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BMRCL

BANGALORE METRO RAIL CORPORATION LIMITED RTU System


Functional & Design Specification

Abstract:

This document presents the Architecture, Features of Remote Terminal


Unit of ABB proposed for BMRCL Project

Document identity: YN1K220067-RTU_FDS Revision: 01

Approved by Checked by Prepared by YR WK Total Pages

Vijayan SR Prasanna S Kumar Mithunraj 10 04 30

Doc No: YN1K220067-RTU_FDS

Page 1 of 30
YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

1 INTRODUCTION---------------------------------------------------------------------------------------------------------------------3
1.1 PURPOSE -------------------------------------------------------------------------------------------------------------------------3
1.2 REFERENCES ---------------------------------------------------------------------------------------------------------------------3
1.3 CHANGE DETAILS ----------------------------------------------------------------------------------------------------------------3
1.4 CLAUSE COMPARISON OF TECHNICAL SPECIFICATION AND FDS -------------------------------------------------------4
1.5 DOCUMENT CHANGE CONTROL -----------------------------------------------------------------------------------------------6
1.6 ABBREVIATIONS AND SYNONYM -----------------------------------------------------------------------------------------------7
2 OVER VIEW---------------------------------------------------------------------------------------------------------------------------8
2.1 SYSTEM DESCRIPTION ----------------------------------------------------------------------------------------------------------8
2.2 REMOTE TERMINAL UNIT (RTU 560) ----------------------------------------------------------------------------------------9
2.2.1 CENTRAL PROCESSING UNIT ----------------------------------------------------------------------------------- 11
2.2.2 TIME SYNCHRONISATION ---------------------------------------------------------------------------------------- 11
2.2.3 RTU COMMUNICATION--------------------------------------------------------------------------------------------- 11
2.2.4 REMOTE PROGRAMMING FACILITY -------------------------------------------------------------------------- 11
2.2.5 Safety features -------------------------------------------------------------------------------------------------------- 12
2.2.6 Redundancy------------------------------------------------------------------------------------------------------------ 12
2.2.7 I/O MODULE SPECIFICATIONS ---------------------------------------------------------------------------------- 12
2.2.7.1 DIGITAL INPUT MODULE ------------------------------------------------------------------------------------------------------12
2.2.7.2 ANALOGUE INPUT MODULE -------------------------------------------------------------------------------------------------13
2.2.7.3 DIGITAL OUTPUT MODULE ---------------------------------------------------------------------------------------------------13
2.2.8 RTU PANELS----------------------------------------------------------------------------------------------------------- 14
2.2.9 ENVIRONMENT CONDITIONS ------------------------------------------------------------------------------------ 14
3 RTU 560------------------------------------------------------------------------------------------------------------------------------ 15
3.1 RTU 560 SYSTEM ARCHITECTURE ----------------------------------------------------------------------------------------- 15
3.2 SYSTEM CONCEPTS ----------------------------------------------------------------------------------------------------------- 16
3.2.1 560CMU05 -------------------------------------------------------------------------------------------------------------- 16
3.2.1.1 Block diagram of 560CMU05--------------------------------------------------------------------------------------------------17
3.2.2 Power Supply UNIT 560PSU01 ----------------------------------------------------------------------------------- 19
3.2.3 Digital Input Module 23BE23-------------------------------------------------------------------------------------- 21
3.2.4 Digital Output Module 23BA20 ----------------------------------------------------------------------------------- 22
3.2.5 Analogue Input Module 23AE23 --------------------------------------------------------------------------------- 24
3.2.6 Local / Remote Selector Switch --------------------------------------------------------------------------------- 26
3.3 RTUTIL 560 -------------------------------------------------------------------------------------------------------------------- 27
3.3.1 RTUtil 560 FEATURES ---------------------------------------------------------------------------------------------- 27
3.3.2 System Requirements ---------------------------------------------------------------------------------------------- 27
3.3.3 RTUTIL 560 Structures --------------------------------------------------------------------------------------------- 28
3.3.4 General DATA Structuring View --------------------------------------------------------------------------------- 28
3.4 REMOTE MONITORING AND CONTROL ------------------------------------------------------------------------------------- 29
4 RTU TYPE AND LOCATION --------------------------------------------------------------------------------------------------- 30

Figure 3-1 Typical Configuration of Control System....................................................................................... 15


Figure 3-2 RTU Rack ........................................................................................................................................... 16
Figure 3-3 Block diagram of 560CMU05............................................................................................................ 17
Figure 3-4 Front view of 560CMU05 .................................................................................................................. 19
Figure 3-5 Board Layout and Fuse position ..................................................................................................... 20
Figure 3-6 Board Layout with setting position................................................................................................. 21
Figure 3-7 Front Plate ......................................................................................................................................... 23
Figure 3-8 Front Plate23AE23 ............................................................................................................................ 25
Figure 3-9 Overview RTUtil 560 components ................................................................................................... 28

Page 2 of 30
YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

1 INTRODUCTION

1.1 PURPOSE

This document describes the Remote Terminal Unit system architecture and functional design proposed for
control and monitoring of the Traction Posts, Auxiliary substations, Receiving substations and Depots for the
Rail corridor covering East-West and North-South of Bangalore Metro Rail Corporation Limited (BMRCL).

