Pulsar INTRW - v1.0 Operating instructions

Brand: Pulsar

Model: INTRW - v1.0

Category: Networking

Type: Operating instructions

Pulsar INTRW - v1.0 is a Wi-Fi to RS485 converter designed to integrate power supply units with a WLAN/WAN network. It features a user-friendly web interface for configuration, supports various security protocols (WEP, WPA, WPA2), and operates in multiple modes, including virtual serial port and TCP outlet. With its hermetic IP65 enclosure and 5-year warranty, the INTRW ensures reliable communication and data protection in demanding industrial environments.

Interface

RS485-WiFi

v.1.0

CODE: INTRW

Edition: 1st (6th Jan 2013)

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CONTENTS

1. General description. ................................................................................................................................2

2. Arrangement of the components............................................................................................................3

3. Installation................................................................................................................................................4

3.1 Main guidelines....................................................................................................................................................................4

3.2 Connecting to the RS485 bus. ..............................................................................................................................................4

3.3 Installation of the interface...................................................................................................................................................4

4. Configuration of the RS485-WiFi interface..........................................................................................6

4.1 Factory settings of the interface. ..........................................................................................................................................6

4.2 Introductory information. .....................................................................................................................................................6

4.3 STEP 1 – Restoring the factory settings...............................................................................................................................6

4.4 STEP 2 – Configuration of the IP address............................................................................................................................7

4.5 STEP 3 – Assigning the SSID identifier for Wi-Fi network. ...............................................................................................8

4.6 STEP 4 – Selecting the communication mode. ..................................................................................................................13

4.6.1 Communication in LAN/WAN......................................................................................................................................13

TCP Sockets profile settings.................................................................................................................................................................15

Setting the serial port............................................................................................................................................................................16

Settings in the PowerSecurity program.................................................................................................................................................17

4.6.2 Communication in the WLAN serial bridge mode.......................................................................................................19

Settings of the ‘Serial Bridge’ profile – Client/Server..........................................................................................................................19

Setting the parameters of the serial port.. .............................................................................................................................................19

Settings in the PowerSecurity program.................................................................................................................................................20

5. Setting the communication parameters of the PSU............................................................................23

5.1 Configuration of the PSU with an LCD display.................................................................................................................23

Stetting the address of the PSU............................................................................................................................................23

Setting the parameters of the serial port.. ............................................................................................................................24

5.2 Configuration of the PSU with an LED display.................................................................................................................25

Setting the address of the PSU.. ...........................................................................................................................................25

Setting the parameters of the serial port.. ............................................................................................................................25

6. Specifications..........................................................................................................................................26

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Features:

• operating in the Wi-Fi network

• compliant with the IEEE 802. 11b standard

• operation mode: full or half-duplex (auto-sensing)

• embedded web server for configuration

• data encryption: WEP, WPA, WPA2

• operates with numerous popular protocols, e.g. TCP, UDP, DHCP

• assigning a static or dynamic IP address (DHCP server)

• operates in modes: virtual serial port, TCP outlet

• power supply 10 ÷ 30V DC

• works with the PowerSecurity software

• LED indication

• hermetic enclosure IP65

• warranty - 5 years form the date of production

1. General description.

The RS485-WiFi interface is a device intended for converting signals between the RS485 bus and the

Ethernet network and dedicated for working with power supply units of the PSBEN (Black Power) group connected

to WLAN/WAN network. To work correctly, the device requires external power supply within the range of 10 ÷ 30V

DC e.g. drawn from a PSU of the PSBEN series. The device is mounted in a hermetic enclosure that protects it

against adverse environmental conditions.

The range of transmission in the Wi-Fi wireless network amounts to approx. 30m inside

buildings and depends on its construction.

Before using a communication system in the Wi-Fi network, make certain that the technical

conditions of the dedicated place ensure stability of connection.

2. Arrangement of the components.

The picture below shows the arrangement of the most important components and connectors of the RS485-

WiFi interface.

Fig.1. The view of the interface.

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Table 1. Description of the components.

