. The applications can be simulated and tested on the PC prior to
downloading to the XCell target processor.
eXpress is fully compliant with the IEC 61131 application development standard. The
IEC 61131 standard defines a set of application programming methods to enable end
users to generate applications in a simple and user-friendly manner. It provides for
graphical programming (Ladder Diagrams, Function Block Diagrams, and Sequential
Function Charts) as well as text-based programming, (Structured Text and Instruction
Lists). This enables users to easily configure their own applications to run on XCell.
Applications developed in accordance with this standard are more maintainable and
supportable for the future.
2.3.5.2 Protocols
The XCell processor also supports a number of industry standard protocols to allow the
system to communicate with Intelligent Electronic Devices (IEDs) and Master Control
Stations. These protocols normally communicate via the serial interface of the cell
processor but may also use the built in Ethernet port included on the CPR-041 cell
processor, depending on the protocol implementation.
Page 3 of 44
3.1 Rack
3.1.1
A 3-cell rack accommodates up to three individual cells complete with cell processors, plant
interface modules and LAN interconnections. The term cell is used throughout this guide to
describe one XCell processor module and up to four plant interface modules. Different rack
styles are available accommodating different numbers of processors and I/O modules.
The processor is always located on the left hand side of the cell and is 8HP wide with the
plant interface modules located to the right of the processor, the plant interface modules are
5HP wide.
Note: HP defines Horizontal Pitch or the amount of
horizontal rack space required of each module. 1HP =
5.08mm with a standard 3-cell rack accommodating
84HP.
Page 4 of 44
3.1.2
The XCell rack and modules are designed to facilitate easy insertion and removal.
The power switch on the processor module is located near the lower module handle as shown
in Figure 4.
On/Off
Switch
The following two sections describe the procedures for inserting and removing modules.
3.1.2.1 Installing and Grounding a Module
1. When inserting Processor modules ensure that the module On/Off switch is in the Off
position before insertion. When inserting I/O modules ensure that the associated
processor module (to the left hand side) is switched Off. If unsure, remove power from the
rack.
2. Insert the end of the module into the start of the guide rails of the required slot and slide
towards the back of the rack. Press the module firmly into the connectors at the rear (do
not push on the extractor handle, apply pressure only on the front panel and do not use
excessive force or you may damage the module). Once the module has engaged into the
connectors and is fully inserted, the extraction handles will move into a position
perpendicular to the front panel (see Figure 6 (a) for reference).
3. Gently
tighten
the
securing screws on the
front of the module to
provide the necessary
earth. Ensure that you
do
not
over-tighten
these screws.
Securing
Screw
Page 5 of 44
Extractor
Handle
Securing
Screws
(b)
(a)
3.2 Earthing
All XCell racks MUST have their frame connected to a safety earth. Within the rack all
modules are connected to the safety earth through the rack frame. This connection is
achieved through the module front panel secured to the rack with the securing screws on the
front panel of the modules. These form an electrical contact between the module and the rack
when firmly fastened (but do NOT over tighten). It is essential for correct operation that all
modules are securely fitted via the securing screws.
3.2.1
Earthing a rack
Connect a braided earth cable to the side of the rack using an earth contact
washer that pierce the metalwork.
Connect the opposite end of the earth cable to the safety ground.
Where XCell equipment is supplied in an enclosure, grounding connections for each rack
within the enclosure will already be in place. It will be necessary however to ground the
enclosure.
Note: Braided ground wire should be used to facilitate high frequency conduction and not
single conductor earth wire.
Page 6 of 44
Connect to
safety earth
3.2.2
Earthing an enclosure
Each rack within the enclosure MUST be separately connected to the enclosure
safety earth point. A loop connection is not permitted.
Page 7 of 44
3.3 Power
The DC supply MUST be within the specified voltage range for the supplied system.
The Power Supply MUST be properly rated for the installed system.
NOTE: For details on the calculation of the power
requirements of a XCell system please refer to the
appropriate section in this manual.
The external supply MUST be properly fused with an anti-surge (slow-blow) fuse.
The equipment is designed to operate with either positive or negative earth systems
Each XCell processor module contains an on-board isolated DC-DC converter that generates
all the voltages required by the cell. This arrangement ensures that the external DC supply is
completely isolated from the internal electronics of the cell. One side of the external DC
supply may be earthed if desired.
