Motorola Enhanced SCADA SolutionsACE3600 – Next Generation RTU forVersatile Utility Applications and Industrial Solutions

In today's highly competitive world it is the bottom linebenefit that counts - and Motorola makes the difference.Over 120,000 Motorola SCADA (Supervisory Control andData Acquisition) RTUs (Remote Terminal Units) installedworldwide and over three decades of accumulatedexperience are evidence of Motorola's ability to offer youtop-class SCADA solutions.

Both the Motorola ACE3600 and the former generationMOSCAD, MOSCAD-L, and MOSCAD-M RTUs utilizeinnovative design,control and data communication features.They facilitate integrated SCADA solutions tailored toapplications in water and electric utilities,telecommunications, public safety, transportation, andother industries.

Motorola RTUs’ unique performance anduncompromising quality commitment translate intooperating and cost benefits for our clients. MotorolaSCADA solutions combined with reliable wired or wirelesscommunications provide exceptional system architectureflexibility, reliable control, enhanced system performance,and data communications security.

Motorola RTUs allow you to build new systems orexpand existing ones, using a wide selection of MasterControl Center (MCC) software, Human Machine Interface-(HMI), data communication links and networks over wires,fiber optics as well as a variety of advanced wirelessmedia. Thus, as your system needs grow, upgrades andexpansions can be easily added.

Motorola SCADA Solutions DeliverUnparalleled Performance

2

3

Electricity Distribution

Distribution Automation (DA) andcomputerized remote control ofMedium Voltage (MV) substationsand power grids help electric utilitiesachieve higher reliability of supply andreduce operating and maintenancecosts.

In the past, Sectionalizer Switchgears,Ring Main Units, Reclosers andCapacitor Banks, wind farm powergeneration connected to theMV power grid were designed for localoperation with limited remote control.Today, using reliable wirelesscommunication, Motorola RTUs providepowerful integrated solutions whenupgrading remotely installed electricequipment. Motorola’s upgradesolutions include integration of CapacitorBank controllers, transducer-less ACMeasurement units and Fault PassageDetection (FPD) units from 3rd partyvendors. These operate as IntelligentElectronic Devices (IEDs) and can beconnected to the RTU via Ethernet, RS-232 or RS-485 ports using MODBUSor DNP 3.0 protocols.

In a Distribution Management System(DMS), Motorola RTUs seamlesslyinterface with a wide range of highperformance control centers suppliedby leading vendors worldwide.Connection to these EMS, and DA/DMScontrol centers is typically provided viaa high performance IP Gateway or OPC-type Interface.

Customers throughout theworld have experience withSCADA solutions that boostoperating reliability, helpreduce operating costs,simplify operatingprocedures and help makemaintenance crews moreefficient.

Motorola designed the nextgeneration ACE3600 RTUas upgradeable andexpandable system toenhance the performance,data security and operatingreliability of remote sites.

Thousands of MotorolaSCADA systems with over120,000 RTUs are operatingworldwide, serving the oiland gas industry, electricand water utilities and publicsafety agencies.

Oil and Gas Industry

Oil and gas operations require remotecontrol for production wellheads, alonglong pipelines and at valves located atdifficult-to-access sites. This industrymust maintain the strictest safetymeasures to prevent and detectleakages or fire at remote installations.Thus each site must be supervised viaRTUs with communications to one ormore control centers.

RTUs in gas installations calculate gasflow according to AGA-3 (AmericanGas Association), AGA-7, AGA-8 andother standard formulas, while RTUsalong oil pipelines perform analogpressure control using PID(Proportional-Integral-Derivative) loops,monitor cathodic protection rectifiers,flow meters and more.

Intrinsically safe connection to RTUsfrom field sensors installed in restrictedzones can be provided by adding barrierdevices to the discrete Input/Outputsignals and RS-232 serial cables.

Motorola SCADA Applications

4

Water and Wastewater

Among the goals commonly citedby municipal and private water utilitiesworldwide are cost savings due toreduction of unaccounted-for-water,maintenance cost reduction, liftstation early problem detection,energy and chemical material costreduction, deferment of expansionsdue to more optimal operation, etc.

Motorola’s wireless and wireddata communication based RTUsprovide solutions to these and otherapplications. They can be configuredto monitor the flow in pipe linesimprove regulation of pressure usingPressure Regulated Valves, cut downon unnecessary consumption andreduce water losses. RTUs collectreal time information on reservoirlevels and pump operation andcommunicate report-by-event baseddata that helps maintain a reliablesupply and stable pressure.