Element

no.

Description

[1]

LEDs – optical indication:

PWR – supply’s voltage

TX – data transmission

RX – receiving data

[2] RST button – reset of the interface’s settings

[3] INIT button – initiation of the interface

[4] Antenna outlet RP-SMA

[5]

Connector of the RS485 bus

A+, B- - RS485 data transmission

SG - signal ground

[6]

Wi-Fi module.

Green LED – network activity (transmitting or receiving)

[7]

Wi-Fi module.

Yellow LED – active connection with the network

[8] Power connector 10÷30V DC

[9] Wi-Fi antenna

3. Installation.

3.1 Main guidelines.

During the installation of the RS485-WiFi interface, follow certain principles that will help to avoid

electromagnetic interferences and incorrect operation of the device:

- provide the interface with power from a source of low ripple factor

- the main supply cable ought to be possibly shortest.

- signal harnesses shall be led in min. 50 cm distance, the cuts between them are to be made at the angle of 90°

- the location of the interface's installation must be distant from devices of significant impulse interferences, e.g.

power invertors, contactors, relays.

3.2 Connecting to the RS485 bus.

The RS485-WiFi interface is connected to the RS485 bus via the ‘RS485’ connector. Connect the wires of

the RS485 bus to the A+, B- terminals of the connector. They are assigned in the same way and the connection is

identical to the rest of devices (A+ to A+, B- to B-).

Use a twisted-pair cable as a transmission wire of the bus. The bus shall be of a ‘point-to-point’ topology,

the ‘star’ type of topology is to be avoided. If the bus wires are of a significant length it is recommended to use a

shielded cable that will prevent from errors during communication and lowers the susceptibility to noise and

emission of radio frequency interference. It is also advisable to mount termination resistors at the ends of the bus.

Their resistance ought to be comparable to the impedance specific for the cable in use, i.e. 120 Ohm.

3.3 Installation of the interface.

1. In the enclosure, mount an isolation duct for a Wi-Fi antenna.

2. Lead the antenna through the isolation duct and then screw it carefully into the outlet of the module. Screw the

nut tight to keep the enclosure airtight.

3. Lead the cable of the RS485 bus through the cable duct and the appropriate hole in the enclosure and then

connect to the RS485 connector of the interface. The wires A+, B- must be connected identically in all devices,

i.e. A+ to A+, B- to B-. In the shielded cables, the shield is to be connected to the terminal of signal ground SG.

4. Optional: mount 120 Ohm terminating resistors at the end of the RS485 bus.

5. Lead the supply cable through the cable duct and the appropriate hole in the enclosure and then connect it to

the ‘Power’ power connector. The power source shall deliver voltage from the range of 10-30V DC, e.g. from a

power supply unit of the PSBEN group. The best solution is to use a PSU that is plugged into the RS485 bus

and located close to the interface.

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Fig.2. The view of the interface with a description of the wires.

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4. Configuration of the RS485-WiFi interface.

4.1 Factory settings of the interface.

Username - root

Password - dbps

IP address

Acquired automatically from the DHCP database of the router

Network’s name (SSID)

No name

Connection with the Wi-Fi network

Connection to a random available Wi-Fi network

Network security

No preset protection

Communication parameters of a serial port

No configuration

4.2 Introductory information.

Parameters of the RS485-WiFi interface can be configurable in order to adjust them to the intended

operation mode. The configuration is via web browser after correct logging, i.e. typing correctly username and

password.

The ‘Digi Device Discovery’ program is also helpful as it allows previewing important parameters of the

interface at the preliminary stage of the configuration. The application seeks out modules available at the range of

a router and informs about the assigned IP address and MAC unique address.

Download the ‘Digi Device Discovery’ program from the following page:

http://www.pulsar.pl/pl/pliki/digi_discovery.exe

To perform the configuration of the RS485-WiFi interface, a minimal connection arrangement is to be set,

as shown below:

Fig. 3. A diagram of connections between the interface and a PC

that enables performing the configuration.