3.3.1
The XCell system can operate over a wide range of input supply voltages, normally 20-72V
DC or 110VDC with Power Converter. However for the range of acceptable supply voltages
for your system configuration please check with the individual Module Description sheets
appended to this Users Guide.
3.3.2
Power Connection
Where a Power Converter unit is fitted at the rear of the rack the customer power should be
connected to the input of this Power Converter unit.
Where a Filter Unit is attached to the rack the customer power should be connected to the
input of this Power Filter unit.
Filter
Unit
DC-
External DC
Source
DC+
Circuit
Breaker
Page 8 of 44
Figure 10 Sample connection to the power input connector (DC1+ and DC1-) using ferrite
protected power cable
Watchdog
Connector
Power
Filter Input
Connectors
Power
Connectors
if no Filter
fitted
Page 9 of 44
Best Practice
Take a separate
fused supply to
each rack
DC in
3.3.3
Dual Supply
The XCell system provides for high reliability operation by allowing the connection of a
secondary (redundant) power supply to the unit. This second supply will ensure that on the
failure of the primary supply the secondary will continue to provide power to the unit ensuring
that the unit continues uninterrupted operation. This dual supply facility is provided within the
XCell Filter Unit using a shared diode arrangement and on each XCell processor using an onboard shared diode arrangement.
3.3.4
Power Consumption
The power requirements of an XCell system depends on the number of cells and the mix of
plant interface modules installed. The power consumption of each module can be found in the
module Data Sheet or the module Technical Description.
When calculating the total power requirements the field interface requirements must also be
taken into account. For example, when calculating the power requirements for Digital Output
relay modules there is a power requirement for the module electronics but there is an
additional requirement for each relay that can be active in the system at any time. The power
for the relay coils is provided through the front connector on the module and not through the
rack supply.
Number of Digital Outputs In many systems only one
control output will be active at any time so this will
minimise HDO power requirements
Page 10 of 44
Within an XCell rack the cells are inter-connected by a copper LAN that runs along the
backplane within the rack. Under normal circumstances a copper interface is used to
interconnect racks within an enclosure and fibre optics are used to connect outside the
enclosure to other enclosures.
It should be noted however, that a copper LAN is more susceptible to electrical interference
and should be kept to a minimum. While it is theoretically possible to have a copper segment
of up to 60m, it is not recommended to go beyond a few meters. Shielded cable should
always be used for FieldNet copper LAN. Fibre optic LAN using the OPI-04x should be used
for networking outside enclosures. Fibre optics must also be used where the number of XCell
processors exceeds 32 or where network distances of up to 1.5km are required. The OPI-04x
provides redundancy using dual fibre optic loops to protect against a single point of failure.
Most large installations call for a mixture of copper and optical fibre connections.
3.4.1
Where the system consists of a single rack then a terminating resistor must be fitted at both
ends of the rack across the network connections L1A and L1B.
Terminating
resistor
Terminating
resistor
R
Page 11 of 44
FieldNet Network
Network
Terminating
Resistor
120 Ohms
Network
Terminating
Resistor
120 Ohms
The Fieldnet LAN racks MUST be connected in series through all XCell racks as
shown below.
It is important that L1A on one rack is connected to L1A on the other rack and
L1B is connected to L1B. Improper connection can result in intermittent
communications.
Page 12 of 44
Network
Terminator at
both
extremities
Twisted
pair cable
R
Twisted
pair cable
Earth cable
screen at
one end
R
Earth cable
screen at
one end only
Network
Terminator at
both extremities
Page 13 of 44
3.4.2
3.4.2.1 Introduction
Fibre optics are immune to electrical interference and are therefore the preferred transmission
medium around a substation. Microsol Fibre Optic modules should be used in the following
circumstances:
32 XCell processor modules are used in the system
long transmission distances of up 2km are required
transmission in an electrically noisy environment
Generally used outside the equipment enclosure
To provide FieldNet LAN redundancy
The module operates at 5Mbits/sec and is specifically designed for the XCell FieldNet LAN.
Each OPI module connects to the FieldNet LAN via the RS485 connection and has two fibre
transmitters and receivers. It uses multi-mode (ST2 connection) fibre optics.
The OPI module is powered from 19-72V DC and has a Fail Relay for each pair of fibres. The
maximum distance between any two OPI modules is 1500m and the maximum distance
between the two farthest nodes is 2000m. Please refer to the OPI-040 Module Description
sheet for further details about this product.