Without a SCADA solution, this typeof operation would require additionalpumps, storage tanks and pressureregulating equipment.

Siren Warning Systems

Electronic sirens warn the generalpublic in cases of severe weatherconditions, civil defense air raidalerts, pollution and radiation alertsaround nuclear power plants. Toxicgas clouds might emanate fromchemical plants or hazardous wastedumps. In order to minimize thoserisks, operators require a reliablemethod for immediately alerting thepublic – wireless triggering ofmultiple sirens is the preferredmethod. Such solutions often requireredundant data communications.

ACE3600 RTUs installed at remotesites provide communicationbetween the sirens and the controlcenter and expand the usage optionsof the system. They are capable ofselecting combinations of tones orpre-recorded voice messages. Theuse of multiple control centers,which communicate with all sirensoffer advanced and flexible functionssuch as activation of sirens inselected groups, backup control,silent test, download of pre-recordedpublic warning messages as well asredundancy.

Public Safety and Fire StationAlerting

Accurate dispatch capability offire equipment and ambulances in acommunity is an importantrequirement of Emergency Servicesdepartments. This action must bedone quickly and effectively tomaximize the responsiveness to thecommunity.

A wrongly communicated addressdue to incorrect voice comprehensioncan lead to loss of life. RTUs can beprogrammed so that upon receipt ofan alert at the fire station, they turnon lights, connect the voice dispatchmessage to the building publicaddress system, open the fire stationdoors, identify the vehicles assignedto the task, and then send a messageto dispatch when all vehicles haveleft the station.

These solutions also support aComputer Aided Dispatch (CAD)interface at the Dispatch ControlCenter, which permits easy andoptimal selection of the regional firestation(s) and activation of vehiclesin each station. The Dispatch ControlCenter can also provide voice dispatchcapability and redundant two-waycommunications.

Natural Disaster WarningSystems

Governments today are acutely awareof the risk to the general publicresulting from pollution, floods,storms, mud slides, earthquakes,Tsunami events and otherenvironmental dangers. This createsa need for innovative solutions, whichhelp report the status of electronicsensors located across a wide area.

Applicable SCADA software is usedto collect and communicate criticalinformation from RTUs to the controlcenter. This data is processed andmade available to the public via radio,TV, the Internet, etc.

Thanks to its low power consumption,solar panel operation and versatilecommunications, the MOSCAD-M, isparticularly suited for this application.

Each RTU can report directly to thecontrol center or can communicate ina hierarchical fashion via ACE3600based data concentrators located atselected sites. Having such solutionsin place, improves public awarenessand upon a disaster provides quickpublic notification.

5

The wide range of SCADARTUs and communicationsolutions offered byMotorola, including theACE3600, allow Motorolaor its partners to integrateturnkey solutions withversatile control centersand interface to 3rd partysensors, IEDs and PLCunits.

The ACE3600 RTU isdesigned to allow bothhorizontal and verticalsystem expansion, whichenhances the performanceand operating reliability ofremote installations.

ACE3600 RTUs for AdvancedSCADA Solutions

At the heart of the Motorola ACE3600 technologyis its powerful processing and communicationscapability that allows powerful local processingalong with polling communicationscombined with peer-to-peer and RTU-to-host eventbased reporting.

On-site control conducted by the ACE3600 RTUcan be based on local conditions, downloadedparameters as well as system-wide conditionsusing data imported via RTUs from other sites.The protocol conversion capability of ACE3600allows integration of intelligent sensors throughEthernet, RS-232 or RS-485 ports.

The processing capability of ACE3600 providespowerful calculation and data analysis for themost critical, real-time monitoring and controlapplications. ACE3600 may emulate a numberof widely used communication protocols. Thisfacilitates gathering and analyzing data frommultiple sensors and IEDs at remote sites.

The ACE3600 RTU provides on time datatransmission to numerous locations with accessto the SCADA system via a wireless networkor an Internet/Intranet connection.

Each RTU in the network can also act asa communication node or Store & Forward(S&F) data repeater to cover a widergeographical area. This function also supportsredundant data transfer links to achieve an evenhigher level of data reliability and dead spotelimination.

