Westermo Merlin 4100 Series Industrial Cellular Router User Guide

Westermo Merlin 4100 Series Industrial Cellular Router

Product Information

Specifications

• Interface Specifications: Available on the user manual
• Type Tests and Environmental Conditions: Detailed on page 16 of the user manual

Product Usage Instructions

Safety and Regulations:

Warning signs are provided to prevent personal injuries and/or damages to the product. Different levels are used:

• WARNING: Indicates a potentially hazardous situation with possible death or major injury.
• CAUTION: Provides information to avoid misuse, confusion, or misunderstanding leading to minor or moderate injuries.
• NOTICE: Highlights general but important information to prevent minor damage to the product.
• NOTE: Indicates information that is noteworthy but does not pose a direct threat.

Safety Information

• Read the manual completely and ensure understanding of all information available.
• Verify that your application complies with the safe operating specifications of the product.

SAFETY DURING INSTALLATION

The product must be installed and operated by qualified service personnel in an apparatus cabinet or similar area with restricted access to service personnel only.

FAQ

Q: Where can I find more information on the software included in the product?

• A: Specific license terms and copyright details for the software are included in each software package.
• For more information, please visit the product webpage. Source code requests can be directed to your sales or support channel.

General Information

Legal Information

• The contents of this document are provided “as is”. Except as required by applicable law, no warranties of any kind are made concerning 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, consequential, or indirect damages howsoever caused.
• More information about Westermo can be found at www.westermo.com.

About This Guide

• This guide is intended for installation engineers and users of Westermo products.
• It includes information on safety and regulations, a product description, installation instructions, and technical specifications.

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.

Safety and Regulations

Warning Levels

Warning signs are provided to prevent personal injuries and/or damages to the product.

The following levels are used:

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 energizing 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.

HAZARDOUS VOLTAGE

• Do not open an energized product. Hazardous voltage may occur when connected to a power supply.

PROTECTIVE FUSE

• It must be possible to disconnect manually from the power supply. Ensure compliance to national installation regulations.

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.

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 the 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.

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.

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.

Compliance Information

Simplified Declaration of Conformity

• Hereby, Westermo declares that this product complies with applicable EU directives and UK legislation. The full declaration of conformity and other detailed information is available at www.westermo.com/support/product-support.

Product Description

• The Merlin 4100 router is a versatile LTE cellular router suited to a variety of industrial deployments.
• The compact and rugged design makes it ready for harsh environments that require remote access such as SCADA, CCTV, telemetry, smart grid, digital signage, and intelligent traffic systems.
• The Merlin series is designed from the ground up to achieve best-in-class Cybersecurity.
• High-security VPNs, stateful inspection firewalls, 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.
• A dual-use port is software-configurable to act either as an RS-232 serial port or as a dry contact digital input. The serial port facilitates 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.
• This compact unit is suited to tight spaces. Its high MTBF, wide temperature range, and voltage supply ensure the Merlin 4100 can deal with the demands of industrial and utility applications.

Available Models

• See the datasheet for a full list of models available

Hardware Overview

Connector Information Merlin Power Input

Illustration| Position| Product marking| Direction| Description
---|---|---|---|---
****| 1| DC+| Input| Supply voltage
2| DC-| Input| Supply voltage

Table 2. 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.

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.

Serial Port

• Merlin 4100 has a dual-use legacy port that is configurable in software to act either as an RS232 port or as a digital input.
• The serial port is named as follows, also the identifier for use within the terminal server configuration when the port is configured to operate as RS-232:

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.

Table 3. RS-232 connection

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.

port
4| Ground| –| Signal Ground, not chassis ground

Table 4. Digital input port

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 behavior.

Press duration| PWR/CONFIG LED behaviour| Router behavior on depress
---|---|---
0-3 seconds| Solid on| Normal reset to running-config. No special LED activity.
3-15 seconds| Flashing fast| Releasing 3-15 seconds switches the router back to factory configuration. Note: this will wipe the configurations, both config1 and config2.
15-20 seconds| Solid on| Releasing 15-20 seconds performs a normal reset to running-config.
20-30 seconds| Flashing slowly| 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.

30 seconds| Solid on| Releasing after 30 seconds performs a normal reset.

Table 5. Merlin series router reset behavior

LED Indicators

• The LED indicators described in this section are all single-color LEDs. When the router is powered on, the power LED is green.

