Data Delivery Devices RFScada 2DI-4DO Long Range Spread Spectrum Bi-Directional Wireless Telemetry Unit User Manual

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 11 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
installation, the cabinets may be supplied without any holes and the customer may drill 
the cabinet then install the cable clamps in a suitable position. Use caution when drilling 
the cabinet and always ensure that any power is removed from the device beforehand, 
otherwise damage to the device and serious injury may occur.  
Before drilling the cabinet it is usually best to remove the main internal panel that 
holds the circuit board, battery and internal antenna to prevent damage to the device. 
To do this carefully remove the 4 stainless steel screws that mount the main panel to 
the cabinet. Use caution removing these since the screw threads have been treated 
with low strength thread locker to prevent coming loose from vibration.  
 
NOTE 
Be especially careful by the antenna, it is securely located to 
both the board via a precision connector and to the panel via 
a non metallic stand, do not attempt to lift the panel by the 
antenna since damage to the main board and antenna will 
result.  
 
Once the panel has been removed from the cabinet, drill holes large enough 
(commonly available ‘step’ drills are very useful for these size holes) for the cable 
clamps or conduit fittings and install the clamps tightly. Remove any dust or particles 
remaining from drilling, then replace the panel in the cabinet and complete wiring of the 
inputs, outputs and power to the device. Secure power and signal cables to the inside of 
the case using Ty-Wraps included with the unit. Close the front door and secure with a 
suitable padlock (latch close version) or by tightening the door closing screws (screw 
close version).  
 
Possibly lethal line voltages will be present on 
the unit’s circuit board when connected to AC 
line power. Before attempting to gain access, 
test or modify connections refer to a qualified 
electrician for assistance, instructions on safe 
operation and to ensure that connections meet 
all applicable safety procedures, standards and 
codes. The front door should always be 
securely closed either by using a suitable 
padlock (latch close version) or by tightening 
the door closing screws (screw close version) 
to prevent access by unauthorized personnel.  
 
Apply power to the unit and verify correct operation.    
 
 
 
 
 
                                  
DANGER 
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 12 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
Typical Wiring Installation 
 
 
 
 
Component Identification, Signal and Wiring Reference. 
  
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 13 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
Component Identification 
 
 
 
 
 
This diagram identifies components, connectors and LED’s on the RFScada board 
assembly. Refer to the following chart and detailed notes for an explanation of items 
identified.  
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 14 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
 
 
Connector Pin  Function 
J1  1  117 VAC Line Hot AC power in 
J1  2  Ground In  
J1  3  117 VAC Line Neutral AC power in 
J2  1  External 12 Volt DC input positive 
J2  2  External 12 Volt DC input negative (connected to ground) 
J3  1  Local contact input One (5 Volt DC via 1 K Ohm pull up resistor) 
J3  2  Local contact input One (connected to ground) 
J3  3  Local contact input Two (5 Volt DC via 1 K Ohm pull up resistor) 
J3  4  Local contact input Two (connected to ground) 
J4  1  Remote relay one contact normally closed 
J4  2  Remote relay one contact common 
J4  3  Remote relay one contact normally open 
J4  4  Remote relay two contact normally closed 
J4  5  Remote relay two contact common 
J4  6  Remote relay two contact normally open 
J5  1  Remote AC relay status contact 
J5  2  Remote AC relay status contact  
J5  3  Comms OK status relay contact   
J5  4  Comms OK status relay contact   
J6  1  12 Volt battery Positive 
J6  2  12 Volt Battery Negative (connected to ground) 
 
All signals are identified by the preceding diagram and chart. Note that not all the 
connections need to be used; these will vary depending on the application.  
 
J1, AC Line Input 
This is 115 VAC line power and ground connection to the unit. 
 
 
The non-metallic enclosure does not provide 
grounding from any conduit connections. Use 
grounding type bushings and jumper wires if 
metal conduit is used.  
 
If the RFScada unit is operating from an external DC supply this connecter may not be 
used.  
 
 
J2, External 12 Volt DC Input 
This is the low voltage input power connector, and if used is connected to a 10 to 18 
Volts DC external power source (NOT the backup battery in the RFScada case). Note 
that pin 2 is connected to ground on the circuit board and is common to all the other 
CAUTION 
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 15 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
pins that connect to ground. If an external ground is not connected via the 115 VAC 
power connector (J1), then an external ground should be connected to this pin.  
 
 
The non-metallic enclosure does not provide 
grounding from any conduit connections. Use 
grounding type bushings and jumper wires if 
metal conduit is used.  
 
