westermo Merlin 4700 Series Industrial VDSL Cellular Router User Guide

westermo Merlin 4700 Series Industrial VDSL Cellular Router

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 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.

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.

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:

Level of warning| Description| Consequence personal injury| Consequence material damage
---|---|---|---

WARNING

| Indicates a potentially hazardous situation| Possible death or major injury| Major damage to the product

CAUTION

| Indicates a potentially hazardous situation| Minor or moderate injury| Moderate damage to the product

NOTICE

| Provides information in order to avoid misuse of the product, confusion or misunderstanding| No personal injury| Minor damage to the product

NOTE

| Used for highlighting general, but important information| No personal injury| Minor damage to the product

Table 1. Warning levels

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.

HAZARDOUS VOLTAGE
Do not open an energised 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 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.

Figure 1. WEEE symbol for treatment of product disposal

Compliance Information

• EN/IEC 61000-6-3, Emission light industrial environments

Safety|

• EN 62368-1, Safety Communication Technology

Table 2. Agency approvals and standards compliance

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

Product Description

Product Description

The Merlin series of versatile cellular routers provide high speed data network connectivity for demanding industrial and smart grid applications. Coupled with the Zero Touch deployment software Activator, it provides cost- effective, reliable, and consistent onboarding of routers in large-scale projects.

This compact, rugged unit is suited to tight spaces. Its high MTBF and wide temperature range support maximum service life.

To achieve best-in-class cybersecurity, the Merlin series is equipped with a TPM (Trusted Platform Module) chip that keeps cryptographic keys secure. Secure Boot ensures that the unit boots using only software that is signed and trusted by manufacturer. A set of cybersecurity tools is available as standard including VPN and stateful Firewall support for data security and user authentication.

The built-in industrial protocol gateway enables several devices using different protocols to be accessed via a common protocol interface. The unit supports up to 6 digital inputs and 2 outputs for local control or monitoring. Support for more digital inputs and outputs is possible using external modules.

Available Models

See datasheet for full list of models available.

Hardware Overview

Figure 3. Location of interface ports and LEDs, illustrated by a Merlin-4708-V-T4G-S2-DI6-DO2-LV model

Connector Information Merlin

Power Input

Illustration| Position| Product marking| Direction| Description
---|---|---|---|---

DC INPU

| 1| DC+| Input| Supply voltage
2| DC-| Input| 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.

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.

Digital I/O Interface

Figure 4. Pinout of the digital I/O sockets

On the first digital I/O socket, there is a 4 x 2 pin connector comprising two inputs and two outputs. The second digital I/O socket has four inputs.

The relay contact output has 220 VDC 2A rating.

The output is connected to a pair of relay contacts that are normally open, that is open when no power is applied.

Serial Ports

A pair of asynchronous serial ports may be present on the router. The serial ports are named as follows, also their identifiers for use within the terminal server configuration:

Figure 5. Serial ports

Each serial port is software configurable to operate in either RS-232 or RS-485 mode.

The pin numbering of the serial port connector is shown below.

Figure 6. 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.

Table 4. RS-232 connection

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.

Two-wire: Transmit/Receive

4| | | |
5| R+| | In| Four-wire: Receive
6| T+| T+/R+| Out/In| Four-wire: Transmit

Two-wire: Transmit/Receive

7| | | |
8| | | |

Table 5. RS-485 port pinout

DSL Port

The router has a single ADSL2+/VDSL2 port with a RJ11 connector.

Console Port

The router has a USB console port with a type C connector. The router acts as a device.

Antennas

The router has two SMA connectors for mobile radio LTE antennas, one for MAIN and the other for AUXiliary.

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| PWR/CONFIG LED behaviour| Router behaviour 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 6. Merlin series router reset behaviour

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

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. Boot loader 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
DSL| SYN| Blinking: DSL link is synchronising; Solid On: DSL link is synchronised
DAT| Blinking: data is passing on the DSL link
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| Data link connected and signal strength is between -89 to -69 dBm
Both LEDs on| Data link connected and signal strength >-69 dBm

Table 7. 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 bottom is the LINK LED, and the SPEED LED is on the top.

Figure 7. Merlin 4700 Ethernet ports

Table 8. Ethernet LED behaviour and descriptions

Dimensions

Dimensions are stated in millimetres and are regardless of model.

Figure 8. Dimensional drawing

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 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.

