Motorola ACE3600 series remote terminal unit RTU

Motorola ACE3600 series remote terminal unit RTU

Overall system architecture

The complete SCADA system consists of four main parts

ACE3600 RTU (on-site): collects on-site DI/AI signals and executes DO/AO output; Capable of local logical operations; Upload data through communication networks; Receive control instructions issued by the upper level. Supports peer-to-peer communication, allows direct data exchange between RTUs, supports distributed intelligent architecture, and also supports traditional centralized SCADA.

Communication system: supports various media such as wired, VHF/UHF cluster/conventional radio, IP Ethernet, etc; The core private protocol is MDLC (Layer 7 OSI protocol), which has the ability to store, forward, and multi hop relay.

FEP front-end processor: deployed in the control center, completes the conversion between MDLC protocol and SCADA master station protocol (OPC, Modbus), and maintains the on-site database; Simultaneously supporting remote program download and diagnostic upload.

SCADA Manager monitoring and management software: operator human-machine interface, screen display, alarm, report, permission password management, can export Excel reports.

STS (System Tool Suite): PC engineering software that completes RTU configuration, program download, hardware diagnosis, and log reading. It can access any on-site RTU locally or remotely through the MDLC network.

Hardware overall structure

ACE3600 adopts a modular card rack architecture, supporting wall mounted, 19 inch standard cabinet installation, and NEMA4/IP65 outdoor protective enclosure.

1. Rack Frame Specifications

Rack type, I/O slot quantity, applicable scenarios

No I/O slot rack 0, only power supply+CPU, no IO

3-slot rack with up to 3 I/O modules for small sites

5-slot rack with up to 5 I/O modules for medium-sized sites

7-slot rack with up to 7 I/O modules for medium to large sites

An 8-slot rack can support up to 8 I/O modules and 19 inch cabinets, with a maximum local IO capability

Supporting accessories: metal chassis, NEMA4 IP65 protective shell, the interior of the shell can accommodate a radio, 6.5Ah/10Ah sealed lead-acid 12V backup battery.

All I/O modules support hot swapping, and each module is equipped with an ERR fault indicator light and channel status light; There are two forms of terminals: direct insertion TB terminals or TB Holder integrated terminal sockets, which support prefabricated cables. Some I/O modules can be optionally equipped with a 24V isolated auxiliary power supply to provide power to external sensors and dry contacts.

2. Power Supply Module

The power supply is fixed in the leftmost slot of the rack, with multiple models to choose from:

Low voltage DC: 10.8-16V (basic version)

Wide voltage DC: 18-72V; With charging/without charging version

AC communication: 100-240V, with/without battery charger

Version with charger: seamless automatic switching of 12V backup battery when the main power fails; Temperature compensated charging, overcharge protection, supports battery diagnostic discharge testing.

All power supplies have overcurrent, overheating, and short circuit protection; Fan without fan convection heat dissipation; Panel status LED; Equipped with a global relay suppression control interface, it can block all EE type relay outputs as a whole.

Backup battery: 6.5Ah, 10Ah sealed lead-acid battery, working from -30 ℃ to+60 ℃.

3. CPU module (2 models)

CPU3610: Basic version; Freescale MPC8270 32-bit processor, VxWorks real-time operating system; Flash16MB、SDRAM32MB； Without onboard Ethernet port; I/O expansion is not supported.

CPU3640: Enhanced version, comes with 10/100M Ethernet Eth1; This model is required to support I/O expansion racks.

CPU resources:

Onboard serial port: SI1 can be configured with RS232/RS485; SI2 fixed RS232;

Two expandable plug-in slots PI1 and PI2, which can be equipped with RS232/RS485/Ethernet/wireless radio modems;

RTC real-time clock, equipped with rechargeable lithium battery and SRAM option for data logging, can be saved for up to 60 days when powered off;

Hardware: buzzer, 2 panel buttons, multiple sets of status LEDs; Firmware supports local/remote STS software upgrades; Upgrade failure automatically rollback old firmware.

All I/O module types

All modules are optically isolated and support sleep mode and freeze test mode; When there is a fault, the channel can be configured with KLV to maintain the previous value/PDV to force the preset value; Support event timestamp recording.

1. Digital input DI module

Low voltage 24V DI: 16DI/32DI; Supports IEC61131-2 Type2; Some channels support high-speed counters; Support AC/DC signal input; Hardware input filtering adjustable from 0-50.8ms; Support event triggered interrupts.

High voltage DI: 16 channel 120/230V AC/DC high voltage input, does not support counting function.

2. Digital output DO relay module

Divided into two types of relays:

EE electric excitation relay: power loss/module fault contact returns to the disconnected state;

ML magnetic holding relay: maintains output state when powered off. Model:

Low voltage: 8DO/16DO (2A), mixed SPST Form-A and SPDT Form-C contacts;

High voltage: 12DO 120/230V (3A); Features: Relay with feedback loop for loop reading; Support global hardware suppression locking output; Configurable fault KLV/PDV.

