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User Guide for westermo models including: 4400 Industrial Cellular Router, 4400, Industrial Cellular Router, Cellular Router, Router
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DocumentDocumentw w w. we s t e r m o. c o m Merlin 4400 Series Industrial Cellular Router Table of Contents 1. General Information ........................................................................................................... 3 1.1. Legal Information .................................................................................................... 3 1.2. About This Guide .................................................................................................... 3 1.3. License and Copyright for Included FLOSS ............................................................... 3 2. Safety and Regulations ...................................................................................................... 4 2.1. Warning Levels ....................................................................................................... 4 2.2. Safety Information ................................................................................................... 5 2.3. Care Recommendations .......................................................................................... 7 2.4. Product Disposal ..................................................................................................... 7 2.5. Compliance Information ........................................................................................... 8 2.5.1. Agency Approvals and Standards Compliance ............................................... 8 2.5.2. Simplified Declaration of Conformity .............................................................. 8 3. Product Description ............................................................................................................ 9 3.1. Product Description ................................................................................................. 9 3.2. Available Models ..................................................................................................... 9 3.3. Hardware Overview ............................................................................................... 10 3.4. Connector Information Merlin ................................................................................. 10 3.4.1. Power Input ................................................................................................ 10 3.4.2. Serial Ports ................................................................................................ 11 3.4.3. Console Port .............................................................................................. 12 3.4.4. Antennas ................................................................................................... 13 3.4.5. Reset Button .............................................................................................. 13 3.5. LED Indicators ...................................................................................................... 14 3.6. Ethernet Port LED Behaviour ................................................................................. 15 3.7. Dimensions ........................................................................................................... 15 4. Installation ....................................................................................................................... 16 4.1. Mounting the Router .............................................................................................. 16 4.2. Cooling ................................................................................................................. 16 4.3. Connecting Cables ................................................................................................ 16 4.4. Connecting the Antenna ........................................................................................ 16 4.5. Inserting SIM Cards ............................................................................................... 17 4.5.1. Inserting SIM 1 Card ................................................................................... 17 4.5.2. Inserting SIM 2 Card ................................................................................... 17 4.6. Powering Up ......................................................................................................... 17 5. Specifications .................................................................................................................. 18 5.1. Interface Specifications .......................................................................................... 18 5.2. Type Tests and Environmental Conditions ............................................................... 