RuggedCom RuggedRouter RX1000 Installation guide

RuggedRouter

®

RX1000 Family

Industrially Hardened

Cyber Security Appliance

Installation Guide

August 2, 2011

www.ruggedcom.com

Copyright

Dissemination or reproduction of this document, or evaluation and communication of its contents, is not

particularly for the purposes of patent application or trademark registration.

This document contains proprietary information, which is protected by copyright. All rights are reserved.

No part of this document may be photocopied, reproduced or translated to another language without

the prior written consent of RuggedCom Inc.

Disclaimer of liability

We have checked the contents of this manual against the hardware and software described. However,

deviations from the description cannot be completely ruled out.

RuggedCom shall not be liable for any errors or omissions contained herein or for consequential

damages in connection with the furnishing, performance, or use of this material.

The information given in this document is reviewed regularly and any necessary corrections will be

included in subsequent editions. We appreciate any suggested improvements. We reserve the right to

make technical improvements without notice.

Registered Trademarks

RuggedRated™, ROS™ and eRSTP™ are trademarks of RuggedCom Inc. RuggedRouter

®

and

RuggedSwitch

®

are registered trademarks of RuggedCom Inc. Other designations in this manual might

be trademarks whose use by third parties for their own purposes would infringe the rights of the owner.

Contacting RuggedCom

Corporate Headquarters

US Headquarters

Europe Headquarters

RuggedCom Inc.

300 Applewood Crescent

Concord, Ontario

Canada, L4K 5C7

Tel: +1 905 856 5288

Fax: +1 905 856 1995

Toll-free: 1 888 264 0006

RuggedCom

1930 Harrison St., Suite 209

Hollywood, Florida

USA, 33020

Tel: +1 954 922 7938 ext. 103

Fax: +1 954 922 7984

Toll-free: 1 888 264 0006

RuggedCom

Unit 41, Aztec Centre,

Aztec West, Almondsbury, Bristol

United Kingdom BS32 4TD

Tel: +44 1454 203 404

Fax: +44 1454 203 403

Email: [email protected]

Technical Support

Toll Free (North America): 1 866 922 7975

International: +1 905 856 5288

Email: [email protected]

Web: www.RuggedCom.com

Federal Communications Commission Radio

Frequency Interference Statement

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC

Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is

operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not

installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required

to correct the interference at his expense.

Caution

This product contains a laser system and is classified as a “CLASS 1 LASER PRODUCT”.

Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous

radiation exposure. This product contains no user-serviceable parts. Attempted service by unauthorized personnel shall

render all warranties null and void.

Should this device require service, see the “Warranty” section of this installation guide.

Important Notice for Cellular Options

If this equipment is ordered with one of the cellular radio options, it must be installed and operated with the following

guidelines to ensure safe operation and maintain compliance.

Cellular Safety And Hazards

Do not operate the cellular modem in:

 Areas where blasting is in progress.

 Explosive atmospheres like refueling points, fuel depots and chemical plants.

 Near equipment that is susceptible to any form of radio interference like medical and life support equipment.

 Maintain at least 20 cm separation distance between the antenna and user’s body at all times.

 Ensure that the maximum gain stated for the cellular option selected is not exceeded to keep RF radiation within

limits of FCC/IC regulations.

Table of Contents

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Table of Contents

Federal Communications Commission Radio Frequency Interference Statement ........... 3

Table of Contents .............................................................................................................. 4

Table of Figures ................................................................................................................ 5

Table of Tables ................................................................................................................. 6

1 Product Overview ....................................................................................................... 7

1.1 Functional Overview ........................................................................................... 7

1.2 Feature Highlights ............................................................................................... 7

2 Panel Description ....................................................................................................... 9

2.1 Display Panel Description ................................................................................... 9

2.2 Ethernet Panel Description ............................................................................... 11

3 Installation ................................................................................................................ 12

3.1 Mounting ........................................................................................................... 12