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 into 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 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
Rated current| 580 mA at 12 VDC

170 mA at 48 VDC

Rated frequency| DC
Inrush current| 2.74 x 10-3 A2s at 12 VDC
Polarity| Reverse polarity protected
Redundant power input| No
Isolation| All other ports
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, 1000 Mbits/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-232/485

Electrical specification| Configurable for EIA RS-232 or EIA RS-422/485
Data rate| RS-232: 50 bit/s – 1 Mbit/s

RS-485: 50 bit/s – 20 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

RS-485: Up to 1200 m/0.74 mi, depending on data rate and cable type

Isolation| To all other ports
Connection| RS-232: RJ-45 according to EIA-561 RS-485: RJ-45
Shielded cable| Recommended
Number of ports| 2
I/O connection, Relay output

Maximum voltage/current| 220 VDC/2A
Connect resistance| <100mΩ
Isolation| To all other ports
Connector| Detachable latch terminal
Conductor cross section| 0.14 – 1.5 mm² (AWG 28 – 16)
Stripping length cable| 7 mm
Number of ports| 2
I/O connection, Digital input

Maximum voltage/current| 24 VDC
Voltage levels| Logic one: >9.9 VDC Logic zero: <7.4 VDC
Isolation| To all other ports
Connector| Detachable latch terminal
Conductor cross section| 0.14 – 1.5 mm² (AWG 28 – 16)
Stripping length cable| 7 mm
Number of inputs| 6
Console port

Electrical specification| USB 2.0 host interface
Data rate| 115.2 kbit/s
Circuit type| SELV
Data format| 8 data bits, no parity, 1 stop bit, no flow control
Connection| USB receptacle connector type C

Type Tests and Environmental Conditions

Environmental phenomena| Basic standard| Description| Test levels
---|---|---|---
ESD| EN 61000-4-2| Enclosure| Contact: ±4 kV Air: ±8 kV
Radiated RF immunity| EN 61000-4-3| Enclosure| 10 V/m at (80 – 3000) MHz
5 V/m at (3 – 6) GHz
1 kHz sine, 80% AM
Fast transients| EN 61000-4-4| Power port| ± 1 kV, direct coupling
Ethernet ports| ± 1 kV, capacitive coupling clamp
I/O port
Serial ports
DSL port
Surge| EN 61000-4-5| Power port| L-E: ± 1 kV, 12 Ω, 9 μF, 1.2/50 μs L-E: ± 1 kV, 42 Ω, 0.5 μF, 1.2/50 μs L-L: ± 0.5 kV, 2 Ω, 18 μF, 1.2/50 μs L-L: ± 0.5 kV, 42 Ω, 0.5 μF, 1.2/50 μs
Ethernet ports| L-E: ± 1 kV, 2 Ω, direct on shield, 1.2/50 µs
I/O port| L-E: ± 1 kV, 12 Ω, 9 μF, 1.2/50 μs
RS-232| L-E: ± 1 kV, 2 Ω, 0,5 µF
RS-422/485| L-E: ± 1 kV, 42 Ω, 0,5 µF
DSL port| L-E: ± 1 kV, 42 Ω, 0,5 µF
Conducted RF immunity| EN 61000-4-6| Power port| 10 V, 80% AM, 1 kHz; (0.15-80) MHz
Ethernet
I/O port
Serial ports
DSL port
Power frequency magnetic field| EN 61000-4-8| Enclosure| 30 A/m; 50 Hz
Radiated RF emission| EN 61000-6-3| Enclosure| Class B (Light industrial), 30 MHz to 12.7 GHz
Dielectric strength| UL 62368-1| Power port to all other ports| 1 kVrms, 50 Hz, 1 min
UL 62368-1| I/O port to all other ports| 1 kVrms, 50 Hz, 1 min
RS-232 port to all other ports
RS-422/485 port to all other ports
DSL port to all other ports
UL 62368-1IEEE 802.3| Ethernet TX to all other ports| 1 kVrms, 50 Hz, 1 min

Table 9. EMC and electrical conditions

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

EN 60068-2-2

| Operational| -20 to +65°C a.
Humidity| EN 60068-2-30| Operational| 5-95 % relative humidity
MTBF| Telcordia| Ground benign, 25°C| 1,500,000 hours
Enclosure| EN 62368-1| Aluminium| Fire enclosure
Weight| | | 760 g
Cooling| | | Convection

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

Table 10. Environmental and mechanical conditions

Revision Notes

CUSTOMER SUPPORT

Westermo • Metalwerks Gatan 6, SE-721 30 Vasteras, Sweden
Tel +46 16 42 80 00 Fax +46 16 42 80 01
E-mail: info@westermo.com
www.westermo.com

References

• Westermo ᐅ Robust and Secure Industrial Networking Solutions
• Product support, user guides and software downloads ᐅ Westermo

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