SCADA SYSTEM FOR INDUSTRIES

1. ©
2003
ABB
Power
Technologies
1
-
Network
Management
Data Acquisition
Process Communication
Unit PCU400
Network Manager

2. ©
ABB
Power
Technologies
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2
Network Manager - Data Acquisition
 Facilitates Real-time Supervisory Control of
 Power Stations
 Substations
 Key information points in a distributed power network
 Development of Process Communication
 Interfacing RTUs, SA- and IED-systems
 Use of standardized protocols;
WAN instead of leased line to the station
 Deregulation leads to need for flexibility and versatility
 IT-security
 Data Communications
 Redundant Solutions
 Enterprise Wide
 PCU400 is the solution for Network Manager

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Power
Technologies
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Functions:
 Front-End for Network Manager
 RSP protocol to Application Servers (AS)
 Down line loading of database from AS
 1–24 multi-drop lines to RTUs
 Protocol configurable per line
 Various communication media
 Distributed configuration is supported
 Redundancy
Application
Servers
RSP protocol over
Ethernet LAN or WAN
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WT
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15
PCU400
RTU or
SCS system
Available RTU protocols
Can be distributed
over WAN
PCU400 as Front-End to Network Manager

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ABB
Power
Technologies
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PCU400 Distributed Functionality
The Data Acquisition System is distributed
in two software components:
 RCS Application
 Supervision of PCU connection via TCP/IP comports
 Handling of line switchover
 Handling of redundant lines
 Interfaces the SCADA application
 Communication statistics
 Handling of telephone connections and modem pools
 Scaling of measurands
 RSP Master
 Database loading
 PCU400
 Protocol translation
 Time synchronization
 RSP slave
PCU400
RCS Application

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ABB
Power
Technologies
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PCU400 in Network Manager
PCU400 A
RTU lines
PCU400 B
Other Applications Other Applications
RSP Links
LAN or WAN
Real-time
Database
(Avanti)
Real-time
Database
(Avanti)
RCS Application RCS Application
Main Server A Main Server B

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ABB
Power
Technologies
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PCU400 Mainframe
 Industrial PC Chassis or Desktop
 PCI slot, half or full length
 Hard disc or Flash memory (embedded)
 CDRW-device
 Intel Pentium 4 compatible CPU
 Minimum 256Mb Memory
 Redundant Ethernet ports for Dual-LAN
 Ethernet port for Communication Modules
 Graphic card
 Wall or 19” Rack-mount
 PCU400 embedded version is without
moving parts

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ABB
Power
Technologies
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PCU400 Embedded
Connectors available
 Parallell port
 PS2 keyboard/mouse
 USB 2 ports
 VGA
 COM1 and COM2
 Powered by 24 V DC
 Ethernet to Host
 Optional 2 Ethernet and
4 COM ports

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ABB
Power
Technologies
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PCU400 Embedded - specification
 H6023-based (Hectronic), CPU is Geode GX1-300, 300MHz
 2 - 6 COM, 1 - 3 Ethernet
 RAM 256MB
 CompactFlash 256 MB - 1GB
 Power 7-28V DC
 Temperature range +5ºC to 45ºC
 Size is about 220mm x 110mm x 77mm
 Operating System Windows XP embedded
 Option 1) Extended temperature range -40ºC to 80ºC
 Option 2) Two additional Ethernet interfaces plus four additional COM-
ports
With option 2 included a complete 6 channel PCU400 with redundant LANs is realized. A
third Ethernet interface extends with more COM-ports using the OCC2 Communication HUB.

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ABB
Power
Technologies
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PCU400 Communication Module
 Communication Module
 8 channels per unit, max 8 units per CPU (=64 channels)
 64 kbps per channel in parallel
 Byte and Bit-sampling
 Protocol support for Indactic33, Sinaut8, ADLP80 and asynchronous
 Ethernet connection to PCU mainframe, allows distribution
 DIN-mounted
 DC powered

10. ©
ABB
Power
Technologies
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PCU400 Communication Functionality
 Asynchronous UART communication (speed 50 – 64000 bps)
 Bit synchronous communication (bit sampling 50 – 4800 bps)
 Dial-up (phone) Low level driver support of Hayes
commands used with RP570
 RS232 (control signals supported)
 LAN (single, dual), NetRAIN –
Redundant Array of Independent Network adaptors (two
interfaces appears using the same IP-address)
 Security arrangement same as the operating system