3.2 Power Supply Wiring and Grounding ................................................................ 15

3.3 Failsafe Alarm Relay Wiring ............................................................................. 23

3.4 Console Port Wiring .......................................................................................... 24

4 Communication Ports ............................................................................................... 25

4.1 RJ45 Twisted-Pair Data Ports .......................................................................... 25

4.2 Fiber Optic Ethernet Ports ................................................................................ 26

4.3 WAN Ports ........................................................................................................ 28

4.4 DSL ................................................................................................................... 29

4.5 DDS .................................................................................................................. 30

4.6 Modem Port ...................................................................................................... 31

4.7 Serial Card ........................................................................................................ 32

4.8 RS485 Wiring .................................................................................................... 33

4.9 Transient Protection on Communication Ports ................................................. 34

4.10 Precision Time Protocol (PTP) Card ................................................................. 34

4.11 RS232 EXT Modem Card ................................................................................. 39

4.12 Cellular Modems ............................................................................................... 40

5 Technical Specifications .......................................................................................... 43

5.1 Power Supply Specifications ............................................................................ 43

5.2 Failsafe Relay Specifications ............................................................................ 43

5.3 Twisted-Pair Port Specifications ....................................................................... 44

5.4 Fiber Optic Specifications ................................................................................. 44

5.5 IEC 61850-3 Type Tests ................................................................................... 45

5.6 IEEE 1613 Type Tests ...................................................................................... 46

5.7 Environmental Type Tests ................................................................................ 47

5.8 Operating Environment ..................................................................................... 47

5.9 Agency Approvals ............................................................................................. 47

5.10 Cellular Modem Certifications ........................................................................... 48

5.11 Mechanical Specifications ................................................................................ 49

6 Warranty .................................................................................................................. 50

Table of Figures

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Table of Figures

Figure 1: LED Display Panel ............................................................................................. 9

Figure 2: Ethernet panel LED description ....................................................................... 11

Figure 3: RX1000 Rack mount orientation options ......................................................... 12

Figure 4: 19” Rack Mount Adapters ................................................................................ 13

Figure 5: Rack mount adapter mounting location ........................................................... 13

Figure 6: RX1000 Panel/DIN Rail mounting diagram ...................................................... 14

Figure 7: RX1000 Series Phillips Screw Terminal Block ................................................. 15

Figure 8: RX1000 Series Phoenix Plug Terminal Block .................................................. 15

Figure 9: Chassis Ground Connection ............................................................................ 16

Figure 10: AC Single Power Supply Wiring Example ...................................................... 18

Figure 11: AC Dual Redundant Power Supply Wiring Example ...................................... 18

Figure 12: DC Power Supply Wiring Examples ............................................................... 19

Figure 13: DC and AC Power Supply Wiring Example ................................................... 20

Figure 14: AC Input to PS1 and 48VDC Input to PS2 for PoE ........................................ 21

Figure 15: Dielectric Strength (HIPOT) Testing .............................................................. 22

Figure 16: Failsafe Alarm Relay Wiring ........................................................................... 23

Figure 17: Console port location on display board .......................................................... 24

Figure 18: RX1000 Console cable .................................................................................. 24

Figure 19: RJ45 jack pin configuration ............................................................................ 25

Figure 20: 10FL ST connector ........................................................................................ 27

Figure 21: 100FX MTRJ connector ................................................................................. 27

Figure 22: 100FX / 1000LX LC connector ....................................................................... 27

Figure 23: 100FX / 1000LX SC connector ...................................................................... 27

Figure 24: 100FX / 1000LX ST connector ....................................................................... 27

Figure 25: RJ45 jack pin configuration ............................................................................ 28

Figure 26: WAN (T1/E1) Card location ........................................................................... 28

Figure 27: RJ11 jack pin configuration ............................................................................ 29

Figure 28: RJ45 jack pin configuration ............................................................................ 30

Figure 29: RJ11 jack pin configuration ............................................................................ 31

Figure 30: V.90 Modem Card location ............................................................................ 31

Figure 31: RS232/RS485/RS422 via RJ45 pinout .......................................................... 32

Figure 32: Conceptual RS485 wiring diagram ................................................................ 33

Figure 33: PTP Card Panel Description .......................................................................... 35

