Brodersen RTU32M

• Modular RTU with or without integrated I/O and communication device.
• Real-Time Linux Operating System.
• KEMA Certified Communication Protocols include (>20 available):
• Full Modbus Suite.
• IEC60870-5-101/103/104
• IEC61850 Client / Server Protocol
• (GOOSE compliant)
• DNP3 Master & Slave.
• OPC UA
• Binding – Global Distribution and Subscription of Event-Based Time Stamped Variables.
• Communication Protocols can also be created as part of the logic application interface.
• Communication interfaces: 2 x Ethernet 10/100, 1x USB are featured on the CPU module.
• Full EN/IEC61131 PLC runtime – also used for special and flexible data manipulation.
• Includes power supply monitoring of the RTU32M supply voltage and temperature.
• Support for redundant power supplies and CPUs.
• Hot-swappable I/O.
• Full remote management with configuration, programming, and flexible distribution of all levels of software from and to RTUs in remote locations.

TYPE 1 CPU SPEED

• The CPU module speed is managed via the RTU performance license options:
• DL-200MHZ-RL (Default) 200MHz
• DL-500MHZ-RL 500MHz
• DL-900MHZ-RL 900MHz

TYPE 1 RAM SIZE

• DL-128MB-RL (Default) 128MB
• DL-256MB-RL 256MB

TYPE 2 CPU SPEED

• The CPU module speed is managed via the RTU performance license options: DL-2GHZ-RL 2GHz

TYPE 2 RAM SIZE

• DL-1GB-RL 1GB

RUNTIME TYPE 1 & 2 CPU

• Typical cycle time 1msec
• Scan time LB2 I/O 0.5msec

Figure 1: Self-discovering I/O

Figure 2: Discovered I/O

TYPE 1 CPU HARDWARE

• CPU: ARM Cortex – A7
• Freescale i.MX6, 200-900 MHz
• Memory: RAM: 128-256MB SDRAM
• NAND Flash: 128MB
• NVRAM/FRAM: 128KB
• Micro SD Card Flash disc – removable
• RTC: Integrated and supercapacitor backed
• RealTimeClock with 1 msec resolution 10 ppm
• Interfaces: LAN: 2x 10/100Mbps RJ45
• 1 x USB 2.0 Host.

TYPE 2 CPU HARDWARE

• CPU: ARM Cortex – A53
• Freescale i.MX 8M Plus
• Quad-Core, 2 GHz
• Real-time
• Co-processor: 800MHz Cortex-M7
• DMIPS: 16,560
• Memory: RAM: 1GB SDRAM
• NAND Flash: 8GB
• NVRAM/FRAM: 128KB
• Micro SD Card Flash disc – removable
• RTC: Integrated and supercapacitor backed
• RealTimeClock with 1 msec resolution 10 ppm
• Interfaces: LAN: 2x 10/100/1000 Mbps RJ45
• 1 x USB 2.0 Host.

ELECTRICAL

• Power consumption (from backplane bus):
  – Current consumption: 200mA (typ.) @ 12V
  – Power consumption: 2.4W (typ.)
• Separated/Safe Extra Low Voltage (SELV) limits:
  – VAC (RMS) 30V
  – VAC (Peak) 42.4V
  – VDC 60V

MECHANICAL

• Mounting DIN 35
• Width 24 mm
• Height 111.5 mm
• Depth 94.5 mm
• Weight 102 grams

ENVIRONMENTAL CONDITIONS

• Ambient operating temperature range -25°C to +75°C
• Ambient storage temperature range -40°C to +85°C
• Marked degree of protection IP20
• Humidity 0…99.8%
• Ventilation Restrictions No
• Pollution degree 2

STANDARDS

EMC:

• IEC 61000-6-2: EMC – Immunity standard for industrial environments
• IEC 61000-6-4: EMC – Emission standard for industrial environments
• IEC 50121-4: Railway applications
• EMC – Emission and immunity of the signaling and telecommunications apparatus
• IEC 60950-1: Safety requirements for Information Technology equipment
• IEC 61010-1: Safety requirements for electrical equipment for measurement, control, and laboratory use.

Environmental:

• IEC 60068-2-1: Environmental testing – Cold
• IEC 60068-2-2: Environmental testing – Dry heat
• IEC 60068-2-30: Environmental testing – Damp heat, cyclic (12 h + 12 h cycle)
• IEC 60068-2-78: Environmental testing – Damp heat, steady state
• IEC 60068-2-6: Environmental testing – Vibration (sinusoidal)
• IEC 60068-2-27: Environmental testing – Shock

SAFETY PRECAUTIONS

• Follow the national safety regulation (IEC 61010-1).
• Only skilled personnel are to install and operate the modules.
• Modules can only be mounted in an end-use enclosure which provides protection against fire, electrical and mechanical hazards.
• If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

Data Sheets

• RTU32M_Datasheet
• RTU32M&N_MTBF
• Communication module datasheet
• I/O modules datasheet

Manuals & Guides

• RTU32 User Guide
• IO Module User Manual
• Online configurator
• Redundancy User Guide
• SIL-2 Guide RTU32M
• IEC 62351 understands what it is
• Remote IO

APP Notes

• App-note HTML5

Drivers

• EN/IEC60870 Configurator User Guide
• RTU32/IEC61850 Server Presentation
• RTU32/IEC61850 Client Presentation
• RTU32/EN/IEC60870 Presentation
  
• RTU32 IEC60870-5-101 Interoperability doc
• RTU32 IEC60870-5-104 Interoperability doc
• RTU32 DNP3 Slave Device Profile
• OPC UA User Guide
• Getting started with 61850 Client

Brochure

• RTU32M Sales Brochure
• Remote IO

Certificates

• CE Declaration RTU32M
• IEC61850 Client KEMA
• IEC61850 Server KEMA
• IEC60870 KEMA
• ISO 9001-2015
• ACHILLES UVDB
• EN IEC 61000-6-2 EN IEC 61000-6-4 EN50121-4  EN 50121-4:2016/A1:2019
• E N61000-6-5:2015, EN60255-26:2013, EN 55011:2016, EN55032:2015
• EN 60068 Vibration
• EN 60068 Climate

Software Download

Brodersen Worksuite (download free trial limited to 40 I/O)

Worksuite Installer

Code Generator Download

Test Tool for 60870-5-104, 101, 104. Simulate SCADA and get to commissioning with a tested solution. Get a password from sales. The test tool is not free. Our engineers have spent time on it, so you can free up yours.