It is important to understand that the Microsol Fibre modules, as used with Microsol XCell
equipment, are merely extensions of the FieldNet highway - the performance over fibre links
in terms of data rate, message-throughput etc. is the same as if the electrical FieldNet
highway were used.
The module supports redundant fibre paths to protect against a single point of failure. The
modules can be used in a variety of system configurations including:
Point to point connections
Star configurations
Fibre bus configurations
Fibre loop configurations
Page 14 of 44
Redundant
Rx/Tx Pair
The first diagram shows a non-redundant point-to-point link with just a single Rx and Tx fibre
connecting both systems. The second, and most widely used implementation, uses the inbuilt
redundancy of the OPI-040 and two Rx and Tx pairs. The data is transmitted on both Tx fibres
from each OPI. Therefore the system will still operate with one Rx and one Tx fibre broken.
3.4.2.4 Fibre Star Configurations
The OPI-040 can be used to connect distributed/remote units in a star configuration. It simply
uses separate point-to-point links to ach of the distributed segments. As with the point-to-point
links described above these can be configured in non-redundant or redundant configurations.
The following diagram shows three star links with redundant fibre on each link. A hierarchical
star configuration can also be implemented using the OPIs.
Redundant
Rx/Tx Pair
Page 15 of 44
Page 16 of 44
3.4.3
Fibre connections are made using the ST-2 connectors and all other connections are made
via the 10-way screw terminals on the front of the module. The following connections are
provided on the module:.
RS485 LAN connection (TRx+ and TRx-) connects to L1A and L1B on the XCell Rack
3.4.4
The OPI module provides two alarm output contacts to indicate the status of the two fiberoptic receive ports. If receive activity on one of the fiber-optic ports stops for 1 second, the
appropriate relay will be energised, closing a contact to indicate a fault. The contacts come in
the form of normally open contacts that close on failure. The fault indication will clear once
receiver activity resumes.
When power is first applied to the unit, the relays remain de-energised to suppress any fault
indication until data is received at one of the fiber-optic receivers, or one minute has elapsed,
whichever occurs first.
Refer to the Module Description for details on contact ratings.
Page 17 of 44
Cell
processor
Up to four
plant
interface
modules
Serial
ports
Copper LAN
Figure 26 Plant Interface Modules
It is very important that the plant interface module has the correct voltage and input range for
the particular site conditions.
Microsol also provide a range of screw Termination Modules that connect to the plant
interface modules via standard cables with 37-way D-type connectors at both ends. The plant
wiring is then made to the individually labelled screw terminals on the Termination Module.
Refer to the termination Module Descriptions for details of specific modules.
Custom interface modules are also available to minimise re-wiring in retro-fit installations.
Page 18 of 44
Plant Wiring
Plug n play
wiring
Plant Interface
Modules
Termination
Modules
Termination Modules:
Allow wetting voltage to be applied so that dry contacts in the plant can be
supplied from inside the RTU
Page 19 of 44
The following Table gives a sample of DIN-rail termination modules that may be used with some of the
main XCell Plant Interface modules.
XCell
Module
Part No.
Termination
Board
HDI-05x
64 Channel
Module
Digital
Input
TDI-040 (2 off
required)
64 Channel Digital
Termination Board
Input
HAI-03x
TAI-040
HDO-04x
TDO-040
HDO-04x
TAI-040
HDO-04x
IPC-16 (2 off
required)
Fibre Optic RX Fail relay contacts (refer to the Fibre Optic Module Description)
3.6.1
Each XCell processor provides a set of watchdog relay contacts which can be used to monitor
processor status. These contacts are controlled by the processor watchdog. Immediately
after a processor powers up, the watchdog relay closes and remains closed as long as the
cell continues to operate. If power is removed from a cell, or a cell halts for any reason, then
the watchdog relay will
open.
Watchdog relays may be
connected in series to
monitor the health of
multiple cells / racks within
a system enclosure and a
common indicator brought
out to indicate a cell failure.
Not
connecting
this
indicator will not affect the
operation of a cell.
Watchdog
Bottom
Terminal
Page 20 of 44
The Watchdog contacts are connected in series across the rack backplane as shown in the
diagram below. The Watchdog connection is available through the bottom Watchdog Terminal
at each end of the rack.