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ABB
Power
Technologies
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Communication Lines in Network Manager
LAN or WAN
Database - Object level
Hardware level
Line Pool
Line Unit #1
Line Unit #2
Line Unit #3
Line Switch
Line Pool # 1 = COM-line 1
A B
Line Unit #1
A B
Line Unit #2
A B
Line Unit #x
Ch. 1A Ch. 2A Ch. xA
PCU # 1
Ch. 1B Ch. 2B Ch. xB
PCU # 2  Each Line Unit side is
connected to a PCU number
 The PCU can be distributed
 Each RTU belongs to one
Line Pool
 Line switch only if
redundant PCUs
Line 1, to RTU

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Power
Technologies
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Standard protocols (used in most projects)
 IEC 60870-5-101
 ABB RP570 (use is decreasing)
 IEC 60870-5-104 (use is increasing)

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Power
Technologies
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PCU400 Implemented protocols
Slave Protocols Master Protocols Master Protocols cont´d
IEC 60870-5-101 IEC 60870-5-101 TG709
IEC 60870-5-104 IEC 60870-5-104 TG065
ADLP180 ADLP80 USART
RP570 ADLP180 SINAUT 8 FW (DPDM)
Teleconnect III RP570/571 Indactic 35
DNP 3.0 Indactic 33,33/41A WISP
OPC server Indactic 2033 WISP+
Conitel 300 Teleconnect III
MODBUS RTU Netcon 8830
Field Buses TG800 HNZ
 LON DNP 3.0 Teleconnect II
 SPA-bus Mobitex ECMA 24
 GCOM Siemens ST1 DDE and OPC client

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Power
Technologies
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PCU400 Hardware Assembly
HUB
1 2 3 4 5 6 7 8
Ethernet
1 2 3 4 5 6 7 8
Ethernet
1 2 3 4 5 6 7 8
Ethernet
External or Internal

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Power
Technologies
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PCU400 Line Switch
 Line Switch
 1 RTU line per unit
 Speed up to 115 kbps
 Connection to A and B system
 Test connector for line analyzer
 DIN-mounted
 Redundant power input
 Galvanic isolated B-side

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Power
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Application Program Interface (API) for Openess
 APIs gives flexibility to integrate protocol libraries
 PCU400 optionally provides
 A DDE interface
 An OPC-client interface
 An interface from ASE (USA-based company)
 ABB will add more APIs
 PCU400 users may add protocols using:
 DDE
 OPC
 ASE
 Toolkit

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Power
Technologies
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Schematic of Software Interfaces
RSP Plug-In Slave
RSP bus
Plug-In
XML
DDE Master
OPC
LON 3rd party
3rd party
Control Center Communication
Process Equipment Communication
FTP/HD
Engineering Tool
(MS Excel)

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Power
Technologies
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Operators Interface (device control)
 Device in/out of service, status
 Device restart
 Redundant RTU line switching (active/passive)
 Line unit switch (online/standby)
 Communication statistics (4 counters)
 Block/Deblock points

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Technologies
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View and Test web-interface (option)
 Commissioning of PCU400
 Test of database – I/O
 Test of IED equipment

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Power
Technologies
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Local Control web-interface (option)
Station Overview
 System overview
 Station overview
 Control
 Event & Alarm list
 Parameter Setting
 Fault Distance Rec.

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Power
Technologies
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Data Acquisition, Security
5
4
LAN 1
LAN 2
Application Server A Application Server B
RCS Application B
RCS Application A
1
PCU400 A PCU400 B
Line switch
RTU
1. Redundant PCUs
2. Dual LAN
3. Line Unit, A and B
side
4. Logging between
RCS applications in
a redundant system
5. Logging between
Application Servers
… Connection if dual
LANs
RSP lines
RTU lines
2
3 3

22. ©
ABB
Power
Technologies
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RCS Application, Time Synchronization
Time messages sent to RTU
Cyclic broadcast message (TSIL)
(Y, M, D ,h, min, sec)
Minute
pulses
Time base
Application Server A
RCS Application
ASCII-string
PCU400

23. ©
ABB
Power
Technologies
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Dual ported memory
Communication Board
PCU400, Time synchronization
Minute pulse
Time message Free running counter
Clock Server
Protocol
Driver
Write the Time message
to com board
Write number of tics until
sending should occur
The board stops transmission
until the tics are executed. Then
sending occurs
Time fetch via
DLL

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Power
Technologies
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Functions:
 Data Gateway/Concentrator
 Web-interface
 Local Station Control
 Local configuration via MS Excel
 Allow connection to existing systems
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Configuration Tool
WEB-interface
Local Control
Remote Master Systems
RTU or Protection relay
E.g. IEC 870-5-101
REC 561 REL 5x1
PCU400 as Gateway for SA and SCADA systems