1.2 REFERENCES

Sl. Author / Date /


Reference Title
No Publisher Version

1 BMRCL specification Chapter 18 SCADA System BMRCL 2008 Oct

2 GC/S/PL/PMR- EP1-CC Traction Power Supply


GC 2010-02-17
1488/2010/1488/10221 Contract- Names of Stations

3 GC/S/TPP/PMR-
Review GC 2010-03-12
1681/2010/1681/10987

1.3 CHANGE DETAILS

Sl. Page Before


Section Section Title After Revision Remark
No No. Revision

RTU will be designed


specifically for each of
1 System
2.1 8 RSS RSS: At each RSS the RSS depending on
Description
Approved SLDs &
Equipment drawings

The parameters like Power,


System
Energy consumed etc are
2 Description,
2.1 9 - calculated and are available The line Inserted
under Operation
for the predefined time
principle of RTUs
interval

Each of the above


System
mentioned RTU Type is
3 Description,
2.1 8 - designed specific for the The line Inserted
under Operation
station to address the I/O
principle of RTUs
requirement of the Station

4 RTU Type and Station names are revised based on the above
4 30 -
Location referred document

Page 3 of 30
YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

1.4 CLAUSE COMPARISON OF TECHNICAL SPECIFICATION AND FDS

Sl. FDS
TS Clause Description Description
No. Clause
18.2.3.2 Remote Terminal Unit (RTU)

2/ Overview /
A 18.2.3.2.1 RTU definition and location of installation
4 RTU Type and Location

System description /
2.1 /
B 18.2.3.2.2 The various types of RTU RTU Type and Location
4
System description /
2.1 /
C 18.2.3.2.3 RTUs at RSS and KPTCL GSS RTU Type and Location
4

D 18.2.3.2.4 Hardware Configuration


E 18.2.3.2.4.1 RTU shall have minimum following configuration:

CPU shall have 32bit microprocessor, dedicated


F 18.2.3.2.4.2 2.2.1 Central Processing Unit
peripheral bus controller, non-volatile memory

RTU communication requirement over serial and


G 18.2.3.2.4.3 2.2.3 RTU Communication
Ethernet ports
Shall have communication ports for
a) communication with 3 control centers on IEC 2.2.3 RTU Communication
60870-5-104 protocol
Shall have communication ports for
b) communication with numeric relay on IEC 60870- 2.2.3 RTU Communication
5-103 61850 protocol
Support data acquisition from Energy meters on
c) 2.2.3 RTU Communication
MODBUS protocol

RTU shall have one HMI port which can be used


d) 2.2.4 Remote Programming Facility
for configuration purpose

RTU shall be provided with Ethernet port for


interfacing with Telecom equipments at TER.
e) 3.2.1.1 Block diagram of CMU05
SCADA RTU connection with TER is in the
scope of EP1-CC Contractor
H 18.2.3.2.4.4 CPU is connected with 3 types of I/O modules:
2.2.7.1 / Digital Input Module /
a) Digital Input Modules
3.2.3 Digital Input Module 23BE23
2.2.7.2 / Analogue Input Module /
b) Analogue Input Modules
3.2.5 AI Module 23AE23
2.2.7.3 / Digital Output Module /
c) Digital Output Modules
3.2.4 Digital Output Module 23BA20
2.2.4 / Remote Programming Facility/
I 18.2.3.2.4.5 Facility of RTU remote programming via HMI port 3.3 RTUtil 560

RTU offered for ASS, TSS, RSS shall have


J 18.2.3.2.4.6 redundant CPU & Power supply modules 2.2.6 Redundancy

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

RTUs shall communicate with OCC and BCC.


Shall have provision for communication over
3.2.1.1
K 18.2.3.2.5 10Mbps LAN; support minimum 4 communication Block diagram of CMU05
ports for host and PCU level communication

L 18.2.3.2.6 RTU shall include the following security and safety features as a minimum for control outputs:

a) Select-check-operate sequence for control output


No more than one control point shall be selected 2.2.5 Safety Features
b)
at any given time
Control selection shall be automatically cancelled
3.4 Remote Monitoring and
M 18.2.3.2.7 if the “operate” command is not received within
Control
the set time period

No control command shall be generated during


N 18.2.3.2.8 2.2 Remote Terminal Unit
power up/down of RTU

RTU shall be intelligent, fully autonomous in


operation and modular in construction. RTU shall
O 18.2.3.2.9 2.2 Remote Terminal Unit
be configured to suit the I/O requirements of the
selected equipment they are connected to

RTUs shall be suitable for either floor mounting


and shall be suitably robust. RTU shall be of
P 18.2.3.2.10 2.2.8 RTU Panels
same make and type and individual components
shall be interchangeable between RTUs

RTU shall be capable of being fully interrogated


Q 18.2.3.2.11 3.2.1.1 Block diagram of 560CMU05
or reconfigured from portable test equipment

It shall be possible to disable a RTU locally to


allow maintenance or reconfiguring of the RTU
Local / Remote Selector
R 18.2.3.2.12 without affecting other parts of SCADA system.
3.2.6 switch
When disabled or enabled, a change of status
condition shall be recorded as an event

