westermo Merlin 4400 Series Cellular Router User Manual
- June 1, 2024
- westermo
Table of Contents
westermo Merlin 4400 Series Cellular Router
Specifications
- Interface Specifications: 17
- Type Tests and Environmental Conditions: 18
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 |
---|---|---|
WARNING | Indicates a potentially hazardous situation | Minor or moderate |
injury, Moderate damage to the product
CAUTION| Provides information to avoid misuse, confusion, or
misunderstanding| No personal injury, Minor damage to the product
NOTICE| Used for highlighting general, important information| No personal
injury, Minor damage to the product
NOTE| |
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:
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.
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
The power supply wiring must be sufficiently fused.
It must be possible to disconnect manually from the power supply. Ensure
compliance to national installation regulations.
This product has no internal fuse and should be connected via an external fuse
for protection.
POWER SUPPLY CONNECTION
There are safety regulations governing the power source that can be used in
conjunction with the product. Refer to chapter Interface Specifications.
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
Agency Approvals and Standards Compliance
Type | Approval/Compliance |
---|---|
EMC |
- EN/IEC 61000-6-2, Immunity industrial environments
- EN/IEC 61000-6-4, Emission industrial environments
- EN 50121-4, Railway signalling and telecommunications apparatus (pending)
- IEC 61850-3, Communication networks and systems for power utility automation – Part 3: General requirements
Safety|
- EN 62368-1, Safety Communication Technology
- UL 62368 (pending)
North American standards/approvals|
- UL 62368-1, FCC, PTCRB, AT&T, Verizon, T-Mobile (all pending)
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 4400 series of versatile cellular routers is designed from the
ground up to achieve best-in-class Cybersecurity both in hardware and
software. A tamper-resistant chip keeps cryptographic keys secure. Secure Boot
guarantees that the unit boots using only software that is signed and trusted
by Westermo. A set of cybersecurity tools is available as standard. High
security VPNs, stateful inspection firewall, user authentication and 802.1x
are just a few of the features available to keep the device secure both
locally and when transmitting data over the internet or private network.
Legacy serial (RS-232/485) ports allow the Merlin 4400 to be used in
applications where it is necessary to migrate from modems to an IP
infrastructure. The built-in industrial protocol gateway enables several
devices using different protocols to be accessed via a common protocol
interface.
The Merlin 4400, like all the members of the Merlin family, is compatible with
the Activator zero-touch deployment software. The Activator software ensures
that configurations are generated and deployed from a central server, reducing
configuration mistakes and increasing efficiency during the installation phase
of a project.
This compact unit is suited to tight spaces. Its high MTBF, wide temperature
range and voltage supply ensure the Merlin can deal with the demands of
industrial, smart grid and trackside applications.
Available Models
See datasheet for full list of models available.
Hardware Overview
Figure 3. Location of interface ports and LEDs, illustrated by a Merlin-4407-T4-S2-LV model
No. | Description | No. | Description |
---|---|---|---|
1 | WAN primary SMA connector | 2 | WAN auxiliary SMA connector |
3 | Reset button | 4 | Ethernet RJ45 ports |
5 | Power connection | 6 | Serial ports |
7 | USB-C Console port | 8 | Power and configuration LEDs |
9 | SIM LEDs | 10 | WAN signal strength |
11 | GPS SMA connector |
Connector Information Merlin
Power Input
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.
Serial Ports
A pair of asynchronous serial ports may be present on the router.
Figure 4. Serial ports
Serial port 1 operates in RS-232 mode. Serial port 2 is configurable to
operate in either RS-232 or RS-485 mode. The pin numbering of the serial port
connector, when viewed from the front of the unit, is shown below.
Figure 5. Pin numbering of serial port
RS-232 ports
When you configure a serial port to operate as an RS-232 interface, it
supports the following signals:
- Transmit Data
- Receive Data
- CTS
- RTS
- DSR
- DTR
The pin numbering of the RJ45 socket, when viewed from the front of the unit, is as shown below. The RS-232 interface is wired as a DCE.
Illustration | Pin no. | Signal | Direction | Description |
---|---|---|---|---|
1 | DSR | Out | Data Set Ready | |
2 | DCD | Out | Data Carrier Detect | |
3 | DTR | In | Data Terminal Ready | |
4 | SG | – | Signal Ground, not chassis ground | |
5 | RD | Out | Receive Data | |
6 | TD | In | Transmit Data | |
7 | CTS | Out | Clear To Send | |
8 | RTS | In | Request To Send |
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.