ACE3600 RTU

ACE3600 CPU Module

6

The ACE3600 RTU may simultaneouslycommunicate with other RTUs, PLCs, SCADAcontrol center and IEDs via up to fivecommunication ports.

Secure RTU Operation can be ensuredby utilizing encrypted data communication.

Power Supply operation can be monitoredand controlled via the application and RTUfirmware.

The Digital Output relays are suppliedwith manually switched control lines,which permit disabling relay operation.This function can be activated during fieldmaintenance.

The RTU can be used with a Motorola-supplied high quality rechargeable back-upbattery pack or with a range of 3rd partyrechargeable batteries.

Reduced power consumption operationcan be chosen to extend RTU backupoperating time. A battery diagnostics featureis available to monitor the battery healthand remaining operating time.

All RTU modules are designed for “HotSwap”. If permitted by the application, I/Omodules can be replaced without stoppingRTU operation.

ACE3600 I/O Module

The RTU architecture is” dual-radioready”, which makes it suitable foroperating as a wireless-to-wireless orwireless-to-other data communicationmedium node.

The RTU utilizes VX-Works™ a real-timebased multitasking operating system thatmaximizes operating performance.

The RTU has up to 20 fast counters onthe 32 DI module and 16 bit analogresolution on the AI module. The AI refreshrate is 10 ms, which allows multiplecalculations to be performed quickly.

The RTU operating temperature range is- 40 to +70 C, which ensures reliableoperation under the most challengingenvironments (refer separately to radio andbattery temperature restrictions).

Cost effective RTU configuration ispossible by utilizing a configurable mix ofDI and DO, or AI and AO connections onunique mixed I/O modules.

To withstand harsh outdoor environments,the ACE3600 RTU can be integrated intoa variety of standard or customizedenclosures made from high qualitymaterials, such as painted metal, andstainless steel supplied by Motorola andother types plastic, fiberglass, etc. suppliedby 3rd party vendors.

Note: Motorola continuously addsenhanced features to the ACE3600.

7

8

STS Programming Screen

The main benefits of the STS are:

Project oriented tool - handles multiple sitesfrom a system design approach.

Integrates all SCADA related functions in asingle tool – Configuration, Setup, Programming,Debugging and Maintenance.

Provides a graphical view of system sites andthe entire network.

Automatically manages all project related files.

An inventory library of RTUs, ports and I/Omodules allows creation of new sites simply bydrag & drop operations

Setup of RTUs, ports, I/O modules can be savedin the user library for later reuse in other projects

RTU Network files are created automaticallyper project

Provides batch download of files to all sites ina single command (broadcast)

Implements Graphical User Interface (GUI)based on .NET technology

Setup: System building and setup is performedeasily by dragging RTUs, ports and I/O modulesfrom the Inventory library to the system view.

The system can also be presented in table format.Clicking on a site icon enables the following operations:

Edit site ID, site name, and site description.

Configure Ports, I/Os and other advancedparameters.

Associate files to a specific site.

Save configured items (ports, I/Os or the entireRTU configuration) to User library.

Download or Upload firmware, configuration,Date & Time, network and other associated files.

Upload RTU configuration, Data Loggers,application program source files, etc.

Perform complete hardware test.

Edit Ladder programs associated with the site.

Several RTUs can be grouped under one geographical/logical area in the system view. This permits dividingthe system view into several areas. The STS alsoenables batch file downloading to any group of RTUsin the system. The user may choose which files willbe downloaded to the RTUs in the batch download.This feature saves considerable time and effortduring new system setup or when numerous changesare made to existing configurations.

Programming: The ACE3600 application programsmay be written in "Ladder Diagram or in "C”programming language. Motorola provides a ‘C’ToolKit with comprehensive ‘C’ function library and‘C’ compiler. The STS Application Ladder Programmerenables complete RTU application programming anddebugging. The Application Manager tool enablesquick association of a Ladder Diagram and/or a ‘C’program to any RTU in the system for download.

The System Tool Suite -A Modern Tool for Programming

The System Tool Suite (STS)program is a framework fordesigning, configuring,programming andmaintaining ACE3600 basedSCADA systems. The STSprovides the systemengineer with a centralizedproject oriented intuitive toolthat enables quickimplementation of advancedSCADA projects.The combination ofACE3600's configurationflexibility and straightforwardoperation makes it a perfecttool for implementing andupgrading new and existingSCADA systems atminimum cost and withminimum effort.