Figure 34: IRIG-B Simplified Schematic .......................................................................... 38

Figure 35: DB9 (female) pin configuration ...................................................................... 39

Figure 36: EVDO Modem Faceplate ............................................................................... 40

Figure 37: HSPA Modem Faceplate ............................................................................... 41

Figure 38: SIM Card Access for GSM/EDGE Internal Modem ........................................ 42

Figure 39: RX1000 Series mechanical dimensions ........................................................ 49

Table of Tables

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Table of Tables

Table 1: LED Display – Device status LED behavior definition ....................................... 10

Table 2: LED Display – Port Status behavior definition .................................................. 10

Table 3: RX1000/RX1100 Power terminal block connection description ........................ 16

Table 4: RX1000P/RX1100P power supply connection differences ............................... 17

Table 5: RS232 over RJ45 console cable pinout ............................................................ 24

Table 6: RJ45 Ethernet pin assignment .......................................................................... 25

Table 7: RJ45 T1/E1 pin assignment .............................................................................. 28

Table 8: ADSL RJ11 pin configuration ............................................................................ 29

Table 9: RJ45 DDS pin assignment ................................................................................ 30

Table 10: Modem RJ11 pin configuration ....................................................................... 31

Table 11: RS232/RS485/RS422 via RJ45 pinout ........................................................... 32

Table 12: GPS Antenna Specifications ........................................................................... 36

Table 13: Coaxial Cable Delay ........................................................................................ 37

Table 14: IRIG-B Output Specifications .......................................................................... 38

Table 15: RS232 EXT Modem Card pinout ..................................................................... 39

Table 16: Verizon Contact Numbers ............................................................................... 40

Table 17: EVDO Antenna Requirements ........................................................................ 40

Table 18: HSPA Antenna Requirements ......................................................................... 42

Table 19: GSM/EDGE Antenna Requirements ............................................................... 42

Table 20: Main Power Supply Specifications .................................................................. 43

Table 21: PoE Power Supply Specifications ................................................................... 43

Table 22: Failsafe Relay Specifications .......................................................................... 43

Table 23: Twisted-Pair Port Specifications ..................................................................... 44

Table 24: Fiber Optic Specifications ............................................................................... 44

Table 25: IEC 61850-3 Type Tests ................................................................................. 45

Table 26: IEEE 1613 Type Tests .................................................................................... 46

Table 27: Environmental Type Tests .............................................................................. 47

Table 28: Operating Environment ................................................................................... 47

Table 29: Agency Approvals ........................................................................................... 47

Table 30: Cellular Modem Certifications ......................................................................... 48

Table 31: RX1000 Series Mechanical Specifications ...................................................... 49

Product Overview

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1 Product Overview

1.1 Functional Overview

The RuggedRouter

®

family of products consists of industrially hardened cyber

security appliances with integrated router, firewall, and VPN functionality. The family

includes the RX1000, RX1000P, RX1100, and RX1100P. The RX1000 series can be

used to establish an electronic security perimeter around critical cyber assets found

in control and automation systems, in order to prevent the disruption of operations by

accidental or malicious acts. Ideally suited for electric power utilities, the industrial

plant floor, and traffic control systems, the RX1000 series is designed to protect and

secure SCADA system networks connected to the Internet, or within a company‟s

Wide Area Network (WAN) or Local Area Network (LAN). The RX1100 adds

Intrusion Detection and RuggedCom Gauntlet

®

for NERC CIP compliance.

The RX1000 series includes security functions such as full IPSec Virtual Private

Network (VPN), and firewall capabilities with the capacity to connect hundreds of

remote sites over Frame Relay and PPP. The modular architecture allows the

customization of the number and type of Ethernet and WAN ports. Integrated

modem, serial interface, and time synchronization options are also available.

The RX1000 series is hardened to the RuggedRated

TM

specification which provides

a high level of immunity to electromagnetic interference (EMI) and heavy electrical

surges typical of the harsh environments found in many industrial applications. An

operating temperature range of -40 to +85°C (-40 to 185° F) allows the RX1000 to be

placed in almost any location.