Watchdog
Bottom
Terminal
Wdog
CPR 1
Wdog
CPR 2
Wdog
CPR 3
Watchdog
Bottom
Terminal
3.6.2
In any XCell system it is essential to know if all units are operational. This information is
generally required at the Master Station where any problems should be immediately notified.
This means that any failures must be notified over the communications protocol. For this
reason every XCell processor maintains a pseudo status point for all other processors on the
network. These digital status points can then be mapped to indications at the Master Station.
Any XCell processor module that is found to be non-operational for whatever reason
(powered down, removed, faulty etc.), will result in:
The relevant processor status indication (internal pseudo digital point) being marked as
failed and made available to the Master Station as a digital status point.
The data quality information for all the associated data points for the particular XCell unit
being marked as invalid and notified to the Master Station.
The relevant processor status indication (internal pseudo digital point) being marked as
good and available to the remote Master Station as a digital status point.
The particular unit will transmit the status of all its data points along with their quality
information. This process occurs approximately 1 minute after the unit is started. This
updated information is then returned to the remote Master Station.
Refer to the Workbench I/O Configuration Manual for details on how to configure these
status points
Page 21 of 44
3.6.3
As with the processor modules, it is also essential to know if all Plant Interface modules are
operational. This information is also required at the Master Station where any problems
should be immediately notified. This means that any module failures must also be notified
over the communications protocol. For this reason every XCell processor maintains a pseudo
status point for each of the associate hardware slots in the unit.. These digital status points
can then be mapped to indications at the Master Station. All Plant Interface modules are
checked on a regular basis to ensure that they still operate as configured. Any faults identified
will result in
The relevant module status indication (internal pseudo status point) being marked as
failed and made available to the Master Station as a digital status point.
The data quality information for all the associated data points for the particular module
being marked as invalid and notified to the Master Station.
Refer to the Workbench I/O Configuration Manual for details on how to configure these
status points
3.6.4
Data Quality
All data points in XCell have their data values plus additional data quality information
indicating the reliability or validity of the data value. This can be sent to the Master Station to
indicate a problem with the data value. For example if an analogue value is outside it's
configured range, then the value will be clamped at the maximum value but the quality
information can indicate that it is a suspect value. Similarly, if data is being retrieved from
some external equipment e.g. IED, over a serial link and the link fails then it is important that
an operator viewing the data some time later is informed that this data may no longer be valid
and is therefore suspect. This information can be conveyed by transmitting the point with an
indication that the data is now suspect or invalid.
XCell data quality is set to invalid or suspect under the following circumstances:
If the data is connected to XCell via a serial connection (e.g. IEDs) and the
communications has failed.
While this information is available in XCell it is only useful if the communications protocol and
the Master Station display software support it. Most telecontrol protocols including DNP 3 and
IEC870-5-101/104 support the transmission of data quality along with the data value.
3.6.5
Communications Status
Many XCell protocols also maintain a communications status as a pseudo digital point. If
communications fail then the status gets marked as bad. This can be mapped via another
protocol to a master station.
3.6.6
Most XCell IED protocols maintain pseudo digital points for each of the slave IEDs. If the
protocol is polling a device and it fails to respond after the configured number of retries, then
the device status is marked as bad. These points can be made available to the Master Station
as a digital status points.
Page 22 of 44
Cell
processor
2
3
Module
Slot
Positions
Serial
ports
Copper LAN
Figure 31 - Plant interface module slot positions for jumpers
Details of each jumper setting and function are provided in the Module Descriptions at the end
of this manual.
Page 23 of 44
All of the plant interface modules should have the correct jumper settings
according to the required operation and to their position within the cell. Please
see the appropriate Module Description Sheet for the jumper settings.
All of the modules, processors and plant interface modules, should be secured
in the racks with the two securing screws adequately tightened.
All network connections should be made to the racks via the appropriate network
media (either a copper or optical fibre).
The Power Switch located on the front of each processor module should be
switched off initially.
Power should be supplied to the racks through any associated filter modules
from an adequately sized DC power supply using the power requirements
detailed in the Module Description Sheets.
For the first live test, it is recommended that each cell is powered up individually
using the following sequence. In this way any accidental network conflicts or
wiring problems can be minimised.
Page 24 of 44
Checking that all I/O modules are recognised by the cell processor,
Following this, a simple test procedure is described to verify each I/O channel and test the
serial links in a system.