J3, Local Contact Inputs 
The switch contacts whose status is to be transmitted to the opposite unit are connected 
here. Shorting together pins 1 and 2 on J3 will cause the output relay one at the remote 
RFScada unit to activate; shorting together pins 3 and 4 on J3 will cause the output 
relay two at the remote RFScada unit to activate. Pins 1 &3 are both connected to 5 
volts DC via a 1 K Ohm pull up resistor; pins 2 & 4 are connected to ground. An external 
set of dry contacts will short the inputs to activate the signals, alternatively an external 
open collector transistor may also be used to activate the signal is required. In this case 
the external transistor would need to be able to sink 5 mA. Under no circumstances 
should any external voltage be applied to the pins on J3.  
 
Local Input Status LED’s 
These two green LED’s indicate the present status of each local input at J3. They are 
illuminated when the external input contacts are closed and the signal de-bounce delay 
time has completed, so these LED’s will respond just after changes in the input signals 
have occurred.  
 
J4, Remote Relay Contacts 
J4 is connected to the contacts of two independent single-pole double-throw relays, 
which respond to signals applied at the other RFScada unit. Relay one contacts are 
activated in response to the switch contacts at the other RFScada unit input one, and 
relay two contacts respond to the switch contacts at the other RFScada unit input two. 
Each relay contact is rated at 0.5 Amp 115 VAC, or 1 Amp at 30 V DC. If loads greater 
than this are to be controlled a suitable larger capacity relay should be driven from this 
one. The common, normally open and normally closed contacts for each relay are all 
available at connector J4, but if possible the user should configure the system to use 
‘normally open’ type configuration to ensure failsafe operation. Then in the event of a 
signal wire being damaged, communication signal loss or other failure a suitable alarm 
or course of action may be undertaken.  
 
Remote Relay Status LED’s 
These two red LED’s indicate the present status of each remote relay (connected to J4). 
They are illuminated when the relays are activated, ie the normally open contacts are 
closed. These LED’s are driven form a spare set of contacts on each relay, so they 
indicate the actual present status of the two relays. 
 
J5, Remote Status Output Contacts 
CAUTION 
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 16 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
J5 is connected to the contacts of two independent single-pole single-throw relays, 
which respond to signals at the other RFScada unit. Pins 1 & 2 will be shorted together 
by the relay contacts whenever AC line power is powering the other RFScada unit, 
when AC power is not powering the other unit the relay contacts will open. The contacts 
will close when the AC voltage is above approximately 95 VAC and open when it is 
below about 90 VAC. If the other unit is being powered by an external 12 Volt DC 
source the contacts will be open. Pins 3 & 4 are connected to another set of relay 
contacts, which are activated when good, verified communications are in process 
between this RFScada unit and the other RFScada unit. The contacts will open within a 
few seconds when communications fail for any reason. Each relay contact is rated at 
0.5 Amp 115 VAC, or 1 Amp at 30 V DC. If loads greater than this are to be controlled a 
suitable larger capacity relay could be driven from these.  
 
Remote Status LED’s 
These two yellow LED’s indicate the present status of the remote units AC power and 
the present state of communications between units. They are illuminated when the two 
relays (connected to J5) are activated, i.e. the normally open contacts are closed. 
These LED’s are driven from a spare set of contacts on each relay, so they indicate the 
actual present status of the relays. 
 
Transmit / Receive LED’s 
These two LED’s (red receive, green transmit) illuminate each time the unit completes a 
data transmission or verified data reception. Normally the two LED’s will be flashing in 
sequence as the unit communicates with another. If the unit is unable to receive data it 
will flash just the transmit LED each time it tries to establish communication. These two 
LED’s give a quick indication of communications, and are very useful in the case of 
marginal data communications or antenna adjustments.    
 
J6, Backup Battery Connector 
This is connected to the 12 Volt DC sealed lead acid backup battery. It supplies power 
to the RFScada device when AC line power or an external 12 Volt DC power supply 
fails; then the unit may continue to operate and draw power from the battery via this 
connector. Pin 1 is the positive battery connector, and pin 2 (connected to ground) goes 
to the negative battery connector. The board has a built in, temperature compensated, 
current limited float charger for the external battery. This charger is designed to safely 
charge the standard battery and then keep it continually charged in a ‘float’ mode. This 
charging circuit is protected against reverse polarity, open circuit, a dead or shorted 
battery, over-current in or out of the board and also has an electrically re-settable fuse. 
Under no circumstances should any other voltage or device be connected to these pins, 
the charging circuit is not designed to operate with any other type of battery. If an 
external DC voltage (such as a solar panel, car battery or charging system) is required 
to operate the RFScada unit, then connect the external voltage to connector J2. If the 
backup battery is not required remove it from the RFScada cabinet and unplug the 
connector P6 from connector J6. 
  
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 17 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
Antenna Connector 
The internal antenna is normally attached to this connector. If another antenna needs to 
be used then the internal antenna should be carefully disconnected and removed. See 
the section on external antennas for more details.   
 