For applications requiring high availability, the RX1000 and RX1100 provide the

option for integrated dual redundant power supplies, each capable of

accommodating a wide range of input voltages for worldwide operability. Also unique

is the ability to have each power supply fed from different voltage levels and/or

sources thereby providing great flexibility in creating high availability systems. The

RX1000P and RX1100P provide IEEE 802.3af standard Power over Ethernet (PoE)

on their 10/100BaseTx ports.

1.2 Feature Highlights

Security Appliance Functions

 Integrated Router/Firewall/VPN

 Stateful Firewall with NAT

 Full IPSec Virtual Private Networking

 VPN with 3DES, DES and AES support

RuggedRated™ for Reliability in Harsh Environments

 Meets IEEE 1613 (electric utility substations)

 Exceeds IEC 61850-3 (electric utility substations)

 Exceeds IEEE 61800-3 (variable speed drive systems)

 Exceeds IEC 61000-6-2 (generic industrial environment)

 Exceeds NEMA TS-2 (traffic control equipment)

Product Overview

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RX1000 Family

 -40 to +85°C operating temperature (no fans)

 Conformal coated printed circuit boards (optional)

 18 AWG galvanized steel enclosure

Power Supply Options

 Fully integrated, dual-redundant (optional) power supplies (RX1000/RX1100)

 Power over Ethernet (PoE) on 10/100BaseTx ports (RX1000P/RX1100P)

 Universal high-voltage range: 88-300VDC or 85-264VAC

 Popular low voltage DC ranges: 12, 24 or 48 VDC

 Terminal blocks for reliable, maintenance free connections

 CSA/UL 60950 safety approved to +85°C

Physical Ports

 Ethernet Options (up to 4 ports):

o 10/100BaseTX (with PoE on RX1000P and RX1100P)

o 100BaseFX

 WAN Port Options (up to 8 ports):

o T1/E1 (channelized/unchannelized) supports 2 Mbps G.703 with 120 ohm

balanced connections

o T3/E3 DS3

o 56 Kbps DDS

o DSL (supports G.992.1, G.992.2, G.992 Annex A)

 Serial Ports (up to 8 ports):

o Fully compliant EIA/TIA RS485, RS422, RS232 software selectable serial

ports

o Raw socket mode support allows conversion of any serial protocol

 Embedded Modem Port

 Embedded EvDO – CDMA cellular modem

 Embedded HSPA – GSM cellular modem

 GPS / IRIG-B / IEEE 1588 Time Sync

Protocols

 WAN

o Frame Relay RFC 1490 or RFC 1294

o PPP RFC 1661, 1332, 1321, 1334

o PPPoE over DSL, PAP, CHAP Authentication

 IP

o Routing

o VRRP, OSPF, DHCP Agent

o Traffic prioritization, NTP Host (Stratum 2)

Frame Relay Support

 ISO and ITU compliant, network certified

 ANSI T1.617 Annex D, Q.933 or LMI Local Signaling

Panel Description

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2 Panel Description

2.1 Display Panel Description

RX1000 series products are equipped with a versatile display panel, shown in Figure

1, which provides quick status information for each port, as well as for the entire

device, to allow simple diagnosis and troubleshooting. It features:

 RS232 console port for „out of band‟ console access and configuration

 Power supply and Alarm status indicators

 Convenient port status indicators conveying link activity information

 System reset via push-button if held for 5 seconds

Figure 1: LED Display Panel

Console

Port

Push-Button

LAN/WAN Port

Status Indicators

PPP / GPS

Status Indicators

Device

Status Indicators

Panel Description

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Device status LEDs exist to provide a quick visual indication to operators for

operational status of the unit. Table 1 defines each possible LED color and its

corresponding description.

LED

Color

Description

PS1 / PS2

Green

Power supply operating normal

Red

Power supply failure

Off

No power supply installed

Alarm

Red

Alarm exists – log in to web management

interface to determine alarm code

Off

No alarms exist

Table 1: LED Display – Device status LED behavior definition

The AN/WAN port status indicators as well as the dedicated PPP/GPS status

indicators provide a quick visual indication of the operational status of each function.