The possible LED states are:

• Off
• Flashing slowly
• Flashing quickly
• On

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| On| Power is present
Off| No power. The bootloader does not exist.
Flashing| Booting
Config| On| The router is running a valid configuration file.
Flashing slowly| The router is running in recovery mode (2.5 flashes/second)
Flashing quickly| The router is running in factory configuration (5 flashes/second)
SIM| On| SIM selected and registered on the 3G/4G network
Off| Not selected or SIM not inserted
Flashing| SIM selected and not registered on the network
3G/LTE cellular signal strength LED| Both LEDs off| Data link not connected or signal strength <=-113 dBm
Left LED on

Right LED off

| Data link connected and signal strength <=-89 dBm
Left LED off

Right LED on

| The data link is connected and the signal strength is between -89 to -69 dBm
Both LEDs on| Data link connected and signal strength >-69 dBm

Table 6. LED indicators

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.

LINK LED

__ (green)

| On| The physical Ethernet link detected
---|---|---
Off| No physical Ethernet link detected
Flashing| Data is being transmitted or received over the link
SPEED LED

__ (Amber)

| On| Link operating at 100 Mbps
Off| Link operating at 10 Mbps

Table 7. Ethernet LED behavior and descriptions

Dimensions

• Dimensions are stated in millimeters and are regardless of model.

Installation

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 top hook of the DIN clip rests on top of the DIN rail.
2. Push the lower half of the router towards the DIN rail until the bottom part of the DIN clip snaps into place, indicating that the unit is clamped to the DIN rail.

• To remove the router from the DIN rail, hold the unit firmly on both sides with one hand and firmly push the unit in an upward and then outward direction, so lifting and releasing the unit clear of the DIN rail.

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 meters above the ground beneath it.

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.

Connecting Cables

• Connect one end of the Ethernet cable to port A and the other end to your PC or switch.

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.

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 the risk of damaging the driver or screw.

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.

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.

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.

Specifications

Interface Specifications

DC, Power port

Operating voltage| 9.6 to 60 VDC isolated
Rated current| 320 mA at 12 VDC

200 mA at 24 VDC

Rated frequency| DC
Inrush current| 2.74 x 10-3 A2s at 12 VDC
Polarity| Reverse polarity protected
Redundant power input| No
Connector| Push-in spring connectors
Conductor cross-section| 0.2-2.5 mm² (AWG 24-12)
Stripping length cable| 7 mm
Tightening torque, screw flange| 0.3 Nm
Shielded cable| Not required
Ethernet TX

Electrical specification| IEEE std 802.3
Data rate| 10 Mbit/s, 100 Mbit/s, manual or auto
Duplex| Full or half, manual or auto
Circuit type| TNV-1
Transmission range| Up to 150 m with CAT5e cable or better
Isolation| All other ports
Connection| RJ-45, auto MDI/MDI-X
Cabling| Shielded CAT5e or better is recommended
Number of ports| 4
RS-232

Electrical specification| EIA RS-232
Data rate| RS-232: 50 bit/s – 1 Mbit/s
Data format| 7 or 8 data bits, odd, even or none parity, 1 or 2 stop bits (2 stop bits only when no parity is set)
Circuit type| TNV-1
Transmission range| RS-232: 15 m/49 ft
Number of ports| 1
Connection| RJ-45 according to EIA-561
RJ-45 shielded cable
Digital input

Mode of operation| Dry contact only
Connection| RJ-45 shielded cable

Type Tests and Environmental Conditions

Environmental phenomena| Basic standard| Description| Test levels
---|---|---|---
Temperatures| EN 60068-2-1

EN 60068-2-2

| Operational| -20 to +70°C a.
Humidity| EN 60068-2-30| Operational| 5-95 % relative humidity
MTBF| Telcordia| Ground benign, 25°C| 1,700,000 hours
Enclosure| EN 62368-1| ABS| Fire enclosure
Weight|  |  | Approx 280 g
Cooling|  |  | Convection

a.Refer to the “Safety Information” chapter regarding touch temperature

Table 9. Environmental and mechanical conditions

Revision Notes

port
Rev. E| 2024-01-05| Refresh of content in Type Tests

• Westermo
• Metallverksgatan 6, SE-721 30 Västerás, Sweden
• Tel +46 16 42 80 00 Fax +46 16 42 80 01
• E-mail:info@westermo.com
• www.westermo.com
• Westermo Network Technologies AB, Sweden
• www.westermo.com

Documents / Resources

| Westermo Merlin 4100 Series Industrial Cellular Router [pdf] User Guide
Merlin 4100 Series Industrial Cellular Router, Merlin 4100 Series, Industrial Cellular Router, Cellular Router, Router
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