RTUs shall operate correctly in conjunction with


independent safety systems. Neither normal
2.2.5
S 18.2.3.2.13 operation nor failure of the SCADA equipment Safety Features
connected to such systems shall prevent the
correct and timely operation of such systems
The RTU memory shall be sized. In addition to
holding al necessary programs and data, to store
T 18.2.3.2.14 Central Processing Unit
up to 1,500 data points in the event of a SCADA 2.2.1
communication failure
All recorded events shall be tagged with the date,
real time, in hours, minutes and seconds, and
milliseconds for high resolution of events, and
location of the event. The data shall be stored in
non-volatile read-write memory, in FIFO manner.
U 18.2.3.2.15 3.2.1.1 Block diagram of 560CMU05
Access to stored data in a RTU shall be
restricted by means of security codes. Portable
computers based plug-in devices shall be
provided to read and evaluate stored data. Such
reading shall not erase or corrupt stored data

Page 5 of 30
YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

RTU shall be provided with a clock which shall 2.2.2 /


support time synchronization from master station. 3.2.1.1 Time Synchronization /
V 18.2.3.2.16 The SCADA system shall also initiate time Block diagram of CMU05
synchronization messages when the
communication with RTU is restored

RTU offered shall support PLC programming


3.3
W 18.2.3.2.17 facility as per IEC 61131-3 standards. Necessary RTUtil 560
programming tools shall be offered

RTUs shall be compatible with the I/O signals


from selected equipment. Power supplies
2.2
X 18.2.3.2.18 contained within the RTU shall be available for Remote Terminal Unit
the interrogation of volt-free contacts of the
selected equipment

Each RTU shall be supplied complete with 20%


Y 18.2.3.2.19 2.2.7 I/O Module specification
spare capacity for handling additional I/O signals

RTU panel shall be of IP54 protections class and 2.2.8 /


RTU Panel /
Z 18.2.3.2.20 shall comply with EMC Immunity and emission 2.2.9
Environmental Conditions
as per EC 60870-2-1

1.5 DOCUMENT CHANGE CONTROL

Date Author Version Change Reason

2010-01-22 Mithunraj 00 First submission

2010-03-15 Mithunraj 01 Comments from GC

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

1.6 ABBREVIATIONS AND SYNONYM

ASS: Auxiliary Sub Station


BCC: Back up Control Centre
BMRCL: Bangalore Metro Rail Corporation Limited
CMU: Communication Unit
CPU: Central Processing Unit
CSR: Communication Sub Rack
GSS: Grid Sub station
IEC: International Electro technical Commission
IED: Intelligent Electronic Device
I/O: Input/Output
KPTCL: Karnataka Power Transmission Company Limited
LAN: Local Area Network
LCC: Local Control Centre
LED: Light Emitting Diode
MMI: Man Machine Interface
NTP: Network Time Protocol
OCC: Operation Control Centre
PLC: Programmable Logic Control
RAM: Random Access Memory
RJ: Registered Jack
RSS: Receiving Sub Station
RTU: Remote Terminal Unit
SCADA: Supervision, Control and Data Acquisition
TCP/IP: Transmission Control Protocol/Internet Protocol
TER: Technical Equipment Room
TSI: Time Synchronization Instruction
TSS: Traction Sub Station

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

2 OVER VIEW

The remote equipment interfacing with Power supply equipment will be called RTU. The RTU 560
proposed for BMRCL will be used to interface Substation Equipments, Substation energy meters and
Communication equipments. One RTU shall be installed per Power supply room, centre, unit etc.
provided the distance between the various RTU is such that a link is possible.

RTU 560 is designed for extremely high communication and data processing capability. It fulfills the
requirements for high-end remote terminal units. RTU 560 functions in a multi-processor environment,
with a Central Control Unit and various I/O modules. Consequently the load on the main processor is
greatly reduced resulting in enhanced functionality and accuracy in I/O processing.

2.1 SYSTEM DESCRIPTION

The RTU system proposed for BMRCL comprises of RTU’s installed at GSS, RSS, ASS, ASS cum
TSS and Depot TSS for necessary field data collection and data transfer to different Control Centers
simultaneously. 10Mbps dedicated Fiber Optic link shall be made available by Communication
contractor for the use of SCADA system between each RTUs and Control centers for transferring
data. The RTUs will communicate with the Control centers only and there will not be any
communication between RTUs.

Six types of RTU’s will be commissioned at various Power supply centers along the BMRCL East-
West and North-South corridors,
• Type 1 : Underground stations each ASS
• Type 2 : Underground station ASS plus TSS
• Type 3 : At grade / elevated corridor station and depot ASS
• Type 4 : At grade / elevated corridor ASS and plus TSS
• Type 5 : In depot TSS
• RSS : At each RSS locations

Also a Training RTU will be commissioned at BCC for the purpose of training.
Each of the above mentioned RTU Type is designed specific for the station to address the station
I/O requirement.

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

The Operation principle of RTUs along the corridors is as follows,

• The RTU’s installed in KPTCL GSS which feed power to BMRCL RSS will only collect
data relevant to feeder Circuit Breaker and Energy meters for monitoring and transmits
the data to OCC and BCC. The parameters like Power, Energy consumed etc are
calculated and are available for the predefined time interval. Not possible to issue
commands to the GSS equipments from SCADA terminals
• RTU’s at RSS location will monitor the field equipments; transmit the data to LCC,
OCC and BCC. Field equipment control from Control center is possible
• The RTU’s installed in other than above mentioned locations will collect the data for
monitoring and control. These RTU’s communicate to OCC and BCC

2.2 REMOTE TERMINAL UNIT (RTU 560)

RTU 560 is a state-of-the-art Remote Terminal Unit in a multiprocessor configuration with modular in
nature. The RTU will support distributed processing intelligence, fully independent in operation with
decentralized structure with the task of preprocessing of inputs distributed to the I/O modules.