Although the behavior of each LED display will differ according to hardware, a

standard color scheme has been adopted and is show in Table 2.

Mode

Color

Description

Port Status Indicators

Green (Solid)

Link / Activity

Red

Error

Off

No link, or port not configured

Table 2: LED Display – Port Status behavior definition

Panel Description

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2.2 Ethernet Panel Description

Slots 3 and 4 of the RX1000 series can be populated with standard RuggedCom

dual-port Ethernet modules. Each Ethernet module is equipped with two LEDs that

indicate link/activity status information. The LED will be solid for ports with link, and

will blink for activity. The diagram in Figure 2 highlights each port and its associated

link/activity LED.

Figure 2: Ethernet panel LED description

Port 1

Port 2

Port 3

Port 4

Installation

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3 Installation

3.1 Mounting

The RX1000 series has been designed with maximum mounting and display

flexibility. Customers can order an RX1000 series product that can be mounted in a

standard 19” rack, 1” DIN Rail, or directly onto a panel. For rack mount installations,

the RX1000 series can be ordered with connectors on the front of the unit, or can

located on the rear of the chassis to allow for all data and power cabling to be

installed and connected at the rear of the rack. See Figure 3 for examples of rack

mount orientation.

Figure 3: RX1000 Rack mount orientation options

19” Rack mount I/O Connector Orientation Options

Front: LED Display and I/O Panels Rear: Power Terminal Block

Front: LED Display Rear: Power Terminal Block and I/O Panels

Front

Rear

Front

Rear

Front Mount

Rear Mount

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3.1.1 Rack Mounting

Figure 4: 19” Rack Mount Adapters

Figure 5: Rack mount adapter mounting location

The RX1000 series can be rack mounted using the included rack mount adapter

assemblies shown in Figure 4. Secure the rack mount adapter to the front side of the

chassis using the included black PAN head Phillips screws in the positions shown in

Figure 5. The entire chassis can then be mounted to a standard 19” rack. An

additional two rack mount adapters are included to optionally secure the rear of the

chassis in high-vibration, or seismically active locations.

NOTE: Since heat within the RX1000 is channeled to the enclosure, it is

recommended that 1 rack-unit of space (1.75”) be kept unpopulated and free of

equipment above each RX1000 series product to allow convectional airflow.

Although forced airflow is not necessary, any increase in airflow will result in a

reduction of ambient temperature that will improve long-term reliability of all

equipment mounted within the rack space.

Installation

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RX1000 Family

3.1.2 Panel and DIN Rail Mounting

RX1000 series products can be ordered as a Panel/DIN mount chassis. Both options

involve the use of the Panel/DIN adapters to be mounted on each side of the chassis

enclosure. The adapter allows the chassis to be mounted on the standard 1” DIN rail

using the grooves in the adapter, secured using the included Phillips screw. See

Figure 6 for a Panel/DIN mount diagram.

Figure 6: RX1000 Panel/DIN Rail mounting diagram

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3.2 Power Supply Wiring and Grounding

RX1000 and RX1100 support dual redundant universal high voltage range power

supplies: “Power Supply 1 (PS1)” and “Power Supply 2 (PS2)”. RX1000P and

RX1100P feature a universal high voltage range power supply as PS1, and a

separate 48VDC supply, PS2, to provide Power over Ethernet. The connections for

PS1, PS2 and the fail-safe relay are located on the terminal block as shown in Figure

7 and Figure 8.

Philips S crew Term inal w ith out CoverPhilips S crew Term inal w ith Cover

Safety C over

Screw s

Chassis G round

Connection

Surge / Chassis

G round Jum per

Term inal

Figure 7: RX1000 Series Phillips Screw Terminal Block

Phoenix P lug Term inal w ithout C overPhoenix P lug Term inal w ith C over

Safety C over

Screw s

Safety C over

Chassis G round

Connection

Term inal

Surg e / C hassis

G round Jum per

Figure 8: RX1000 Series Phoenix Plug Terminal Block

The RX1000 Family chassis ground connection, shown in Figure 9, uses a #6-32

screw. It is recommended to terminate the ground connection in a #6 ring lug, and to

use a torque setting not exceeding 15 in.lbs (1.7 Nm).