Illustration | Pin no. | Signal | Direction | Description |
---|---|---|---|---|
Four-wire mode | Two-wire mode | |||
1 | ||||
2 | R- | – | In | Four wire: Receive |
3 | T- | T-/R- | Out/In | Four-wire: Transmit |
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
Console Port
The router has a USB console port with a type C connector. The router acts as
a device.
Antennas
The router has three SMA connectors. They are:
- Two LTE antennas for the mobile radio – a MAIN and an AUXiliary
- Single antenna for GNSS/GPS
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
LED | Status | Description |
---|---|---|
Booting up | The router takes less than a minute to boot up. During |
this time, the power LED flashes.
Other LEDs display different diagnostic patterns during boot up. Booting is complete when the power LED stops flashing and stays on steady.
Power| 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
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 top is the
LINK LED, and the SPEED LED is on the bottom.
Figure 6. Merlin Ethernet ports
LINK LED
__
(green)
| On| 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 8. Ethernet LED behaviour and descriptions
Dimensions
Dimensions are stated in millimetres 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:
- Position the router so that the spring of the DIN-clip rests on the DIN rail.
- 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 aminute 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| 325 mA at 12 VDC
103 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, 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 – 12 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
Number of ports| Up to 2
Connection| RJ-45 according to EIA-561
RJ-45 shielded cable
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: ±6 kV Air: ±8 kV
Fast transients| EN 61000-4-4| Power port| ± 4 kV, direct coupling
Ethernet ports| ± 4 kV, capacitive coupling clamp
Earth
Serial ports
Surge| EN 61000-4-5| Power port| L-E: ± 2 kV, 12 Ω, 9 μF, 1.2/50 μs L-E:
± 2 kV, 42 Ω, 0.5 μF, 1.2/50 μs L-L: ± 1 kV, 2 Ω, 18 μF, 1.2/50 μs L-L: ± 1
kV, 42 Ω, 0,5 μF, 1.2/50 μs
Ethernet ports| L-E: ± 2 kV, 2 Ω, direct on shield, 1.2/50 µs
RS-232| L-E: ± 2 kV, 2 Ω, 0,5 µF
RS-422/485| L-E: ± 2 kV, 42 Ω, 0,5 µF
Power frequency magnetic field| EN 61000-4-8| Enclosure| 100 A/m; 50
Hz
Radiated RF immunity| EN 61000-4-3| Enclosure| 20 V/m at 800 MHz to 1
GHz
10 V/m at 80 MHz to 3 GHz
5 V/m at 2.7 GHz to 6 GHz
1 kHz sine, 80% AM
Conducted RF immunity| EN 61000-4-6| Power port| 10 V, 80% AM, 1 kHz;
0.15 MHz to 80 MHz
Ethernet
Serial ports
Earth
Radiated RF emission| EN 55032, EN
61000-6-4
| Enclosure| 30 MHz to 12 GHz
Conducted RF emission| EN 55032, EN
61000-6-4
| Power port| 150 kHz to 30 MHz
Ethernet| 150 kHz to 30 MHz
Dielectric strength| UL 62368-1| Power port to all other ports| 1.0
kVDC, 1 min
UL 62368-1 IEEE
802.3
| Ethernet TX to all other ports| 1.5 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| -40 to +70°C (-40 to +158°F)a.
Humidity| EN 60068-2-30| Operational| 5-95 % relative humidity
MTBF| Telcordia| Ground benign, 25°C| 1,600,000 hours
Enclosure| EN 62368-1| Aluminium| Fire enclosure
Weight| | | 0.5 kg
Cooling| | | Convection
a.Refer to “Safety Information” chapter regarding touch temperature
Table 10. Environmental and mechanical conditions
Revision Notes
Revision | Date | Change description |
---|---|---|
Rev. B | 2022-03-29 | First version |
Rev. C | 2022-05-26 |
- Revised product codes in the section ‘Available Models’.
- **** Corrected descriptions of points 9 and 10 in section ‘Hardware Overview’.
Rev. D| 2022-11-18| Revised artwork and metrics
Rev. E| 2023-01-25| Extended the set of available models
Rev. F| 2023-05-08| Revised set of available models
Rev. G| 2024-01-10| Refer to datasheet for list of models available
Westermo • Metallverksgatan 6, SE-721 30 Västeràs, Sweden Tel +46 16 42 80 00 Fax +46 16 42 80 01 E-mail: info@westermo.com www.westermo.com