Each I/O board, containing a controller for the basic data acquisition functions, is synchronized with
the central processing unit, with a resolution of 1 millisecond. After being switched on or following
reset, an extensive internal memory test is carried out. Fault or error conditions are detected in the I/O
cards is indicated by red LED. In addition, the configuration and hence the active performance of the
unit are monitored by means of cyclic interrogation of I/O unit status. This task is carried out by
peripheral bus processor. No control command shall be generated during power up or power down of
RTU.

Changes in process information are sent as events with time tag to the central processing unit of the
RTU. When specified, the CPU board performs high-level data acquisition functions, pre-processes
the data and store them in its database and further transmits via the front-end (FE) to the Control
stations. Control commands from the SCADA centre are checked and transferred to the required
output board via the CPU board.

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

Following are the features of the RTU 560,

• Communication in a Local or Wide Area Network via Ethernet interface, serial


communication interfaces for host communication and/or subordinated devices and/or
RTU I/O communication
• Up to 3000 data points per RTU 560
• Support of various communication protocols
• Integrated Human Machine Interface (HMI)
• Web Server
TM
• ELAN520 @ 133 MHz (incorporating an Intel 586 class 32 bit processor)
• Modular Hardware and Software configuration
• Compact Construction
• Low number of board types
• Up to 8 communication interface to Control centers
• Up to 32 communication interface to sub – devices
• State of art configuration tool RTUtil 560 with external data C
• PLC programming facility using multiprogramming

The process data in this project includes analog values, digital status data, and SOE and pulse
accumulator data energy meter data from the substation are being collected by the RTU.

Each I/O board of RTU 560 has its own processor, which is responsible for basic data acquisition
functions. Each board has its own time base, which is synchronized with the Control Unit. Each board
caters to 8 or 16 process signals. Changes in process information are sent as events to the Central
Control Unit together with time information.

The CPU keeps the time information for the entire RTU. It generates a controlled 10 KHz clock and
the internal TSO minute pulses which are needed by I/O master. It distributes the absolute time
information in time message telegrams to I/O master. The I/O master again transmits a time
synchronization instruction cyclically to all I/O controllers on the I/O boards via I/O bus. All I/O boards
are time synchronized by the I/O with resolution of 100Micro seconds and accuracy of +/- 0.3 ms.

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

2.2.1 CENTRAL PROCESSING UNIT

The Central processing unit has 32 bit microprocessor and has a dedicated peripheral bus controller
for handling the I/O functions. The CPU module has non volatile memory. It has communication port
for communication with Operation, backup and local control centers on IEC 60870-5-104. The CPU to
have 64 MB of RAM and 128 MB of Flash Memory to store archived data. The CPU processor will
have minimum speed of 130 MHz. All these features will be available in the redundant CPU as well. In
addition the RTU memory can be sized; it can store up to 1500 data points along with holding all
necessary programs and data in the event of SCADA communications failure.

2.2.2 TIME SYNCHRONISATION

The SCADA system at OCC which support time synchronization via NTP protocol through TCP/IP
link .The Control center initiate the periodic time synchronization messages to the RTU which is
provided with clock which supports time synchronization from Control center through communication
protocol (IEC 60870-5-104). In case of any communication failure and restore, first time
synchronization command initiated to that RTU. The clock in RTU shall be updating the time. When
communication with an RTU is interrupted, RTU uses its own clock for time stamping the events.

2.2.3 RTU COMMUNICATION

Each RTU will be assigned with different IP address and can communicate up to 8 Masters.
The Ethernet port of the RTU’s located in different stations will be connected to a TCP/IP link.
• RTU 560 will communicate with OCC and BCC over IEC 61870-5-104 protocols.
• RTU 560 will acquire data from Field Relay on IEC 61870-5-103 or IEC61850 (for GSS)
protocols.
• RTU 560 will acquire data from the Energy meter and Multifunction transducer using the
MODBUS protocol. These meters and Multifunction Transducer shall be connected in
multidrop mode.

2.2.4 REMOTE PROGRAMMING FACILITY

The RTU supports remote programming facility using RTU programming utility software from Control
Centre. The Ethernet port (Port-E1, E2) on the RTU will be communicating to the OCC via 10Mbps
TCP/IP link for data transfer and control depending on the IP address and subnet mask provided by
the communication contractor for each of the ports. The same port can be used for Remote
programming of the RTU also via HMI.

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

2.2.5 SAFETY FEATURES

The RTU will include the following security safety features for control outputs:
• Select-check-operate sequence for control output
• No more than one control point shall be selected at any given time
More ever, RTU will operate correctly in conjunction with independent safety systems, such as hard
wired safety circuits for over temperature trips, over pressure trips, electrical interlocks on
equipments, etc. Neither normal operation nor failure of the SCADA equipment connected to such
systems shall prevent the correct and timely operation of such systems.

2.2.6 REDUNDANCY

RTU offered for ASS, Traction & Receiving substations and GSS will have redundant CPU and Power
supply unit. Both the CPUs will transmit data to Control centres simultaneously.