9

The ACE3600 RTU is designedfor reliable, secure, versatileand easy connectivity to awide range of SCADA controlcenters offered by leadingvendors worldwide.

Motorola offers multipleinterface options to thesecontrol centers using a rangeof industry standard interfaces.

ACE3600 RTUs maysimultaneously communicatevia five ports including up tothree Ethernet ports.

Motorola SCADACommunication Solutions

LAN Interface Processor (IP Gateway)

The IP Gateway plugs into the standard LAN(Local Area Network) of your Ethernet-basedSCADA system and allows wide area connectivity.Via the IP Gateway, the control center has instantaccess to a large number of RTUs in the networkand collects up-to-date field information. A Client/Server architecture allows the IP Gateway todistribute data to multiple clients – both to oneor more SCADA control centers and to all RTUsin the field.

The Motorola IP Gateway's API (ApplicationProgramming Interface) provides easyimplementation of a driver for the SCADAapplication software. Via the API, the IP Gatewaymay seamlessly integrate with virtually any MasterControl Center (MCC) utilizing industry standardoperating systems. Several major SCADAsoftware vendors have already developed driversfor MOSCAD IP Gateway connectivity.

The IP Gateway provides interface forcommunications with field-installed ACE3600and MOSCAD RTUs.

OPC Interface Server (M-OPC)

The M-OPC uses the OPC (OLE for ProcessControl) and is based on standard MS Windowsconnectivity to a wide range of modern controlcenters. M-OPC runs on a Windows standardPC OS and makes the field data instantlyaccessible to the SCADA computer.

M-OPC manages communications with fieldinstalled Motorola RTUs and providesopportunity for SCADA system owners tomigrate to OPC.

Interface Using CPU as FIU

The ACE3600 may interface to a wide range ofMaster Control centers (MCC) utilizing MODBUSor DNP 3.0 over RS-232 or Ethernet protocols.Such MCC connectivity is established via theACE3600 CPU, acting as a Field Interface Unit(FIU).

Integrated Motorola SCADA Architecture

(*) Similar solutions apply for IEC 60870-5-101 protocol based systems

RF Network options: VHF, UHF, 800 MHz, 900MHz / Microwave / Conventional / Trunking /

Tetra / Priv DataTAC / MAS / iDEN/Canopy/Astro

SCADA Control Center

Ethernet LAN

MOSCADIP Gateway

MODBUS

3rd partyDNP 3.0 RTU

3rd partyMODBUS PLC

Ethernet Interface

RTU & Comm. Node

MOSCADDNP 3.0 RTUDNP 3.0 (*) SCADA

Central and MMIProgrammingTool

RS-232

DNP 3.0 Virtual link over MDLC

DNP 3.0

MDLC RF Network

Printer

RTU and S&F Repeater

FieldInterfaceUnit

ProgrammingTool

FieldInterfaceUnit

Intranet

MDLC Authenticated NetworkRF or Telco

Motorola's experience inSCADA systems and datacommunications providessupport for a large selectionof communication media anddata protocols.

Your SCADA system, nomatter how widely scatteredor complex, can operatethrough radio, cellular,microwave, fiber optic,dedicated or switched wire-lines, RS-232/RS-485 seriallinks, Local Area Networks(LAN) or a versatile datanetwork combining thesemedia.

Integrated SCADA Connectivity

Motorola Data Link Communication (MDLC)Protocol

The ACE3600 and MOSCAD-M RTUs support theMDLC data communications protocol that deliversmajor benefits especially for wireless-based SCADAsystems. Its seven-layer, OSI/ISO compatible structuredelivers powerful network communication functions.

RTUs can connect directly to VHF, UHF, 800/900MHz, trunked and conventional radios, PrivateDataTAC modems, Motorola ASTRO analog and digitalnetworks, iDEN, TETRA, GSM/GPRS, dial-up ATmodems, MAS (Multiple Address System) data radiosusing dual or single frequency, or 900 MHz and 2400MHz Spread Spectrum radios, Wi-Fi media, 5.3 GHz,900 MHz and 2.4 GHz Motorola Canopy, MotorolaMESH products, broadband, etc.