A newly purchased Wi-Fi interface is delivered with basic configuration (factory settings) which is not

adjusted to correct operation in the system.

As the communication with the interface is via radio waves, it is important to adjust your router accordingly

so that it can establish connection with the interface. The most convenient solution is to own a separate router or to

restore the factory settings of the one in use (if possible). If there is more than one Wi-Fi networks in the place

where the configuration is being made, one can avoid communication interference by reducing the power the

interface RS485-WiFi emits. To do so, unscrew the antenna of the interface and place it near the router with which

it is going to be connected.

In this manual, the configuration of the Wi-Fi interfaces has been based on a wireless 'LinkSys WRT54GL’

Wi-Fi router.

4.3 STEP 1 – Restoring the factory settings.

Router:

To restore the factory settings of the router, check the device’s manual and perform actions following the

manufacturer’s instructions. In most cases, the actions narrow down to finding the reset button at the back panel of

the enclosure and holding it for approx. 5s. After releasing the button, wait approx. 1 min for the correct initiation of

the router. The initiation restores the factory settings to:

Address: 192.168.1.1

Username: admin

Password: admin

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RS485-WiFi interface:

To restore the factory settings of the interface, press and hold the INIT button and then press and release

the RESET button one time. Still holding the INIT button, wait approx. 20s during which the interface will be

twinkling: 3 times with the yellow LED [7 – fig. 1] and then 5 more times. Correctly performed initiation restores the

interface’s settings, among others, to:

Address: assigned automatically by the router

Username: root

Password: dbps

After restoring the factory settings of the router and the interface, the yellow LED of the interface [7 – fig.1]

should illuminate constantly indicating the correct logging process into an available Wi-Fi network. If the LED is still

twinkling, it may be necessary to disconnect the module from the power supply and then switch it back on. If these

actions prove insufficient, begin the procedure of restoring the router’s and the interface’s factory settings once

again.

4.4 STEP 2 - Configuration of the IP address.

To ensure a proper progress of the IP address changing procedure, it is recommended to turn off the

firewall of the anti-virus program for the time of configuration process.

If the yellow LED [7 - fig.1] is constantly illuminated, make certain whether the interface has logged into our

router, not other’s. Then, use the ‘Digi Device Discovery’ program as help. First, run the program (Digi

Device Discovery). After launching, the program will display the logged-in RS485-WiFi interface. Identification of

our module can be done by comparing the MAC addresses.

Fig. 4. The window of the ‘Digi Device Discovery’ program

showing a logged-in interface.

The MAC address of the interface is underneath the barcode of the DIGI module.

Fig. 5. The MAC address located on the DIGI module.

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In order to facilitate the further use of the devices online, change the IP address assignment from

automatic into manual. To make such adjustments, click the right button of the mouse on the line with selected

interface and choose: ‘Configure network settings’.

Fig. 6. The window of network settings.

Select the option: ‘Manually configure network settings’ in the window of network settings. From now on,

the automatically assigned IP address will maintain the same on each connection. The automatically assigned IP

connection may be left unchanged or be altered. If altered, be sure that the new address is not already taken and

will not cause conflicts.

Before setting the network address, make certain that none of the devices working in the network is

using it and no address conflict is caused due to that fact.

Click the ‘Save’ button to approve the changes. The ‘Digi Device Discovery’ application will display a

message about a required interface restart which shall be approved by clicking the ‘OK’ button. Next, the window of

device’s resetting progress will appear.

4.5 STEP 3 – Assigning the SSID identifier for Wi-Fi network.

In this manual, the configuration of the Wi-Fi interfaces has been based on a wireless 'LinkSys

WRT54GL’ Wi-Fi router.

To make certain that the RS485-WiFi interface will be connected only to an appointed router, enter the

network identifier. To do that, log into the interface’s router configuration as follows: open the window of a web

browser, type 192.168.1.1 in the address field (router’s default address after a reset) and approve with the ‘ENTER’

button. The page will load and the following window will appear:

Fig. 7. The login window of the Wi-Fi router.