2.2.7 I/O MODULE SPECIFICATIONS

RTU’s will be designed for incorporating 20% increase in I/O requirements. Further 50% extensions
can be carried out by addition of I/O modules, necessary cabling and reconfiguration of software. A
further 100% expansion shall be possible by adding additional interfacing equipment in additional
cabinets and software reconfiguration.

2.2.7.1 DIGITAL INPUT MODULE

The Digital input module has 16 optically isolated channels per module and supports time stamping
with time resolution of 1 millisecond. The digital input module supports configuration of inputs for the
following options:
- Single Indications
- Double Indications
- Digital Measurements

The digital input module supports the programmable parameters like,


- Bounce Filter (Suppression Time)
- Settling time for reliable digital measured value
- Chatter suppression
- Suppression of intermediate position
- Configurable with / without time tagging
- Configurability of message transmission priority

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

Also have following feature for Indication processing of,


- Group or Common alarms shall be configurable from Individual alarms by Boolean operations
- Acquisition of events in chronological order with a time resolution of 1 ms
- Buffering up to 3 changes per input

2.2.7.2 ANALOGUE INPUT MODULE

The Analogue input module has 8 channels per module and supports Dual Slope integration A/D
conversion. The Analogue module supports measured values of,
- Uni-polar and
- Bipolar
Also support programmable parameters like,
- Live zero conversion coefficients
- Cyclic Transmission or threshold value
- Forced zero point conversion coefficient
- Limit Values
- Smoothing factor
- Threshold values
- Cyclic duration
- Priority of Transmission
Supports other parameters like,
- Inputs shall be configurable for 4 to 20 mA / bipolar or live zero
- Accuracy - </= 0.1 %
- Common Mode Voltage: +/- 8 V DC
- Line Interference suppression: > 100 d for fn = 50 or 60 Hz

2.2.7.3 DIGITAL OUTPUT MODULE

The Digital Output module shall support 16 digital output channels per module. The output Module
shall support the following features,
- Duration of Output Pulse
- Release disconnection delay time at response indications
- Select before execute
- Cyclic duration
- Priority of Transmission

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

2.2.8 RTU PANELS

The RTU panel which houses RTU hardware mainly consisting of the CPU, I/O racks, power supplies
and Interface converters etc will be of IP54 protections class. RTU will be designed for floor mounting
and will be powered from 110V DC station battery and battery charger. All RTUs shall be of common
make and configuration depends on the RTU Type. The main modules like- CPU, I/O and Power
supply cards are of same model in each of the RTUs and can be interchangeable, however the
configuration has to be done separately.

2.2.9 ENVIRONMENT CONDITIONS

The RTU hardware will meet the following environmental requirements,

• EMC Immunity: As per IEC 60870-2-1 Level 3 or 4


• EMC Emission: As per IEC 60870-2-1 Class A
• Temperature: 10 to 55 deg C as per IEC 60870-2-2
• Humidity: 5 to 95% as per IEC 60870-2-2

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

3 RTU 560

3.1 RTU 560 SYSTEM ARCHITECTURE

The RTU560 based PLC uses a set of communication units and I/O boards with a good modularity to
build up the configurations optimized for the application and data point profile in the station. Below
shown a typical RTU communication diagram,

Figure 3-1 Typical Configuration of Control System

There will be two types of Racks which holds CPU, I/O and Power supply cards:
1) Basic Rack- 560CSR01: Mainly holds CPU and Power supply units
2) Communication sub rack- 23ET24: Mainly holds Power supply units and I/O cards

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

Figure 3-2 RTU Rack

3.2 SYSTEM CONCEPTS

The RTU 560 family has four types of configurations RTU 560A, RTU 560C, RTU 560D & RTU 560E.
The architecture proposed for the project is based on RTU 560A, which is further detailed in the
section below:
3.2.1 560CMU05

CMU boards (CMU = Communication unit) of the remote terminal unit RTU560.
The essential tasks are:
• Managing and controlling of the I/O boards via the interfaces to the RTU peripheral bus
• Reading Process events from the input boards
• Writing commands to the output boards
• Communications with control centers and local MMI systems via Ethernet 10/100BaseT LAN
interface
• Managing the time base for the RTU560 station and synchronizing the I/O boards
• Handling the dialogue between RTU560 and Web-Browser via LAN interface

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

3.2.1.1 BLOCK DIAGRAM OF 560CMU05

The 560CMU05 controls process events and communications with control centers and local MMI
systems via up to four serial interfaces (CP1, CP2, CPA, CPB) and the two Ethernet
10BaseT/100BaseT LAN interfaces (E1, E2).

The serial communication interfaces 1, 2, A and B are designed for RS232C and RS485 standard.
The interfaces ‘E1’ and ‘E2’ are based for the Ethernet standard 10BaseT/100BaseT. The connectors
of the serial and Ethernet communication interfaces are provided as RJ45 jacks integrated in the
board's front plate.

Figure 3-3 Block diagram of 560CMU05

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

The two microprocessors are the essential hardware parts of the board, which share themselves in
the tasks:
• MPU: 32 Bit Main Processing Unit
• SLC: 8 Bit Serial Line Controller

The SLC works as master for the RTU peripheral bus. The MPU handles the absolute time and date
for the RTU. The real time clock 560RTC0x will be used for the time reference or the time may be set
and synchronized from the central system via the serial lines or via the Ethernet LAN interface.
RTU560 synchronizes itself to the time references supplied by 560RTC0x. The minute pulse signal
and the time information of the 560RTC0x are provided to the 560CMU05 on the back plane of the
sub rack.