F1, AC Power Fuse 
A user replaceable fuse and a transient arresting MOV protect the board. The fuse will 
blow if there is a malfunction in the circuit, or a voltage greater than the board rating is 
applied to the AC line input. The fuse is located underneath a safety cover, which in turn 
is secured by a Ty-Wrap. To test and replace the fuse proceed as follows: 
 
 
Possibly lethal line voltages will be present on 
the unit’s circuit board when connected to AC 
line power. Before attempting to gain access, 
test or modify connections refer to a qualified 
electrician for assistance, instructions on safe 
operation and to ensure that connections meet 
all applicable safety procedures, standards and 
codes. 
 
First remove all AC power to the unit. Cut and remove the Ty-Wrap that secures the 
fuse safety cover. Remove the safety cover. Using an Ohm Meter measure the 
resistance of the fuse, if the resistance is high or infinite the fuse has failed and needs 
to be replaced. If it has failed discard and replace with a spare 2 Amp 250 V that is 
supplied with the unit. Do not use a fuse with any other rating. Replace the fuse safety 
cover and secure with a Ty-Wrap included with the unit. To check the fuse and AC 
operation the 12 Volt battery cable plug P6 may be unplugged from connector J6 before 
re-applying AC line voltage. If the unit does not power up correctly please contact Data 
Delivery Devices LLC for assistance. Once correct operation has been verified the 
battery (if installed) should be re-connected.  
 
Battery Maintenance and Replacement. 
The standard 12 Volt DC 1.2 Amp / hr battery has a limited lifetime, typically between 2 
to 5 years but it will vary depending on the environment and type of use.  
 
NOTE 
The battery life will be severely limited if it is left in a 
completely discharged state. If the RFScada unit is not going 
to be used for some time and will not have AC power applied 
then unplug the battery cable plug P6 to prevent the battery 
from becoming completely discharged. The battery will 
continue to maintain a charge for a year or more without 
requiring charging provided there is no load, so unplug it if 
the unit will not be used. 
 
DANGER 
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 18 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
The battery condition may be verified periodically by simply removing the normal source 
of power (AC line or low voltage DC). The RFScada unit should continue to operate for 
at least 6 hours, if it does not then replace the battery. Acceptable replacement types 
are Power-Sonic PS-1212 or Panasonic LC-R121R3PU. To replace the battery proceed 
as follows:    
 
 
 
Some manufacturers of the sealed, 
rechargeable batteries that may be used in the 
RFScada unit do not recommend charging the 
batteries in a hermetically sealed enclosure. 
Although the batteries themselves are 
completely sealed and may be operated at any 
angle it may be possible, under a certain set of 
rare circumstances for the battery to vent gas 
into the cabinet. This gas could potentially 
create an explosion if subsequently ignited by a 
spark. The battery could possibly vent gas if 
the charging circuit malfunctioned, the 
protective current-limiting fuse shorted out, the 
battery became severally overcharged and 
failed. The RFScada unit has a suitable vent in 
the base of the cabinet, which will allow any 
gas to safely vent in the event of these failures. 
If the internal battery is not required the vent 
may easily be removed and the hole may be 
used for cable access, since it is the same size 
as the cable entry fittings supplied.  
 
 
 
Possibly lethal line voltages will be present on 
the unit’s circuit board when connected to AC 
line power. Before attempting to gain access, 
test or modify connections refer to a qualified 
electrician for assistance, instructions on safe 
operation and to ensure that connections meet 
all applicable safety procedures, standards and 
codes. 
 
DANGER
DANGER
CAUTION 
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 19 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
First remove all AC power to the unit. Unplug the battery cable plug P6 from the board 
connector J6. Cut and remove Ty-Wrap’s that secure the battery. Carefully pull the old 
battery away from the panel. Unplug the cable terminals from the old battery, and plug 
them onto the new battery making sure they are connected red wire to positive (+) 
on the battery and black wire to negative (-) on the battery. Locate the new battery 
in position and secure it with three new Ty-Wraps supplied with the replacement battery. 
Plug the battery cable plug P6 into connector J6 on the board. Return the unit to service 
and re-apply AC power. After the unit has been back in service for a few hours remove 
AC power and verify correct operation using the new battery, if it does not operate 
correctly contact Data Delivery Devices LLC for assistance.  
  
						

							RFScada User Manual Version 1.7 Copyright ©2002 Data Delivery Devices LLC   Page - 20 – 120 NE DeBell Suite B Bartlesville OK 74006      Tel 918-335-3318      FAX 918-335-3328 
Typical Applications and Installations. 
 
Fluid Monitoring / Control 
 
Remotely monitor both high and low levels of a tank and control the fill / drain pumps from 20 miles away 
without interconnecting wires. The RFScada devices also provide automatic local and remote alarms for 
power or system failures, plus full function operation for hours due to the standard built in battery backup.