19 6. Revision Notes ................................................................................................................ 21 2 Merlin 4400 Series 1. General Information 1.1. Legal Information The contents of this document are provided "as is". Except as required by applicable law, no warranties of any kind are made in relation to the accuracy and reliability or contents of this document, either expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Westermo reserves the right to revise this document or withdraw it at any time without prior notice. Under no circumstances shall Westermo be responsible for any loss of data or income or any special, incidental, and consequential or indirect damages howsoever caused. More information about Westermo can be found at www.westermo.com. 1.2. About This Guide This guide is intended for installation engineers and users of the Westermo products. It includes information on safety and regulations, a product description, installation instructions and technical specifications. 1.3. License and Copyright for Included FLOSS This product includes software developed by third parties, including Free/Libre Open Source Software (FLOSS). The specific license terms and copyright associated with the software are included in each software package respectively. Please visit the product web page for more information. Upon request, the applicable source code will be provided. A nominal fee may be charged to cover shipping and media. Please direct any source code request to your normal sales or support channel. Merlin 4400 Series 3 2. Safety and Regulations 2.1. Warning Levels Warning signs are provided to prevent personal injuries and/or damages to the product. The following levels are used: Level of warning Description Indicates a potentially hazardous situation Consequence personal injury Possible death or major injury Consequence material damage Major damage to the product WARNING Indicates a potentially hazardous situation Minor or moderate injury Moderate damage to the product CAUTION Provides information in order to avoid misuse of the product, confusion or misunderstanding No personal injury NOTICE Used for highlighting general, but important information No personal injury Minor damage to the product Minor damage to the product NOTE Table 1. Warning levels 4 Merlin 4400 Series 2.2. Safety Information Before installation: Read this manual completely and gather all information available on the product. Make sure it is fully understood. Check that your application does not exceed the safe operating specifications for the product. SAFETY DURING INSTALLATION The product must be installed and operated by qualified service personnel and installed into an apparatus cabinet or similar, where access is restricted to service personnel only. Before energising and connecting communication cables to the product, ensure a protective earthing conductor is first connected to the protective earthing terminal (only valid for metallic housings). Westermo recommends a cross-sectional area of at least 4 mm2. Upon removal of the product, disconnect the product from the power supply and all other communication ports before disconnecting the protective earthing conductor. SAFETY USE This equipment is not suitable for use in locations where children are likely to be present. HAZARDOUS VOLTAGE Do not open an energised product. Hazardous voltage may occur when connected to a power supply. PROTECTIVE FUSE The power supply wiring must be sufficiently fused. It must be possible to disconnect manually from the power supply. Ensure compliance to national installation regulations. This product has no internal fuse and should be connected via an external fuse for protection. POWER SUPPLY CONNECTION There are safety regulations governing the power source that can be used in conjunction with the product. Refer to chapter Interface Specifications. EARTH CONNECTION For correct function, the earth connection needs to be properly connected to a designated protective earthing rail (only valid for metallic housings). Torque: 3.1 Nm. Merlin 4400 Series 5 INDOOR USE ONLY The device is to be connected only to networks without routing to the outside plant. All communication ports are for indoor use only. REDUCE THE RISK OF FIRE To reduce the risk of fire, use only telecommunication line cords with a cable diameter of AWG 26 or larger. Regarding power cable dimensions, see chapter Interface Specifications. RADIO PRODUCTS Observe the usage limitations of radio products at filling stations, in chemical plants, in systems with explosives or potentially explosive locations. The product may not be used in airplanes. Exercise particular caution near personal medical aids, such as pacemakers and hearing aids. Never perform work on the antenna system during a