The control unit stores configuration files power fail save in a removable Compact Flash memory
card. That allows the RTU560 to have valid configuration data after power on and RTU560 will be
available again after a short initialization.

All recorded events will be tagged with the date, real time, in hours, minutes and seconds and
milliseconds for high resolution events and location of the event. The non-volatile read-write memory
store data in first in first out (FIFO) manner, such that the data will overwrite the earlier recorded data.
Access to stored data in RTU will be restricted by means of security codes. With a Portable computer
loaded with RTU configuration software can be sued to reconfigure the RTU and also it can be
plugged in to read and evaluate stored data.

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YN1K220067-RTU FDS
BMRCL
BANGALORE METRO RAIL CORPORATION LIMITED RTU System
Functional & Design Specification

ERR (1x) red Error / Warning


Transmit data,
Tx (4x) green communication
ports 1, 2, A,B
Receive data,
Rx (4x) green communication
ports 1, 2, A,B

A (2x) green Ethernet


activity E1,E2
(10BaseT/100BaseT)

L (2x) green Ethernet


Link E1,E2
(10BaseT/100BaseT)

Figure 3-4 Front view of 560CMU05

3.2.2 POWER SUPPLY UNIT 560PSU01

The 560PSU01 power supply unit is used in the project, which feed +5 V DC (U1) and the +24 V DC
(U2) for an RTU560 communication unit 560CSR01. We are using R0001 with Input Range 48... 220
V DC.

Processing Functions: The 560PSU01 board has a fixed location in the RTU560 communication
unit. This is slot 1 (P1) and 9 (P2). The primary fuse is placed on the right side of the power supply. If
an output voltage is lost, the green LED is off. The power supply is switched by the ON- -OFF switch
(S1) on the front plate.

Total Power Output: The 560PSU01 supplies a total output of approx. 44,3 W. This is split to: + 5 V
DC und 5 500 mA = 27, 5 W +24 V DC und 700 mA = 16, 8 W

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Redundancy: The RTU will have redundant power supply unit. In this configuration two power supply
units 560PSU01 are operating in parallel mode. They are respectively able to take over the full load if
one power supply fails.

Figure 3-5 Board Layout and Fuse position

Characteristics: The power supply unit 560PSU01 has the following characteristics and functions:
• Potential isolation between the input and the outputs
• Cooling by natural convection
• Electronic power limitation
• Short-circuit proof
• Over-voltage protection
• Controlled load balancing
• 2 light emitting diodes for displaying out-put voltage U1 and U2
• Parallel operation with monitoring of redundant power supply configuration
• Alarm indication (relay) in case of failure

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3.2.3 DIGITAL INPUT MODULE 23BE23

Operation: The 23BE23 board scan all 16 input channels every millisecond and prepares them on
the basis of predefined parameters for the RTU560.

The board 23BE23 will process the following types of signals:


• 16 single indications with time stamp
• 8 double indications with time stamp
• 8 bit digital measured value
• 16 bit measured value
• 16 pulse counters.

Figure 3-6 Board Layout with setting position

Application: The binary input board 23BE23 is used for the isolated input of up to 16 binary process
signals. Scanning and processing of the inputs are executed with the high time resolution of 1ms.
Allocation of an input to a processing function will be done according to the rules of configuration.
Characteristics: Eight inputs each form a group with a common return. The 16 inputs form two
groups. The inputs are potentially isolated by means of opto-couplers. The board allows process
signal voltages from 24 to 60 VDC. The input circuit is dimensioned in that way, that current regulative
diodes keep the signal current constant. The board with rubric R5012 has sixteen light emitting diodes

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to indicate the signal-state. The LEDs are organized in two columns on the front plate. The LED
follows directly the input. The maximum permissible frequency for counter pulses is 25 Hz.
The binary input board 23BE23 will execute the following

Processing functions for the different types of signals:


• Digital filtering to suppress contact bounce
• Suppression of technologically caused chattering signals
• Intermediate position suppression and monitoring for double indications
• Consistency check for all binary input channels allocated to digital measured values
• Summation of increment pulses to form counter values in 31 bit counter value registers
• Relocation of count values into other relocation registers on request.

3.2.4 DIGITAL OUTPUT MODULE 23BA20

Operation: The 23BA20 board has 16 output relays. Two groups of eight contacts have the same
common return. This allows splitting the output channels only to two different process voltage
sources.