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Power
Technologies
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PCU400 SA & SCADA Connectivity
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REC 561 REL 5x1
RTU
LON
RTU protocol
TCP/IP
OPC
XML
WEB-Interface
Base Level
Network Manager
High Level
Industrial IT
PLC Connect
Operate IT
Medium Level
PCU400 Gateway
RSP

26. ©
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Power
Technologies
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Functions:
 Connection of new RTU to old Master System
 Connection of old RTUs to new Master System
 One line to RTUs / Protection relays
 Redundant lines to the Master system
 Media converter (dial-up to leased line)
 Local configuration
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15
Remote
Master System
RTU or
SA system
E.g. IEC 870-5-104
E.g. RP570
Configuration Tool
PCU400 as Converter
Example
Connection of an RTU211 to an IEC870-5-104
network by using the PCU400 embedded.

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ABB
Power
Technologies
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OPC400 Server
 API-Data Access 2.0 (DA)
 API-Alarm and Event (AE)
 All protocols will be available through the OPC-server
 OPC Client also available
RSP bus
OPC DA OPC AE Slave
Plug-In
XML
DDE Master
Protocol
OPC
3rd
LON
3rd part
Control Center Communication
Process Equipment Communication
FTP/HD
EXCEL
Engineering Tool

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Power
Technologies
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PCU400 Data Engineering
 Local in PCU
 COM-port definitions
 Protocol per line (and characteristics)
 Socket TCP/IP address and port
 Runtime database Loaded via RSP or XML
 Loaded per line from RCS Application
(or via PCU400 internal X05 in case of XML)
 Which RTUs on which lines
 I/O for each RTU (logical and possibly physical)

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Power
Technologies
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Data Engineering Tool
SCADA Servers
Loading over LAN/WAN using RSP protocol
File transfer to RTU if supported
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Power System data
PCU400 Data flow - SCADA

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Power
Technologies
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PCU400 Data flow - Gateway
Configuration Tool
MS Excel based
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Power System data
XML-files

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Power
Technologies
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Definitions in the PCU400 system
Basic configuration of the PCU400
- COM port
- COM line
- Line unit
- TCP/IP port
- RSP address

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Power
Technologies
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LAN
The specification of the comport is done in
the files linunit.ini and lu_xxx.ini
Following items defines the COM-port
COM-port number (1-255)
TCP-port
(Socket connection to the PCU SW)
PCU
PCU
Software
Socket
connection
(TCP-port)
Comport
#1
RTU
TCP/IP port and Comport

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Power
Technologies
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Database Objects
 Process Communication Unit (PCU)
 Communication line (group of physical lines)
 Line unit (physical line)
 RTU
 Scan group
 Data types (AMV/DMV, IND, CMD, ACC, REG, SPV, GOM)

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Power
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RSP Address
 Each Line Unit is assigned to a RSP address
 The RSP address is unique within the Comport
 The RSP address is the same for Line Unit A & B side
 Every node in a RCS system must have an address
 The RSP address is within range 1 .. 255. Typically the
following intervals applies:
 [1..127] RTU lines
 [128..199] Emulator lines
 [200..255] Master Lines
Frame type
Datatype
Length
Sequence number
Source line number
Destination line number
RTU number

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Power
Technologies
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PCU400
SW bus (RSP)
RCS400.INI
H99_INP.TXT
H00.INI
Application Server
RP570 RTU’s Indactic33 RTU’s
LINEUNIT.INI
LU002.INI
H14.INI
LU001.INI
H20.INI
1) Line specific parameters, e.g., comport
2) General protocol settings
3) Definition of lines and protocols
4) PCU general parameters
Parameters in PCU400

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Power
Technologies
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Logging tools
 Data traffic can be logged from
 Local interface in Windows
 Remote from a Telnet session via modem or network
 Logging per communication channel
 Logging of RSP traffic per PCU

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Power
Technologies
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PCU400 Installation
 The PCU400 SW is installed from CD
 Installation Wizard
 Manual configuration of protocols and line data
 Upgrade possible from CD or via network
 Remote upgrade important in distributed systems

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Power
Technologies
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PCU400 Development tool
Standard software
Microsoft Development Studio 6.0
Language C and C++
Visual Source Safe
PC based
Portable for site assistance

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Power
Technologies
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PCU400, Protocol layers
Medialayer
Linklayer
Application
RSP
Medialayer
Linklayer
Application
RSP
3rd party
OPC server
OPC client
RSP
Basic Functions ABB Toolkit 3rd part interface

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Power
Technologies
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PCU400 Main Software Components
Windows
XP
WIN32
NT-Driver OCC / TCP-IP
Supervisor
Watchdog
DCU
Control Agent
Remote config
and logging
Trap Manager
Saving of Traps
to HD
Clock Server