thunderstorm. To fulfill human safety, a minimum separation distance of 20 cm or more should be maintained between the antenna of the product and personnel during operation. ELECTROSTATIC DISCHARGE (ESD) Prevent electrostatic discharge damage to internal electronic parts by discharging your body to a grounding point (e.g. use a wrist strap). HOT SURFACE Be aware that the surface of this product may become hot. When it is operated at high temperatures, the external surface may exceed Touch Temperature Limit according to the product's relevant electrical safety standard. CABLE TEMPERATURE RATING FOR FIELD TERMINAL WIRES There may be a requirement on the minimum temperature rating of the cable to be connected to the field wiring terminals, see chapter Interface Specifications. 6 Merlin 4400 Series 2.3. Care Recommendations Follow the care recommendations below to maintain full operation of the product and to fulfill the warranty obligations: · Do not drop, knock or shake the product. Rough handling above the specification may cause damage to internal circuit boards. · Use a dry or slightly water-damp cloth to clean the product. Do not use harsh chemicals, cleaning solvents or strong detergents. · Do not paint the product. Paint can clog the product and prevent proper operation. If the product is used in a manner not according to specification, the protection provided by the equipment may be impaired. If the product is not working properly, contact the place of purchase, the nearest Westermo distributor office or Westermo technical support. 2.4. Product Disposal This symbol means that the product shall not be treated as unsorted municipal waste when disposing of it. It needs to be handed over to an applicable collection point for recycling electrical and electronic equipment. By ensuring the product is disposed of correctly, you will help to reduce hazardous substances and prevent potential negative consequences to both the environment and human health, which could be caused by inappropriate disposal. Figure 1. WEEE symbol for treatment of product disposal Merlin 4400 Series 7 2.5. Compliance Information 2.5.1. Agency Approvals and Standards Compliance Type EMC Safety North American standards/approvals Approval/Compliance · EN/IEC 61000-6-2, Immunity industrial environments · EN/IEC 61000-6-4, Emission industrial environments · EN 50121-4, Railway signalling and telecommunications apparatus (pending) · IEC 61850-3, Communication networks and systems for power utility automation Part 3: General requirements · EN 62368-1, Safety Communication Technology · UL 62368-1 · UL 62368-1 · FCC, PTCRB, AT&T, Verizon, T-Mobile (all pending) Table 2. Agency approvals and standards compliance 2.5.2. Simplified Declaration of Conformity Hereby, Westermo declares that this product is in compliance with applicable EU directives and UK legislations. The full declaration of conformity and other detailed information is available at www.westermo.com/support/ product-support. Figure 2. The European Conformity and the UK Conformity Assessment markings 8 Merlin 4400 Series 3. Product Description 3.1. Product Description The Merlin 4400 series of versatile cellular routers is designed from the ground up to achieve best-in-class Cybersecurity both in hardware and software. A tamper-resistant chip keeps cryptographic keys secure. Secure Boot guarantees that the unit boots using only software that is signed and trusted by Westermo. A set of cybersecurity tools is available as standard. High security VPNs, stateful inspection firewall, user authentication and 802.1x are just a few of the features available to keep the device secure both locally and when transmitting data over the internet or private network. The system has a pair of legacy ports. One is configurable to act either as a RS-232 serial port or as a dry contact digital input. The second is a serial port and is configurable to act either as RS-232 or RS-485. The serial ports facilitate applications where it is necessary to migrate from modems to an IP infrastructure. The industrial protocol gateway feature enables several devices using different protocols to be accessed via a common protocol interface. The Merlin 4400, like all the members of the Merlin family, is compatible with the Activator zero-touch deployment software. The Activator software ensures that configurations are generated and deployed from a central server, reducing configuration mistakes and increasing efficiency during the installation phase of a project. This compact unit is suited to tight spaces. Its high MTBF, wide temperature range and voltage supply ensure the Merlin can deal with the demands of industrial, smart grid and trackside applications. 