Processing function: The I/O micro controller (EAP Ein- Ausgabe-Prozessor/ Input- output processor)
activates any output forced by the VAP of CMU by a command output request. The EAP controls the
time duration of a pulse output by the loaded pulse length time value.
Output monitoring and supervision: Any output is checked and monitored by the EAP by different
tests and supervision functions:

• The output pattern is read back before the output is activated


• The 24 V DC from backplane bus to switch the output relays is supervised during an active
output
• The pulse duration is controlled by the EAP
• Any detected error is indicated by LEDs

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Figure 3-7 Front Plate

Application: The binary output board 23BA20 will be used for the potentially isolated output of up to
16 binary signals to the process. The assignment of an output to a number of processing functions
can be freely undertaken within the scope of the configuration rules. The 23BA20 will be used for the
following types of signal.
• Object commands with 1 or 2 pole output without (1 out of n) check
• Objects commands with 1.5 or 2 pole output with (1 out of n) check
• Set – point messages
• General output messages
The number of object command outputs of a 23BA20 board can be extended to 32 double commands
by connecting in series a maximum of 4 command output modules 23BA20. But the 23BA20 module
also can be used in series with the 23BA20 as an isolating module with 16 interposing contactors for
fully potentially isolated command output.
Characteristics: The binary output board 23BA20 will execute the control of command output
duration function of the individual signal types. Before and during command output the board 23BA20
carries out several monitoring functions like:

• m out of n check of the output on the board 23BA20


• Monitoring of the output bit patterns by re-reading
• Switching voltage monitoring before and during output
• Command output duration monitoring

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If a fault occurs during running of testes the command will be cancelled. The switching through of the
output relays by release relay k1 occurs only following successful testing.

A defective driver stage or a fault in the release relay k1 leads to complete inhibition of the 23BA20
board. Operating states and faults are displayed by light emitting diodes on the front panel of the
23BA20 are:
1. ST: common malfunction information of the board
2. PST: command output fault conditions display the monitoring system responds
3. CO: Command output display during output time

The board micro controller is responsible for interactive communication with the RTU system bus. All
configuration characteristics and processing parameters are downloaded from the communication unit
via the RTU system bus. No parameter setting and adjustment is required on the board. The board is
equipped with both serial and parallel interface to the RTU system bus. During initialization and
operation the board carries out a number of tests. If a fault occurs it is reported to the communication
unit. All fault conditions impairing the function of the board are displayed as common fault signal with
a light emitting diode (ST) on the front panel. The communication unit detects a failure of the board.

3.2.5 ANALOGUE INPUT MODULE 23AE23

Operation: The 23AE23 board scans analog current- or voltage signals and prepares them for the
RTU560 on the basis of predefined parameters.

The 23AE23 board records up to eight analog measured values. The 23AE23 board allows it to
connect all typical measured value ranges.

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Figure 3-8 Front Plate23AE23

It can be configured for the following measured ranges by simple switches and jumpers.
• V ± 2 mA
• V ± 5 mA
• V ± 10 mA
• V ± 20 mA
• V ± 40 mA
• V ± 2 V DC
• V – 0 to +20 V DC
• 4-20 mA

Other effective ranges and live zero signals become generated out of these ranges through
conversion of the communication unit CMU.

Basic checks and computing intensive, cyclical processing function will already be done on the board
and remove therefore the burden from the central unit. Relevant changes transmit the board as event
via the peripheral bus. The 8 differential inputs are not potentially isolated against the RTU power
supply.

Unipolar or bipolar values resolve the 23 AE23 into 4096 steps (12 bit plus sign) for the 100% of the
measuring signal. The differential inputs are protected against static and dynamic over – voltages by
a protection circuit. A low-pass filter suppresses non-line frequency as disturbance.

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The AD converter, operation with the sigma-delta method scans with a higher resolution and has
additional algorithms for a high suppression of line frequency and line harmonics interface voltages.
Even for a deviation of ± 10 % of the line frequency there is still given suppression of > 45 dB. The
internal high resolution allows it to scan all measuring ranges (exception: ± 2 V DC (11 bit + sign))
with the same resolution (12 bit + sign) on one board. A 9th channel is used for automatic zero
calibration.

Measuring range and line frequency is easily to configure by switch registers respectively jumpers.
The micro controller needs these configurations parameters to setup the AD- converter. The micro
controller controls the A/D converter and executes all of the processing functions of the configured
measured values within the conversion time. Furthermore the micro controller is responsible for
interactive communication with RTU system bus.

All configuration characteristics and processing parameters are downloaded from the CMU via the
RTU system bus. During initialization and operation the board carries out a number of tests. If a fault
occurs, it is reported to the CMU. All fault conditions impairing the function of the board are displayed
as a common fault signal with a light emitting diode (ST) on the front panel. A failure of the board is
detected by the CMU.

3.2.6 LOCAL / REMOTE SELECTOR SWITCH

In RTU panel, one Local/Remote switch is provided to facilitate testing, maintenance and
reconfiguration of RTU. When the switch is in local position, Control Supply to Output Relay will be
disconnected. During this time if the command is issued from master station to RTU, there will not be
any voltage that will get extended to output and as a result of that control will be disabled. The change
of switch position is monitored and any change is recorded as an event in SCADA application also the
isolation of a RTU will not affect the other functional part of SCADA system.

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3.3 RTUTIL 560

3.3.1 RTUTIL 560 FEATURES

RTUtil 560 is the configuration and data engineering tool for the RTU560 family, which generates all
files requested to run the RTU560 units. RTUtil 560 allows to download the files into the RTU560 in
the stations via INTRANET using Web Enabled Browser technology or via the communication line,
when the protocol supports file transfer.