These communication devices interface to the RTUvia serial link or direct Ethernet connection. TheACE3600 RTU may communicate with other vendors'PLCs (Programmable Logic Controllers), IEDs andRTUs, using DNP 3.0, MODBUS, Allen Bradley DF/1and other industry accepted protocols.

10

SCADA Communications Network

Motorola RTUs can be equipped for directconnection to your Corporate Intranet LAN, ifavailable at the remote sites. This allows directhigh-speed messaging by reusing an existingcommunication infrastructure investment.

Using the advanced features embedded withinthe ACE3600 RTU such as remote diagnostics,application program and parameteruploading/downloading, and transmission of time-tagged messages result in significantenhancement of the monitoring and controlcapabilities of your SCADA system.

The MDLC protocol supports:

Integrated networks with a mixture of wire-line,LAN and a wide range of wireless synchronousand asynchronous communication links.

Remote control of customer sites utilizingpolling communications, Report-by-Exception andReport-by-Event messages.

RTU-to-RTU (peer-to-peer) communications,as well as RTU communications to multiplehierarchically structured control centers.

Multi-session communications, allowingexecution of simultaneous operations such asStore & Forward (S&F) and routing of data usingRTUs as routing nodes in the network.

Accurate network-wide time synchronizationvia a range of physical and wireless networks,allowing reporting of time-stamped events with1 ms resolution.

Sattelite

Backup RF link

Backup link

LAN

MW

MW

Comm. nodeand S&F

MW

Comm. node Comm. nodeand S&F

S&F

11

Migrating from MOSCAD to ACE3600

MOSCAD-M RTU

MOSCAD RTU

The modular design of ACE3600 provides built-in intelligence and powerful communications thatallows making on-site decisions based on localconditions, downloaded parameters as well assystem-wide conditions using data imported fromACE3600 or MOSCAD RTUs at other sites.

The modularity of ACE3600 with a large selectionof Input/Output modules allows you to configureeach remote site cost effectively. Protocolconversion code loaded into the ACE3600 CPUallows integration of new and existing intelligentsensors through Ethernet, RS-232 or RS-485serial ports.

A range of standard backplanes and enclosuresis available for three, five and seven module sizes,and for a 19'' rack-mount basic frame that accepts8 ACE3600 modules.

The capability of ACE3600 systems canbe significantly improved by direct LANconnection, if available at the remote site.This option allows seamless interface over IPto the SCADA control center as well as othernetworks using the built-in Ethernet connection.

Motorola and its VARs/partners havesupplied thousands of turnkeysolutions with ACE3600 RTUs andMOSCAD family of RTUs, connectedwith versatile control centers, 3rd partysmart sensors and IEDs.

Using the MDLC protocol, newlyinstalled ACE3600 RTUs can beintegrated side by side with existingMOSCAD family RTUs into a singlesystem.

The powerful communicationcapabilities of ACE3600 RTUs enhancethe networking capability, performanceand operating reliability and securityof remote installations. Applicationprogramming for these RTUs can beimplemented using Ladder Diagramor C language.

Using the STS tool, applicationprograms developed for the MOSCADfamily of RTUs can be ported to theACE3600 RTU.

MOSCAD-M is the smallest member of theMotorola RTU family and also uses the MDLCprotocol. The small size enables MOSCAD-Mto be placed in space-restricted locations andinside equipment provided by others.

MOSCAD-M RTUs feature ApplicationOriented Power Management capability thatallows integrating optimal solution for batteryoperated sites.

MOSCAD-M’s I/O capability is sufficient forsmall size SCADA installations and its lowpower consumption makes it ideal for solar-powered sites. Communications by internalor external radio or wire-line modem isavailable. SCADA systems may comprise onlyMOSCAD-M RTUs or may be combined in asystem with ACE3600 RTUs.

Note: The MOSCAD and MOSCAD-L familyof RTUs will not be available for new systemsafter January, 2008. Current users may obtainreplacement MOSCAD and MOSCAD-Lmodules through 2012 only for fieldreplacement.

MOSCAD-L RTU

ACE3600 RTUIntegrated System with ACE3600and MOSCAD family of RTUs

CTH Systems IncCalgary Office#130, 6807 Railway St SECalgary, Alberta T2H 2V6

Phone: (403) 292-0650Fax: (403) 292-0652

CTH Systems IncVancouver Office

Phone: (604) 999-1470Fax: (604) 277-9257

www.cthsystems.com