3.2. Available Models See datasheet for full list of models available. Merlin 4400 Series 9 3.3. Hardware Overview Figure 3. Location of interface ports and LEDs, illustrated by a Merlin-4407-T4-S2-LV model No. Description 1 WAN primary SMA connector 3 Reset button 5 Power connection 7 USB-C Console port 9 SIM LEDs 11 GPS SMA connector No. Description 2 WAN auxiliary SMA connector 4 Ethernet RJ45 ports 6 Serial ports / Digital input 8 Power and configuration LEDs 10 WAN signal strength 3.4. Connector Information Merlin 3.4.1. Power Input Illustration Position 1 2 Product marking DC+ DC- Direction Input Input Description Supply voltage Supply voltage Table 3. Power input The positive input is marked with a plus sign, "+". The negative input is marked with a minus sign, "-". Connect the voltage to the + pin and the return to the - pin on the power input. 10 Merlin 4400 Series NOTICE - POWER SUPPLY Where an AC/DC-adapter has not been supplied, a power supply of no greater than 100 W should be used, with a current limit of 1 Amp. The product can be supplied with power from a source that complies with PS2/LPS according to UL/IEC 62368-1 or with LPS according to UL/IEC 60950-1, the latest edition or equivalent. Such a power supply shall not exceed 100W after 5 seconds. 3.4.2. Serial Ports A pair of asynchronous serial ports may be present on the router. Figure 4. Serial ports Serial port 1 is software-configurable to operate either in serial RS-232 mode or to act as a dry contact digital input. Serial port 2 is configurable to operate in either RS-232 or RS-485 mode. The pin numbering of the serial port connector, when viewed from the front of the unit, is shown below. 18 Figure 5. Pin numbering of serial port RS-232 ports When you configure a serial port to operate as an RS-232 interface, it supports the following signals: · Transmit Data · Receive Data · CTS · RTS · DSR · DTR The pin numbering of the RJ45 socket, when viewed from the front of the unit, is as shown below. The RS-232 interface is wired as a DCE. Merlin 4400 Series 11 Illustration 18 Pin no. 1 2 3 4 5 6 7 8 Table 4. RS-232 connection Signal DSR DCD DTR SG RD TD CTS RTS Direction Out Out In Out In Out In Description Data Set Ready Data Carrier Detect Data Terminal Ready Signal Ground, not chassis ground Receive Data Transmit Data Clear To Send Request To Send Digital input When you configure the port to operate as a digital input, it operates as a dry contact only. The pin numbering of the RJ45 socket, when viewed from the front of the unit, is as shown below. Illustration 18 Pin no. 2 3 4 Table 5. Digital input port Signal +ve -ve Ground Direction Out In - Description Input Input. Default value is zero when nothing is fitted to port Signal Ground, not chassis ground RS-485 ports When you configure a serial port to operate as an RS-485 interface, it supports both two-wire (half-duplex) and four-wire (full-duplex) modes. Configuration between two-wire and four-wire RS-485 modes is under software control. The pin-numbering of the RJ45 connector in RS-485 mode, when viewed from the front of the unit, is shown below. Illustration 18 Pin no. 1 2 3 4 5 6 7 8 Table 6. RS-485 port pinout Signal Four-wire mode RT- R+ T+ Two-wire mode - T-/R- T+/R+ Direction Description In Out/In Four wire: Receive Four-wire: Transmit Two-wire: Transmit/Receive In Out/In Four-wire: Receive Four-wire: Transmit Two-wire: Transmit/Receive 3.4.3. Console Port The router has a USB console port with a type C connector. The router acts as a device. 12 Merlin 4400 Series 3.4.4. Antennas The router has three SMA connectors. They are: · Two LTE antennas for the mobile radio - a MAIN and an AUXiliary · Single antenna for GNSS/GPS 3.4.5. Reset Button Use the reset button to request a system reset. When pressing the reset button, all LEDs turn on simultaneously. The length of time holding the reset button will determine its behaviour. Press duration 0-3 seconds 3-15 seconds PWR/CONFIG LED behaviour Solid on Flashing fast 15-20 seconds 20-30 seconds Solid on Flashing slowly > 30 seconds Solid on Router behaviour on depress Normal reset to running config. No special LED activity. Releasing 3-15 seconds switches the router back to factory configuration. Note: this will wipe the configurations, both config1 and config2. Releasing 15-20 seconds performs a normal reset to running config. Releasing 20-30 seconds reboots the router to recovery mode. Only to be done in case of emergency and under the guidance of Westermo support staff. Note: this may wipe the configurations, both config1 and config2. Releasing after 30 seconds performs a normal reset. Table 7. Merlin series router reset behaviour Merlin 4400 Series 13 3.5. LED Indicators The LED indicators described in this section are all single colour LEDs. When the router is powered on, the power LED is green. The possible LED states are: · Off · Flashing slowly · Flashing quickly · On LED Booting up Status Power Config