3. FET type configurable DI/DO module with 16 channels/32 channels, with 8 channels per group that can be software configured as input or output. For example, 32 channels can be configured with: 32DO/8DI+24DO/16DI+16DO/24DI+8DI/32DI; FET drain output, optocoupler isolation.

4. Analog input AI module 8AI/16AI; 16 bit AD; supports ± 20mA (4-20mA), ± 5V (0-5V, 1-5V); Each channel is independently optically isolated. Function: 50/60Hz power frequency digital filtering; Multi level smooth average filtering; Change threshold COS alarm; Overflow indicator light; Supports wiring of two-wire/four wire transmitters.

5. Analog output AO module, 4-channel AO; 14 bit DA; each channel software selects 0-20mA current or 0-10V voltage output; Optoelectronic isolation, on-site calibratable; Voucher/Iout/Cal calibration status indicator light.

6. Hybrid I/O modules

Mixed I/O: 16DI+4-channel relay DO+4AI; Relays are available in EE/ML versions;

Mixed Analog：8AI +4AO； Current/voltage versions are optional.

I/O Expansion System (Important Feature) CPU3640 implements I/O expansion rack through 100Base TX Ethernet. The main CPU transparently accesses the IO of the expansion rack and can expand up to 110 I/O channels. Extension components:

Expansion Module: Installed in the expansion rack, with Ethernet port and RS232 STS debugging port; Rotate the dial code to set the rack number (1-13); Automatically download firmware from the main CPU when powered on.

Expansion LAN Switch: Installed on the mainframe; Up to 7 expansion racks per switch; Up to 13 expansion racks for 2 switches; The switch performs the highest priority processing on the internal I/O messages of the RTU; Prohibit access to other third-party network devices.

Expansion Power Supply: Expansion rack power supply; It can be powered by cascading DC cables from the mainframe or independently configured with AC/DC power supply.

The maximum distance between the expansion rack and the main rack is 50 meters; Supports deployment in the same cabinet and on-site distributed installation. Cascade power supply must calculate the total power consumption and cable voltage drop, and the recommended voltage should not be lower than 11VDC. The default timeout for communication interruption is 60 seconds, and the expansion rack will automatically restart and reconnect to the main CPU.

Communication capability

1. MDLC Core Protocol

Motorola SCADA specific seven layer OSI protocol; Support storage and forwarding, multi hop relay; Supports three reporting modes: Exception Reporting COS, Polling, and Exception Reporting Report by Exception; Support RTU-RTU peer-to-peer communication.

2. Hardware communication interface

RS232: up to 115.2kbps; Connect to PC, modem, radio GPS、 Third party devices; Supports PPP dial-up.

RS485: up to 460.8kbps, multi drop bus, up to 32 nodes, supports Modbus RTU.

Ethernet 10/100Base-T: MDLC over IP encapsulated UDP2002 port; Support static IP, DHCP, DNS, NTP network timing.

Wireless radio: Supports VHF/UHF conventional radio, analog cluster, ASTRO digital cluster iDEN, TETRA; The radio can have a built-in chassis.

3. Protocol compatibility with native MDLC; Simultaneously supporting Modbus RTU/TCP; Purchaseable authorizations: DNP3, IEC60870-5-101, AGA7/8 gas flow protocol. Time synchronization methods: local RTC, NTP network time, GPS hardware synchronization.

Software Architecture

STS (System Tool Suite): Engineering configuration, hardware diagnosis, firmware upgrade, program download, log reading; Local serial port or remote network access.

C-Toolkit: C language user programming to implement custom logic.

Enhanced PID: PID control function authorization option.

M-OPC, IP Gateway, Legacy Modbus FEP: Control center side software that interfaces with third-party SCADA.

The ordering system document provides a complete ordering process diagram:

Host rack selection: Select the model (F7509 without radio, F75xx with different radio); Determine the number of I/O slots; Select I/O module;

Installation form: Wall mounted metal chassis/NEMA4 shell/19 inch rack;

Selection of power supply and 12V battery;

CPU selection (3610/3640, expansion must select 3640);

CPU plugin communication board;

Additional accessories;

If I/O expansion is required, then follow the complete selection process for the expansion rack.

Important ordering constraints: When using radios or batteries, a metal chassis or casing must be ordered; Only the F7509 model can be used in Europe. The document appendix contains all module ordering part numbers.

Installation and mechanical dimensions

Installation method: Wall mounted, 19 inch cabinet; NEMA4 IP65 outdoor housing.

Safety regulations: comply with national electrical regulations; High voltage I/O must be installed in a restricted access cabinet; The external main circuit requires a 20A protective circuit breaker; It is recommended to use shock-absorbing gaskets in vibration and impact situations.

Provide opening drawings for each rack, chassis, and shell, as well as installation clearance requirements.