4.3.1
Once power has been connected to the rack it is necessary to power up the processor. The
processor power On/Off switch is located on the front panel below the serial communications
ports. To apply power to the processor, move the switch upward to the On position.
4.3.2
After power has been turned applied, the processor runs through a sequence of self-tests that
will be described in the following sections. This self-test can be monitored by observing the
LED displays on the front of the processor module, refer to the following diagram for LED
locations.
The power on sequence comprises three main
segments that MUST be executed successfully
if the processor is to operate correctly:
Status LEDs
CPU
BUG
LD
100
FFS
105
200
300
3-character display
LED matrix display
Function Button
Page 25 of 44
Flashing
On Line LED
On if on network
4.3.3
When powering up a processor module for the first time, it is recommended to clear the nonvolatile memory in case it contains any previously stored configuration data. To clear the nonvolatile memory:
Immediately after the 3-character display shows LD, press the Function button and
hold it down until the process displays FFS. The processor will then reboot and the
non-volatile configuration is now clear.
4.3.4
Each processor module on the XCell network must have a unique address. This is displayed
by default on the 3-character display on the front of the processor. This address can be
changed using the Function button and function menu on the processor module. The menu
option for changing the address, AUN (Adjust Unit Number), is only available for 30 seconds
after power-up. For further details on using the Function button and menu refer to the section
on the Operator Interface. For further details on the AUN option refer to the menu options in
the Operator Interface section. Ten seconds after a cell has powered up the AUN option is
automatically removed from the Function menu and can no longer be selected. Once a unit
number has been set the cell automatically resets.
If a wrong unit number is set, the unit should be powered down and up again and the unit
number re-entered using the AUN option.
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4.3.5
Each processor module supports 4 Plant interface modules located to the right of the
processor. Some of these modules support two sub modules (daughter modules mounted on
the main module). Therefore the processor maintains 8 configuration definitions, one for each
of the 8 possible hardware modules. The eight possible locations are shown in the following
diagram. As most modules occupy two slot positions the same module type will be displayed
for both locations.
S
The SHC option in the function menu identifies the hardware in each half-card position (8 per
cell) as shown above. These positions are referred to by their slot positions in the 3-character
display panel (001 008). The majority of cards occupy a full card position and will therefore
display the same module type for both half-card positions.
When the SHC option is selected the 3-character display shows the hardware installed in the
first Slot position. It does this by toggling the display between the slot number 001 and the
module type installed in that slot. For example it may toggle between 001 and DI6 to
indicate that a 64 channel Digital Input module is present in slot position 1 (the top half card of
the first board). Refer to the following table for abbreviations used for the various module
types.
Type
Description
UNC
DI6
DO4
AI3
HSC
HA5
AOI
AOT
Page 27 of 44
Using the function button the user can move through all 8 possible slot positions. If the cell
hardware does not match the saved configuration then the SHC option will first display the
current hardware for a particular slot followed by the saved configuration for the slot. The
display of the current hardware will toggle between the hardware type and the slot number
prefixed by the letter C. For example if the current hardware in slot 1 is an interrupting
Digital Input module then the display will toggle between C01 and DI6. The saved
hardware display is similar except that the letter S prefixes the slot number.
Following is an example of a saved configuration, which does not match the current
hardware.
Current
Hardware
Saved
Hardware
DI6
HDO
HDO
HAI
DI6
HAI
DI6
DI6
Front Panel
Displayed
Front Panel
Displayed
Slot 1
C01 DI6
S01 HDO
Slot 2
C02 DI6
S02 HDO
Slot 3
C03 HDO
S03 AI3
Slot 4
C04 HDO
S04 AI3
Slot 5
C05 AI3
S05 DI6
Slot 6
C06 AI3
S06 DI6
Slot 7
007 DI6
007 DI6
Slot 8
008 DI6
008 DI6
While the hardware configuration must be saved through the front panel on each processor
individually before use, it can be viewed through Workbench for all processors.
NOTE: Workbench can be used to view the hardware
configuration on all processors.
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Check all I/O modules are recognised using the SHC front panel menu.
4.4.1
The simplest way to check the plant interface modules is using Workbench RTU Live
facilities. Some testing can be done through the processor front panel but for exercising
outputs Workbench is the most appropriate method. In addition, a Microsol I/O Simbox (I/O
simulator unit) may be used for simulating plant signals directly to the front connectors of the
Plant Interface modules.