SIM 3G/LTE cellular signal strength LED On Off Flashing On Flashing slowly Flashing quickly On Off Flashing Both LEDs off Left LED on Right LED off Left LED off Right LED on Both LEDs on Table 8. LED indicators Description The router takes less than a minute to boot up. During this time, the power LED flashes. Other LEDs display different diagnostic patterns during boot up. Booting is complete when the power LED stops flashing and stays on steady. Power is present No power. Boot loader does not exist. Booting The router is running a valid configuration file. The router is running in recovery mode (2.5 flashes/second) The router is running in factory configuration (5 flashes/second) SIM selected and registered on the 3G/4G network Not selected or SIM not inserted SIM selected and not registered on the network Data link not connected or signal strength <=-113 dBm Data link connected and signal strength <=-89 dBm Data link connected and signal strength is between -89 to -69 dBm Data link connected and signal strength >-69 dBm 14 Merlin 4400 Series 3.6. Ethernet Port LED Behaviour There are four Ethernet ports and each has a pair of LEDs: a LINK LED (green) and a SPEED LED (amber). When looking at the port, the LED on the top is the LINK LED, and the SPEED LED is on the bottom. Figure 6. Merlin Ethernet ports LINK LED (green) SPEED LED (amber) On Off Flashing On Off Physical Ethernet link detected No physical Ethernet link detected Data is being transmitted or received over the link Link operating at 100 Mbps Link operating at 10 Mbps Table 9. Ethernet LED behaviour and descriptions 3.7. Dimensions Dimensions are stated in millimetres and are regardless of model. Figure 7. Dimensional drawing Merlin 4400 Series 15 4. Installation 4.1. Mounting the Router The router is fitted with a DIN-rail clip by default. To attach the router to a DIN-rail: 1. Position the router so that the spring of the DIN-clip rests on the DIN-rail. 2. Push the router in an upward direction so that the spring of the DIN-clip compresses and the top hook of the DIN-clip slides and clamps to the DIN-rail. To remove the router from the DIN-rail, simply reverse the procedure. MOUNTING HEIGHT To reduce the risk of personal injury and damage to the device, the unit must not be mounted at a height greater than two metres above the ground beneath it. 4.2. Cooling This product uses convection cooling. Spacing is recommended for the use of the product in full operating temperature range and service life. To avoid obstructing the airflow around the product, use the following spacing rules. Minimum spacing of 25 mm (1 inch) above/below and 10 mm (0.4 inches) left/right of the product is recommended. REDUCE THE RISK OF FIRE To reduce the risk of fire, use only telecommunication line cords with a cable diameter of AWG 26 or larger. Regarding power cable dimensions, see chapter Interface Specifications. 4.3. Connecting Cables Connect one end of the Ethernet cable into port A and the other end to your PC or switch. 4.4. Connecting the Antenna If only connecting one LTE antenna, screw the antenna into the MAIN SMA connector. If you are using more than one LTE antenna, screw the main antenna into the MAIN SMA connector and the secondary antenna into the WAN-AUX SMA connector. Be careful to select an antenna that ensures the equipment complies with local regulatory requirements. In North America, Westermo has indicated to PTCRB the following set of antennas for use with this equipment: Article Number 160-00148 160-00184 Model 2J 2J7724Ma - Cellular/LTE MIMO Magnetic Mount with two 3m LL100 leads, SMA Male 2J 2J2183K-B07H-300LL195-C91GST - Cellular/LTE wall mount antenna with a 3m LL195 lead, SMA Male Table 10. List of antennas for use with this equipment in North America, as indicated to PTCRB 16 Merlin 4400 Series To comply with the requirements of PTCRB in North America: 1. It is recommended to select an antenna from the list above. 2. Should a user select their own antenna, Westermo strongly recommends that it be mounted with at least 20cm of cable. 3. Where a user selects a directly mounted antenna, it must comply with the OTA requirements of the PTCRB. 4.5. Inserting SIM Cards On the rear side of the router there are two SIM slots. To access the SIM cards, first remove the SIM cover using a suitable screwdriver (not supplied). Only the proper driver can drive a specific head size without risk of damaging the driver or screw. The product datasheet indicates the correct size of SIM card to use. A Mini-SIM card (2FF) is of size 25mm x 15mm x 0.76mm. Do not use a card larger than or smaller than that specified in the product datasheet or you may cause damage to the unit. Using the correct SIM card size helps avoid issues such as incompatibility or improper insertion that can lead to device malfunction. 