60870 Test Tool Download

RTU32M – with advanced PLC functionality suitable for plant applications:

• Secure local and remote access to configuration and diagnostics
• Small footprint, high density modular I/O
• Failsafe, hot swap, smart I/O
• Online logic changes (including application restart with outputs held)
• Distributed I/O (segmented bus)
• Remote I/O (serial and LAN based I/O – remote CPUs have no logic app or options)
• Redundancy options (multiple power supplies, CPUs, I/O, LANs etc)
• Global variable ‘binding’ allows fast setup of a single plant wide logic application
• Future proof (option to include logic/smarts in the remote RTUs, when needs change)
• Modern platform, ensuring longevity and continued development of functionality (including new module types).

Most RTUs are well suited for remote site applications (typically <200 I/O)

In the past – when asked to highlight the differences and benefits of using an RTU versus a PLC, the benefits of using RTUs focused on I/O isolation and SCADA protocols that are not well supported by PLCs, such as IEC60870, IEC61850 and DNP3.  These protocols allow for prioritisation of data, logging of time stamped events, inclusion of data quality and described data formats, hence they are well suited for wide area SCADA systems with geographically dispersed remote sites.  As the majority of the remote sites had <200 I/O, physical size and management of distributed I/O did not need to be considered – so the I/O isolation and protocol functionality was enough to make the RTU the best choice.

Not all RTUs suit plant applications (typically >200 distributed/remote I/O)

Plant applications have large amounts of I/O that need to be distributed remotely because of the various separated areas that form the plant.  The physical size of the I/O is important, but the remote I/O must also be managed by the primary/central PLC/RTU ie. as an extension of its own physical I/O.

Online RTU Configurator – Design what you need!

Our RTU Configurator  allows creation of different RTU setups.  Add power supplies, CPU, I/O and comms modules to create appropriate RTU layouts.

It’s a bit different to a ‘stacking bricks’ TETRIS game, but still fun!

Large RTUs and Distributed I/O (expansion I/O using the RTU IO Bus)

Each RTU32M supports up to 60 I/O modules.  The overall backplane bus length can be up to 40m (assuming that appropriate bus cables are used).

Plant solutions need local and remote I/O to be managed in a single application

Most plant applications have a combination of distributed and remote I/O.  An important consideration is management of the remote I/O.  It is much easier to manage the plant automation in a single/central logic application if the remote I/O is ‘connected’ by a background process that ensures remote I/O is referenced in the same way as local I/O.  This also avoids needing logic applications in the remote I/O sites.

Build it and they will come …

It is very tempting to completely fill a test rack with hundreds of RTU modules – just because we can!

Instead, we loaded it with four RTUs to represent the main plant and 3x remote area locations of the example plant application shown below.

Objective – prove one logic application can manage all I/O!

WorkSuite – managing the setup of multiple I/O locations

The Brodersen WorkSuite software makes it easy to setup and manage the sites.  Each site has a ‘project’ that is listed in a common Workspace area as shown below eg. ‘IO Boxes 1-3’ and the ‘IO Box Master’.

The Global Binding Editor – mapping tables make association of remote I/O easy…

The Global Binding Editor allows the association of tags from the various projects in the Workspace to be made by dragging variables in to a table.

Communications between sites then occurs if any of the producer data values change (without needing to setup logic or comms tasks to send/poll data).

An initial ‘proof of concept’ setup example.

Before creating a more complex solution, first look at the simple example below.  Here a few input points from each location are ‘produced’ and sent on change to remote consumer output points.

Note: this simple example is moving ‘physical I/O’ ie. AI and DI values from one site to AO and DO values at another site.

In most plant applications the primary function of the binding protocol is to allow the master to have an image of all remote variables (updates to input images are received from the remote site – writing to an output image sends an update to the remote site).  The variables associated to/from the remote sites can be any variable type (not just physical I/O).

The Global Binding Editor – link and point information, tag debounce/hysteresis

Each communications link reports its connection status and each point has additional status fields that include error status and date and time stamps.  Each point also has a hysteresis option to manage debounce and significant change (minimises excessive event reporting).

Back to the example plant application…

The Master RTU has ~90 of its local I/O variables and ~130 remote I/O variables (‘tags of interest’) mapped from/to the remote sites.  The logic application interacts with the master list of variables (local/remote I/O).

Note: the master has an additional 98 local I/O tags associated to its own physical I/O.

Plant Application – the Binding Editor maps variables from/to the remote sites

The Binding Editor adds a column for each site.  The first column holds producer variables.  In the example plant application, each remote site produces its physical inputs, as listed below.

In the example plant application, the master produces its images of the remote physical outputs, as listed below.

 Plant Application – proving that it works

A selection of local and remote I/O variables have been mapped to a simple pump controller application to demonstrate/prove the concept.

Get on the Brodersen Bus – local and remote I/O solutions!