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Figure 9: Chassis Ground Connection

The RX1000 series can be equipped with either a Phillips Screw Terminal Block or a

Phoenix Plug Terminal Block. The Phillips Screw Terminal Block has Phillips screws

with a compression plate allowing either bare wire connections or crimped terminal

lugs. We recommend the use of #6 size ring lugs to ensure secure, reliable

connections even under severe shock or vibration. Both terminal blocks have a

safety cover which must be removed via two Phillips screws before connecting any

wires. The safety cover must be re-attached after wiring to ensure personnel safety.

Refer to Table 3 and Table 4 below for a description of each terminal, and to the

following sections for wiring examples.

Terminal

Description

Usage

1

PS1 Live / +

PS1 Live / + is connected to the positive (+) terminal if the power source

is DC or to the (Live) terminal if the power source is AC.

2

PS1 Surge Ground

PS1 Surge Ground is connected to the Chassis Ground via a jumper on

the terminal block. Surge Ground is used as the ground conductor for all

surge and transient suppression circuitry.

3

PS1 Neutral / -

PS1 Neutral / - is connected to the negative (-) terminal if the power

source is DC or to the (Neutral) terminal if the power source is AC.

4

Chassis Ground

Chassis Ground is connected to the Safety Ground terminal for AC

inputs or the equipment ground bus for DC inputs. Chassis ground

connects to both power supply surge grounds via a removable jumper.

5

PS2 Live / +

PS2 Live / + is connected to the positive (+) terminal if the power source

is DC or to the (Live) terminal if the power source is AC.

6

PS2 Surge Ground

PS2 Surge Ground is connected to the Chassis Ground via a jumper on

the terminal block. Surge Ground is used as the ground conductor for all

surge and transient suppression circuitry.

7

PS2 Neutral / -

PS2 Neutral / - is connected to the negative (-) terminal if the power

source is DC or to the (Neutral) terminal if the power source is AC.

8

Relay N.O. Contact

Normally open, failsafe relay contact.

9

Relay Common

Failsafe relay common contact.

10

Relay N.C. Contact

Normally closed, failsafe relay contact.

Table 3: RX1000/RX1100 Power terminal block connection description

#6-32 screw with

ext. washer.

#6 ring lug

stainless steel standoff

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Terminal

Description

Usage

5

PS2+

PS2+ is connected to the positive (+) terminal of a 48VDC power supply

7

PS2-

PS2- is connected to the negative (-) terminal of a 48VDC power supply

Table 4: RX1000P/RX1100P power supply connection differences

Installation

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3.2.1 AC Power Supply Wiring Examples

Figure 10: AC Single Power Supply Wiring

Example

Figure 11: AC Dual Redundant Power Supply

Wiring Example

NOTES:

 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker

must be installed.

 Equipment must be installed according to the applicable country wiring

codes.

 When equipped with two high voltage power supplies, independent AC

sources can be used to power the product for greater redundancy.

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3.2.2 DC Power Supply Wiring Examples

Figure 12: DC Power Supply Wiring Examples

NOTES:

 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker

must be installed.

 A circuit breaker is not required for 12, 24 or 48 VDC rated power supplies.

 For dual DC power supplies, Separate circuit breakers must be installed and

separately identified.

 Equipment must be installed according to the applicable country wiring

codes.

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3.2.3 Dual Power Supplies – DC and AC Inputs

Figure 13: DC and AC Power Supply Wiring Example

NOTES:

 88-300VDC rated equipment: A 300VDC appropriately rated circuit breaker

must be installed.

 100-240VAC rated equipment: A 250VAC appropriately rated circuit breaker

must be installed.

 A circuit breaker is not required for 48 or 24VDC rated power supplies.

 Separate circuit breakers must be installed and separately identified.

 Equipment must be installed according to the applicable country wiring

codes.

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RuggedCom RuggedRouter RX1000 Installation guide

RuggedCom RuggedRouter RX1000 Installation guide

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