4.5.1. Inserting SIM 1 Card Ensure the router is powered off. · Remove the SIM cover using a suitable screwdriver. · Hold the SIM 1 card with the chip side facing down and the cut corner facing away from you, to the left. · Gently push the SIM card into the upper SIM slot 1 until it clicks in. · Screw the SIM cover back on with the screwdriver. 4.5.2. Inserting SIM 2 Card · If you are using a second SIM, hold the SIM 2 card with the chip side facing up and the cut corner front right facing away from you. · Gently push the SIM card into the lower SIM slot 2 until it clicks in. · Screw the SIM cover back on with the screwdriver. 4.6. Powering Up Plug the power cable first into the device and then to a suitable power source. The router takes less than a minute to boot up. During this time, the power LED flashes. Other LEDs display different diagnostic patterns during boot up. Booting is complete when the power LED stops flashing and stays on steady. Merlin 4400 Series 17 5. Specifications 5.1. Interface Specifications DC, Power port Operating voltage Rated current Rated frequency Inrush current Polarity Redundant power input Isolation Connector Conductor cross section Stripping length cable Tightening torque, screw flange Shielded cable 9.6 to 60 VDC 325 mA at 12 VDC 103 mA at 48 VDC DC 2.74 x 10-3 A2s at 12 VDC Reverse polarity protected No All other ports Push-in spring connectors 0.2-2.5 mm² (AWG 24-12) 7 mm 0.3 Nm Not required Ethernet TX Electrical specification Data rate Duplex Transmission range Isolation Connection Cabling Number of ports IEEE std 802.3 10 Mbit/s, 100 Mbit/s, manual or auto Full or half, manual or auto Up to 150 m with CAT5e cable or better All other ports RJ-45, auto MDI/MDI-X Shielded CAT5e or better is recommended 4 Digital input Mode of operation Connection Dry contact only RJ-45 shielded cable RS-232/485 Electrical specification Data rate Data format Transmission range Connection Configurable for EIA RS-232 or EIA RS-422/485 RS-232: 50 bit/s - 1 Mbit/s RS-485: 50 bit/s - 12 Mbit/s 7 or 8 data bits, odd, even or none parity, 1 or 2 stop bits (2 stop bits only when no parity is set) RS-232: 15 m/49 ft RS-485: Up to 1200 m/0.74 mi, depending on data rate and cable type RJ-45 according to EIA-561 RJ-45 shielded cable 18 Merlin 4400 Series Console port Electrical specification Data rate Circuit type Data format Connection USB 2.0 host interface 115.2 kbit/s SELV 8 data bits, no parity, 1 stop bit, no flow control USB receptacle connector type C 5.2. Type Tests and Environmental Conditions Environmental phenomena ESD Fast transients Surge Basic standard Description EN 61000-4-2 Enclosure EN 61000-4-4 EN 61000-4-5 Power port Ethernet ports Ear th Serial ports Power port Power frequency magnetic field Radiated RF immunity EN 61000-4-8 EN 61000-4-3 Ethernet ports RS-232 RS-422/485 Enclosure Enclosure Conducted RF immunity EN 61000-4-6 Radiated RF emission Conducted RF emission Dielectric strength EN 55032, EN 61000-6-4 EN 55032, EN 61000-6-4 UL 62368-1 UL 62368-1 IEEE 802.3 Table 11. EMC and electrical conditions Power port Ethernet Serial ports Ear th Enclosure Power port Ethernet Power port to all other ports Ethernet TX to all other ports Test levels Contact: ±6 kV Air: ±8 kV ± 4 kV, direct coupling ± 4 kV, capacitive coupling clamp L-E: ± 2 kV, 12 , 9 F, 1.2/50 s L-E: ± 2 kV, 42 , 0.5 F, 1.2/50 s L-L: ± 1 kV, 2 , 18 F, 1.2/50 s L-L: ± 1 kV, 42 , 0,5 F, 1.2/50 s L-E: ± 2 kV, 2 , direct on shield, 1.2/50 µs L-E: ± 2 kV, 2 , 0,5 µF L-E: ± 2 kV, 42 , 0,5 µF 100 A/m; 50 Hz 20 V/m at 800 MHz to 1 GHz 10 V/m at 80 MHz to 3 GHz 5 V/m at 2.7 GHz to 6 GHz 1 kHz sine, 80% AM 10 V, 80% AM, 1 kHz; 0.15 MHz to 80 MHz 30 MHz to 12 GHz 150 kHz to 30 MHz 150 kHz to 30 MHz 1.0 kVDC, 1 min 1.5 kVrms, 50 Hz, 1 min Merlin 4400 Series 19 Environmental phenomena Basic standard Description Temperatures EN 60068-2-1 EN 60068-2-2 Operational Humidity EN 60068-2-30 Operational MTBF Telcordia Ground benign, 25°C Enclosure EN 62368-1 Aluminium Weight Cooling a.Refer to "Safety Information" chapter regarding touch temperature Table 12. Environmental and mechanical conditions Test levels -40 to +70°C (-40 to +158°F)a. 5-95% relative humidity 1,600,000 hours Fire enclosure 0.5 kg Convection 20 Merlin 4400 Series 6. Revision Notes Revision Rev. B Rev. C Rev. D Rev. E Rev. F Rev. G Rev. H Date 2022-03-29 2022-05-26 2022-11-18 2023-01-25 2023-05-08 2024-01-10 2024-07-02 Change description First version Revised product codes in the section 'Available Models'. Corrected descriptions of points 9 and 10 in section 'Hardware Overview'. Revised artwork and metrics Extended the set of available models Revised set of available models Refer to datasheet for list of models available Extra warnings, dual-use serial port Merlin 4400 Series 21 EN_REV H 2024 07 @ Westermo Network Technologies AB, Sweden