4.4.1.1 Test Digital Input Modules
Depending on the type of digital input being used, simulate an input changing by either
shorting the input terminals together or applying an external voltage across the input
terminals. Using Workbench RTU Live (Refer to Workbench User Manual) display the
hardware modules for the appropriate unit (click on the Unit, select Information and I/O
Modules) and view the associated I/O channel status. Check that the correct input is ON and
also check that this causes the corresponding LED in the front panel LED Matrix Display turn
ON. Ensure that the LED Matrix Display is set to display I/O status using the LED menu
option on the front panel Function Menu. Remove the input and check that the status in
Workbench goes OFF and the front panel LED turns OFF. Repeat this test for each of the
input channels on the system.
Page 29 of 44
Page 30 of 44
4.5.1
The network is critical to the operation of most systems and it is important to ensure that it is
functioning correctly. There are a few ways to check the network operation:
The OLU (Online Units) display in the front panel function menu
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5 Operator Interface
A number of important parameters must be set using the processor front panel Function
Menu for correct system operation. The most important of these being the processor address
/ unit number and the stored hardware configuration. Other operating parameters may be
configured and downloaded from a PC using Microsols Workbench configuration tool.
The following sections describe the general use of the operator interface.
Status LEDs
3-Character Display
Function Button
5.1.1
Status LEDs
Two Status LEDs provide information about the state of the cell.
The software toggles this LED in normal
Active LED
operation to indicate that the processor is functioning.
On-Line LED
This LED indicates that the processor is
communicating on the FieldNet network.
5.1.2
3-Character Display
Figure 36 - CPR-041
Operator Interface
Message Codes
Function Menu
Function Menu The 3-Character display may also be used in conjunction with the Function
Button to provide a Function Menu for a variety of user diagnostics and configuration
parameters. Refer to the section on Function Menu for further details.
Page 32 of 44
5.1.3
LED Matrix
This matrix of 128 LEDs may be used for a number of different purposes as selected by the
Function Button Menu. These include:
I/O Display
Debug Display
I/O Display Generally this LED matrix is used to display the status of the hardwired I/O.
Each LED represents a physical hardware channel within that cell. For digital inputs and
outputs the state of the LED indicates the state of the physical input or output. If the LED is
ON, it indicates that the input or output is ON, and if the LED is OFF the input or output is
OFF. For analogue input channels, the LEDs cycle through each of the channels indicating
that the channels are being scanned. The cycle speed of the LEDs does not always
correspond to the scan rate of the particular module. For HSC Counter modules, the LEDs
cycle through the corresponding channel LEDs to indicate that the channels are present and
being processed. The LED cycle on the HSC module is much faster than for analogues.
Online Units Display The LED Matrix can be used to display the active units
communicating on the FieldNet LAN. Each LED represents an XCell Unit address. Note: For
display purposes those units with addresses greater than 128 will have their LEDs overlap
with those in the range 1-128.
Debug Display The matrix can also be used for specific application debug information.
Some protocols update the Debug LEDs to provide user information on the current state of
the protocol operation. Refer to the specific applications for further information on the use of
the Debug Display.
Page 33 of 44
The function button drives the function menu. The function button is used to:
Select an option
Increment a value
Exit an option
Accept a setting
The message display shows the menu options and settings, which can be changed using the
function button.
The function button should be pressed and held pressed for:
A count of one (1 second)
To exit a menu
Press the function button and hold for a count of two (2) before releasing it
Page 34 of 44
5.2.2
The following diagram shows the menu functions available for the CPR-041 processor. Many
options are only available during the first 10 seconds after the cell processor has rebooted.
AUN
SCL
OR
DLT
Available for 10
seconds after boot
only.
CAL
HYS
C04
NET
TBL
RTU
SHC
SAV
LED
GPA
GPB
FSD
OLU
DBG
FFS
Figure 37 - Block Diagram of the CPR-041 Menu Tree
Page 35 of 44
Select the AUN, (Alter Unit Number), option from the function menu.
Each of the 3 digits in the unit number must be changed separately starting on
the right hand side.
Increment each digit in the message display until the desired value is displayed.
Hold the function button to accept the required digit and then proceed to set the
next digit. The unit number must be between 1 and 250, numbers 0 and 251-255
are reserved for system purposes.