To have access to the router’s configuration, type:

Username: admin

Password: admin

Approve your entries with the ‘Login’ button. In no time, the window that enables adjustments will appear.

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Choose the ‘Wireless’ tab. Now, type the SSID network identifier which is the name of the network within

which the Wi-Fi interfaces will be transmitting data to the computer. In the ‘Wireless Network Name’ field, type any

name, e.g. ‘PowerSecurity’. Other settings shall remain unchanged.

Fig. 8. The window of changing the network identifier.

Approve the implemented changes by clicking the ‘Save Settings’ button, and then approve by clicking

‘Continue’. The router will get reset. Meanwhile one will observe a momentary power loss of the interface indicated

by the twinkling of the yellow LED. After the reset, the network connection will be restored, the interface will no

longer indicate problems and the yellow LED will be constantly illuminated.

Now, make appropriate adjustments of the Wi-Fi interface’s configuration.

Return to the ‘Digi Device Discovery’ program and double-click the line of the chosen interface. The window of the

default web browser will open. Log in correctly to obtain access to the configuration of the Wi-Fi interface.

Fig. 9. The login window of the Wi-Fi interface.

Type:

Username: root

Password: dbps

Approve your entries with the ‘Login’ button. In no time, the window that enables adjustments will be loaded.

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Fig. 10. The panel of the interface’s configuration.

On the left from the window, there is a menu. Choose the ‘Network’ option from the ‘Configuration’ group.

Another window will be loaded. Choose ‘WiFi LAN settings’ at the bottom. The following window will appear:

Fig. 11. The “Wi-Fi LAN Settings’ window.

Now, type the SSID network identifier, the same one that has been typed in the router’s configuration.

Type: ‘PowerSecurity’ in the ‘Network name’ field. The remaining settings should be made according to the picture

above and approved by clicking 'Apply’.

The ‘Apply’ button cannot be omitted!

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From the same window, choose the ‘WiFi Security Settings’ tab at the bottom. Settings from this tab are

responsible for protection against attempts of unauthorized connection by other users.

In the tabs: ‘Network Authentication’ and ‘Data Encryption’ choose these methods of authentication and

data encryption that are supported by the router in use. Our router operates on the ‘WPA-PSK’ key and the “TKIP’

encryption therefore this is what we select. ‘Open system’ is also worth selecting in both cases.

Fig. 12. Window of the ‘WiFi Security Settings’.

Next, in the ’WPA PSK’ section, in the field: ‘Passphrase’ and ‘Confirm’ enter any password that will later

serve as the connection key.

Type password, e.g.:

Passphrase: blackpower

Confirm: blackpower

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Such implemented changes shall be approved by clicking the ‘Apply’ button. After that, the message

informing about approved changes will appear. Now the interface has been reprogrammed. However, to make it

operate accordingly to the adjustments, it needs to be reset, but only after adjusting the router.

To do that, change the panel in the browser into the router’s configuration (the router may demand logging

into the page again) and choose the ‘Wireless’ menu and the proper ‘Wireless Security’ tab. The adjustments

should be made according to the picture below and they must be identical to the ones of the interface.

Fig. 13. The window of the ‘Wireless Security’ router.

Approve the changes by clicking the ‘Save Settings’ button and then by clicking ‘Continue’.

Only now can the Wi-Fi interface be reset. It can be done by pressing the ‘Reset’ button on the module or

by cutting off the power for a few seconds. After the reset, the connection between the interface and the router

should be re-established (the yellow LED is constantly illuminated).

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4.6 STEP 4 – Selecting the communication mode.

Communication with the RS485-WiFi interface is possible in various modes. The selection is made by

choosing the appropriate profile in the web browser of the interface and configuring appropriate parameters. The

profile selection must be made on the basis of LAN connection between interfaces and power supply units taking

part in the communication.

4.6.1 Communication in WLAN/WAN network.

- Communication in WLAN network:

Shown below is a block diagram of communication in WLAN.

Fig.14. A block diagram of WLAN communication system.