The basic topics of RTUtil 560 are:


 User interface structured according to the principles of EN 61346 -1
 Documentation of all important project steps
 External data interface concept (Microsoft EXCEL import)
 Multilingual tool (user interface and help files)
 Delivery version with setup, installation and de-installation program on CD-ROM
 Supported on MS Windows NT 4.0 / 2000 / XP Professional platform

3.3.2 SYSTEM REQUIREMENTS


The minimum hardware requirement for the data engineering tool RTUtil 560 are:

 Operating system: MS Windows NT 4.0 / 2000 / XP Professional


 Memory: 128 MB RAM
 Processor: Pentium class > 500 MHz
 Hard disk: > 200MB free disk space

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3.3.3 RTUTIL 560 STRUCTURES

RTUtil 560 enables the user to control the whole engineering process of an RTU based system.
RTUtil 560 manages all configuration data. To meet the requirements the internal software structure
of RTUtil 560 is split up into different function parts as shown in the figure below.

Figure 3-9 Overview RTUtil 560 components

3.3.4 GENERAL DATA STRUCTURING VIEW


The general view of the user on the engineering data is implemented on the basis of the international
Standard EN 61346 (IEC 1346) -1. This standard describes the structuring principles and reference
designations for industrial systems, installations and equipment. In the user interface this standard is
presented in trees showing the RTU from different points of view. To describe the whole process the
view is split up into three trees. IEC 1346-1 defines how to split up a system (function-, product- and
location-oriented structure).

The user interface structure offers three trees to describe the system structure used for an RTU560A.

 Network Tree:
The Network Tree shows the lines and protocols between the RTUs and/or Control Centers for
routing the data points through the network.
 Signal Tree :
In the Signal Tree the location and designation of signals are shown. The signal location describes
the place of the data points in the primary process.
 Hardware Tree:
The Hardware Tree presents the structure of an RTU560A with the levels:
 Cabinet

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 Rack
 Board

3.4 REMOTE MONITORING AND CONTROL

The status of equipment like breakers, isolators, disconnections will be shown to the operator in the
mimic diagram of the Operator station. The equipment is connected to the system using RTU. Inputs
for the indications are taken from the potential free contacts available on the device. The indications
will be processed by the Digital Input modules and sent to the system. Any change in the status of
equipment will be associated with an event. The event is displayed in the Event List. If the changed
status is an alarming condition then the alarm is shown on the top of the screen and an audible
warning will be configured.
For emergency or abnormal condition, the operator will have the control of the equipment from the
main control room. Control shall be provided for two state devices like Circuit Breakers, motor
operated switches etc. The operator can undertake the function of isolation of faulty equipment and
sections and may return them back to service on the establishment of normally. For the control of the
field equipment, the commands from the Software will be sent to the field using the Digital Output
Cards of the RTU. The hardwired contacts wired to the RTU will give the back indication to show the
change in the status of the equipment on execution of the command. The control selection shall be
automatically cancelled if the ‘Operate’ command is not received within the set time period and each
command is awaited for the acknowledgment before proceeding further.

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4 RTU TYPE AND LOCATION


For interfacing remote equipment with Power supply equipments One RTU will be installed per Power
supply room, centre, unit etc. The list of RTUs as follows:
Type-1 Underground ASS & GSS Type-4 Elevated / at grade ASS & TSS
A E-W corridor A E-W corridor
1 City Railway Station 1 Mysore Road
2 Kempegowda (Interchange) 2 Attiguppe
3 Sir.M.Visveshwaraya 3 Hosahalli
4 Vidhan Soudha 4 Toll Gate
5 Cubbon Park 5 Magadi Road
6 City Railway Station 6 Mahathma Gandhi Road
7 Vidhan Soudha 7 Trinity
8 Hoody Substation 8 Halasuru
9 HAL Substation 9 S.V.Road
Baiyappanahalli (TSS situated in the
10 V Valley Substation 10
Depot)
11 Remco Substation B N-S corridor
B N-S corridor 1 Peenya
1 Kempegowda (Interchange) 2 Yeshwantpur
2 Chickpete 3 Mahalakshmi
3 Krishna Rajendra Market 4 Kuvempu Road
4 Chickpete 5 Sampige Road
5 SRS Peenya Substation 6 Lalbagh
C S Extn- optional 7 Jayanagar
1 Khoday’s Substation 8 Rashtreeya Vidyalaya Road
Type-2 Underground ASS & TSS C N Extn- optional
A E-W corridor 1 Nagasandra
1 Kempegowda (Interchange) 2 Jalahalli
2 Sir.M.Visveshwaraya D S Extn- optional
3 Cubbon Park 1 Jaya Prakash Nagar
B N-S corridor 2 Puttenahalli
1 Kempegowda (Interchange) Type-5 In depot TSS
2 Krishna Rajendra Market A E-W corridor
Type-3 Elevated / at grade ASS & depot 1 Baiyappanahalli Depot
A E-W corridor B N-S corridor
1 Deepanjali Nagar 1 Peenya Depot
2 Indiranagar RSS RSS
3 Baiyappanahalli Depot A E-W corridor
4 OCC at Baiyappanahalli 1 Baiyapanhalli Depot
B N-S corridor 2 Mysore Road
1 Peenya Industry B N-S corridor
2 Yeshwantpur Industry 1 Peenya RSS
3 Sandal Soap Factory
4 Rajajinagar C S- Extn optional
5 Srirampura 1 Puttenahalli RSS
6 National College
7 South End Circle E Training RTU
8 Peenya Depot
C N Extn- optional
1 Dasarahalli
D S Extn- optional
1 Banashankari

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