Accepting the value on the third digit will save the new Unit Number and proceed
to reboot the processor with the new network address accepted.
Page 36 of 44
6 XCell Operation
6.1 Software Description
All processors on the XCell LAN operate independently and communicate on a peer-to-peer
basis with all other units. Each unit runs its own application software and publishes its data
onto the network. Other units that require the data simply subscribe for the data. The
application software loaded in each unit depends on the functionality required of that unit. All
application software is stored in Flash Memory and can be updated through one of the serial
ports. The only software that is mandatory in every unit is the BASE software that contains
the basic functionality of every unit, including:
Other software applications are pre-loaded into the units before shipment, based on the
system specifications. Typical application software modules include:
IOSERVER
Express
Slave Protocols
Master Protocols
Other
Applications
Page 37 of 44
Control
Station
IEC 104
protocol
X protocol
DNP
protocol
IEC 61131
Apps
S/W APPs
BASE
IO SERVER
IEC104
Control
Station
S/W APPs
BASE
IO SERVER
DNP Master
Modbus Master
Express 61131
S/W APPs
BASE
IO SERVER
DNP Slave
X Slave
Slave 1
Plant I/O
Slave 2
Slave 3
DNP protocol
Plant I/O
Plant I/O
Slave 4
Modbus protocol
All units publish their data (I/O Data, IED Data, eXpress Pseudo Data, Apps Specific Data,
etc.) onto the network and applications in any other unit can subscribe for the data and use it.
Slave protocols that communicate with the Master Control Stations usually subscribe for all
data.
Control
Station
DNP
protocol
IEC 61131
Apps
IEC 61131
Apps
Subscriber
Applications
Publisher
Applications
Slave 1
Slave 2
Slave 3
Plant I/O
DNP protocol
ID Message identifier
VALUE The current data value
TIME The time of detection to the nearest millisecond.
QUALITY Quality information relating to the value
Page 38 of 44
7 Installing/Updating Firmware
When an XCell system is delivered it should be pre-loaded (in the factory) with the required
firmware for the system operation. As each processor is an independent processing node on
the network it may be assigned any firmware application that is appropriate to that node. For
example, an XCell processor that is responsible for communicating with a Master Station
must be loaded with the appropriate communications protocol firmware. These protocols can
then be configured using Workbench to assign the data points and addressing that are
required for the particular link.
Generally these applications are pre-loaded based on the initial system requirements. The
firmware is stored in non-volatile Flash memory that can be loaded and upgraded using a
serial connection without the need to change EPROMs. Most applications can then be
configured using the appropriate Workbench configuration tables.
In certain circumstances it may be necessary to upgrade the installed firmware or add some
new functionality. This can be done using the Flash Programmer utility in Workbench over a
serial connection to the unit.
Detailed instructions on loading new firmware can be found in the Workbench User Guide
under the section on Flash Programming.
All of these options will periodically update the system time but the lowest unit number will still
maintain synchronisation every six seconds between these periodic updates.
Page 39 of 44
Time can be synchronised from the Master Station on a periodic basis but the accuracy that
can be achieved over most protocols is in the order of 50ms. Most Master Stations
synchronise the RTU time every 15 or 30 minutes depending on the number of RTUs on the
line.
GPS Time
This is by far the most accurate method of time synchronisation. Most GPS receivers
synchronise time every minute to an accuracy of less than 1ms. This is usually done through
a serial port on one XCell processor which immediately synchronises all other processors on
the network.
Onboard Real Time Clock
The CPR-041 can be fitted with an optional RTC chip that maintains real time in the event of
power loss. This is read at system startup to provide realtime to the system. The RTC time is
accurate to the second, it has no millisecond ability. Once the system is running, the RTC
time is updated whenever time is set in the cell.
All digital inputs are timestamped to 1ms in the Interrupt Service Routine to ensure the most
accurate timestamp.
7.3 Redundancy
The XCell system is designed to provide a high level of redundancy and therefore high
availability for the user. All the main components provide a high level of redundancy /
availability as highlighted in the following areas:
Power supply The hardware generally accepts power from two independent
sources and diode Ors them together. This means that either power source could fail
and the system would continue to operate without interruption.
Fibre Network The fibre modules provide redundant fibre paths for communications.
As fibre is often prone to fracturing or connection damage this redundancy is an
essential requirement for many systems. This fibre redundancy is completely
transparent to the system operation and there is no switchover time if either path fails.