The topology of the network is based on wireless Wi-Fi router connected to another PSU segments

(connected in the RS485 bus) via the RS485-WiFi interface. Each interface has a static IP address.

Communication between a PC and the final PSU is by giving the IP address of the interface, the address of the

PSU in the RS485 network and the number of the port responsible for the communication.

If the foregoing topology has been chosen, proceed to chapter 'TCP Sockets profile settings' to make the

configuration of the interfaces.

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- Communication in WAN network:

Fig.15. A block diagram of WAN communication system.

Communication between a PC and the final PSU is by the Internet with the public IP address of the router

connected to the interface. Data from the router are redirected to the RS485-WiFi interface, connected to the

RS485 bus, and then forwarded to the PSU on the basis of the bus address. In this manner, one can establish

communication with power supply units located in different power systems.

If we select communication via WAN, an additional configuration of the router is required. Set the ‘Port

forwarding’ function by following the device’s manual and acting accordingly to the producer’s guidelines.

To configure the function of redirecting the connection, give the IP address of the RS485-WiFi interface and the

number of the port responsible for the communication.

After correct configuration of the router, configure the interfaces by proceeding to 'TCP Sockets profile settings'

chapter.

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TCP Sockets profile settings.

After logging in the interface configuration page, select the ‘Serial Ports’ option from the ‘Configuration’

group. Then, select ‘TCP Sockets’ from the ‘Select Port Profile’ window and approve your choice by clicking

‘Apply’.

Caution! If the interface was configured before, the ‘Serial Port Configuration’ window with current profile will

appear instead of ‘Select Port Profile…’. In such case, click ‘Port 1’ and then ‘Change profile…’ at the top of the

next window. Only now, will the ‘Select Port Profile…’ window appear and the ‘TCP Sockets’ profile can be chosen.

Make setting adjustments in the ‘TCP Server Settings’ subsection as shown below:

Fig. 16. Settings of the ‘TCP Sockets’ profile.

Approve the settings by clicking “Apply’.

If the port 2101 is already taken, choose another one, e.g. 2102. The selected port number is to be used

consistently from now on.

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Setting the parameters of the serial port.

Select the ‘Basic Serial Settings’ tab at the bottom of the page and adjust the settings as shown in the

window below:

Fig. 17. Setting the parameters of the serial port communication.

Approve the settings by clicking ‘Apply’. Next, select the ‘Advanced Serial Settings’ tab at the bottom and make

adjustments in the ‘TCP Setting’ section accordingly to the picture below. Approve the changes with the ‘Apply’

button.

Fig. 18. Configuration of communication parameters of the serial port. – the ‘TCP Settings’ tab.

Reset the RS485-WiFi interface by pressing the ‘RST’ button on the module or by cutting off the power for

a few seconds. After the reset, the connection between the interface and the router should be re-established after

approx. 30s.

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Settings in the PowerSecurity program.

For further configuration, the PowerSecurity program is required. Download it from the following page:

http://www.pulsar.pl/pl/pliki/PowerSecurity.exe

The program is saved as an executable file therefore does not require installation in the system. From the

menu bar choose: Power supplies > New Power Supply. There will appear the window of Connection Setting which

all settings are to be adjusted.

Three parameters are particularly important:

- the TCP address that indicates the interface located in a given segment of the network topology

Caution! If the connection is via WAN, use the public IP address of the router.

- the address in the ‘Power Supply’ window indicating directly the PSU in the RS485 bus, connected to the

segment addressed by the TCP

- the TCP port, the number of port responsible for data transmission

Take notice to the preview refreshing period. It is to be prolonged according to the number of power supply

units in the system not to cause communication interference. Prolong the reply period for the same reason.

Fig. 19. The window of connection configuration – an example of settings.

PSU Description

Name

The name that is to be assigned individually to each PSU.

Address

The address of the PSU in the RS485 bus.

Caution! Addresses within same bus cannot be repeated.

Refreshing Period

of View [ms]

100 ÷ 60 000ms;

Parameters refreshing time in the preview window.