Multiple communication links With the XCell design all data is shared and available
at all other units. This means that any cell can run the same protocol and provide a
backup in the event of a communications failure.
EXpress 61131 Running the same IEC 61131 applications in two or more units can
provide powerful application redundancy. One unit is designated as Main and the
other as Backup. The IEC 61131 logic in the Backup unit simply monitors the state of
the Main unit and enables the algorithms if the Main unit is faulty.
Page 40 of 44
The IO Server that handles the various Plant Interface modules, has many tables to
determine how the I/O is processed, e.g. scaling on analogues, filtering on digitals.
Master protocols that interrogate IEDs have tables to determine what IED addresses
and data points to retrieve and what communication parameters to use.
Slave protocols that communicate with Master Stations have tables to determine the
data points to transfer and the protocol addresses assigned to each point.
These tables are configured using Workbench configuration tool. With this tool the user can
choose the required tables for each processor and define all the associated parameters. The
tables are then downloaded to the appropriate XCell processor unit and stored in non-volatile
Flash memory. Refer to the Workbench User Manual for exact details on how to configure
and download tables.
Table 1
Unit 2
Workbench
Table 5
Table 4
Table 3
Table 2
Table 1
Table 3
Table 2
Table 1
Unit 2
Table 4
Table 3
Table 2
Table 1
Unit 3
Unit 1
7.4.1
Workbench Connection
Workbench is connected to the XCell system through serial Port 1 on any XCell processor
module. The connection between the Workbench PC and serial Port 1 should use the
following connections.
XCell Port 1
Pin
PC Com Port
Pin
2 - Rx
3 Tx
3 - Tx
2 - Rx
5 Signal Gnd
5 Signal Gnd
Page 41 of 44
XCell DB-9
PC DB-9
1
7.4.2
It is possible to erase all the configuration data from the Flash File System as outlined in
section 4.3.3 Clearing Stored Configuration Data.
Alternatively it is possible to use Workbench to erase the files in the cell processor file
system. To do this, refer to the Workbench User Manual.
7.4.3
I/O Processing
XCell supports a variety of plant interface modules that generally fall into the following
categories:
Digital Inputs
Digital Outputs
DC analogue inputs
DC Analogue Outputs
AC analogue inputs
It is the configuration tables defined in Workbench that determine how the individual channels
are processed. For example, digital input channels can be handled as single point alarms,
double point plant status, TAP position Indicators, BCD inputs etc. For each of these software
types there are corresponding configuration tables in Workbench. Simply specify the physical
input channels associated with software types and the type specific parameters such as filter
times etc and download them to the appropriate XCell unit. The IOSERVER application in that
unit will then process the I/O according to the downloaded tables and their defined
parameters.
Outputs can be defined as single-stage, three-stage, pulsed or latched. Again the IOSERVER
will process them according to the downloaded configuration.
Page 42 of 44
For details on I/O configuration refer to the Workbench User Manual and the Workbench I/O
Configuration Manual.
7.4.4
XCell supports a variety of standard and proprietary serial protocols that enable it to
communicate with a variety of Master Stations. These protocols generally have two or three
configuration tables associated with them:
1. GEN Table - General protocol / communication parameters. This table
defines baud rates, retry counts, timeouts and any general parameters
relating to the protocol
2. MAP Table Defines the points to be accessed / transferred over the
protocol and their associated protocol addresses. It also defines any specific
parameters about how those points are to be transferred e.g. with timestamp,
or the associated buffer Class.
3. LRU Table Some XCell protocols support Logical RTUs and these
protocols generally have a third table (LRU) defining the addresses and
timeouts relating to each of the Logical RTUs.
The specific tables will be found in Workbench under the appropriate protocol Tab under
Slave Protocols.
7.4.5
XCell supports a variety of standard and proprietary serial protocols that enable it to
communicate with a variety of IEDs or other slave RTUs. Most XCell Master protocols support
multi-dropped IEDs or slaves on the one serial line. However, each device generally has an
impact on the overall performance of the communications and required data storage.
Generally, a maximum of approximately 20-30 devices is advised on any serial link.
Page 43 of 44
7.6 Diagnostics
For system diagnostics refer to the Workbench User Manual under RTU Live or XCell Monitor
User Manual.
Page 44 of 44