CONNECTION

Type

Modbus RTU – TCP/IP

TCP Address

The address of the RS485-WiFi interface in WLAN.

Caution. If the connection is via WAN, use the public IP address of the router.

TCP Port

2101

The number of the TCP port.

Response Timeout

[ms]

100 ÷ 60 000ms;

Time of reply from the PSU.

Delay Between

Polls [ms]

Minimum break between subsequent transmissions.

Number of

retransmission

Number of retransmissions after which the program will report a connection failure.

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After loading the connection configuration the window with a ‘Preview’ tab will open. In the top left-hand

corner there is an icon which is to be clicked to make a connection with the PSU. As the connection has been

made, the window will display current parameters of the PSU. They will be automatically updated according to the

previously set refreshing cycle.

Fig. 20. The PSU preview window.

To set the connection between the RS485-WiFi interface and any PSU connected to the RS485,

check whether the communication parameters of the power supply unit’s serial port are correct. The

transmission parameters of the power supplies are preset to 19200 bauds 8E1. If the values were

altered before, make the settings again accordingly to the information from the chapter: ‘Setting the

communication parameters of the PSU’.

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4.6.2 Communication in the WLAN serial bridge mode.

Shown below is a block diagram of communication in the ‘Serial Bridge’ serial bridge mode in WLAN.

Fig.21. A block diagram of communication system in the serial bridge mode.

The topology of the network is based on a wireless router which serves as a bridge between two segments

of the RS485 bus. Each bus is connected to the RS485-WiFi interface, where one is the Client, and other the

Server. Each interface has a static IP address. Communication between a PC and the final PSU is by entering the

PSU address in the RS485 bus.

Settings of the ‘Serial Bridge’ profile – Client/Server.

To configure the interface, connect the switch/router to the computer, as shown in fig. 3.

After logging in the interface configuration page, select the ‘Serial Ports’ option from the ‘Configuration’

group. Then, select ‘Serial Bridge’ profile from the ‘Select Port Profile…’ window and approve your choice by

clicking ‘Apply’. Configuration of the ‘Client’ interface differs from the ‘Server’ one therefore it is to be performed

separately.

Caution! If the interface was configured before, the ‘Serial Port Configuration’ window with current profile will

appear instead of ‘Select Port Profile…’. In such case, click ‘Port 1’ in the displayed window and then ‘Change

profile…’ at the top of the next window. Only now, will the ‘Select Port Profile…’ window appear and the ‘Serial

Bridge’ profile can be chosen.

Configuration of the ‘Client’ interface. Configuration of the ‘Server’ interface.

Fig. 22. ‘Serial Bridge’ profile settings for the interfaces ‘Client’ and ‘Server’.

In the ‘IP Address’ Fidel of the ‘Client’ interface configuration, type the real IP address of the ‘Server’ interface

Approve your settings with the ‘Apply’ button.

If the port 2101 is already taken, choose another one, e.g. 2102. The selected port number is to be used

consistently from now on.

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Setting the parameters of the serial port.

The settings describes in this subsection are to be applied to both RS485-WiFi interfaces. Select the ‘Basic

Serial Settings’ tab at the bottom of the window and adjust the settings as shown in the window below:

Fig. 23. Setting the parameters of the serial port communication.

Approve the settings with the ‘Apply’ button.

Next, select the ‘Advanced Serial Settings’ tab at the bottom of the window and adjust the settings in the ‘TCP

Settings’ section accordingly to the picture below. Approve the changes with the ‘Apply’ button.

Fig. 24. Configuration of communication parameters of the serial port – ‘TCP Settings’ tab.

Reset the RS485-WiFi interface by pressing the

‘RST’ button on the module or by cutting off the power for

a few seconds. After the reset, the connection between the interface and the router should be re-established within

approx. 30s.

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Pulsar INTRW - v1.0 Operating instructions

Brand: Pulsar

Model: INTRW - v1.0

Category: Networking

Type: Operating instructions

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Pulsar INTRW - v1.0 Operating instructions

Pulsar INTRW - v1.0 Operating instructions

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