industrial communications gateway

INDUSTRIAL COMMUNICATIONS
GATEWAY
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iCG5125 is a multi-functional
communications gateway/controller
suitable for Industrial Automation
applications. iCG5125 offers multiple serial
and Ethernet ports for connecting to
SCADA/HMI systems and field devices (IEDs),
along with a rich set of communication protocols.
Substation
Automation
System Gateway
iCG5125 provides data concentrator function
(aggregation of data from multiple sources) and
protocol conversion function (converting data acquired
on one protocol format and transfer of the same on
another protocol). A single unit of iCG5125 can handle
multiple devices providing a common and consistent
interface to SCADA/HMI centers.
Protocol Converter /
Data Concentrator
IEC 101 ó
IEC 104
Router
M2M Gateway
Serial Device Server
Apart from these functions, the iCG can also be deployed
as a substation gateway, SCADA communications frontend, terminal server (serial device server), and M2M
gateway.
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SCADA
Communications
Front-End
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PRODUCT HIGHLIGHTS
HARDWARE SPECIFICATIONS
Core
Physical Characteristics
19”-wide, 1U-high rack mount chassis
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Operating Temperature – 0 – 70 C
Humidity – 95% RH
400MHz 32-bit RISC Processor
128MB RAM (Optional 256MB)
128MB Flash (Optional 1GB)
1MB NVRAM
Input Power
The iCG has two options for connecting the input
power. The AC input option allows connecting
230VAC source to the unit. The DC input allows
connecting 18-60VDC source. This option is
suitable for remote sites where typically
24V/48VDC battery systems exist.
Communications
8/16x RS232/RS485 Ports
Surge Protected, Isolated
RS232 Tri-state Option for fallback
switch function
2x 10/100Mbps Ethernet Ports
2x 10/100Mbps Ethernet Switch (1x MAC)
with ring (daisy-chain) function
Surge Protected, Isolated
IEEE 1588v2 (PTP) Support
The unit allows installation of two power supply
modules for redundant/parallel operation for use
in critical or high availability applications. This
feature is available as a factory-fitted option.
A potential free NO contact (24/48VDC @ 0.1A)
is provided for power supply failure indication.
Redundancy
Main Board
Two units can be linked in hot-standby
configuration
The iCG is powered by a low-power 32-bit RISC
processor operating @ 400MHz. Standard
configuration provides 128MB RAM, 128MB flash
for non-volatile storage, 1MB NVRAM for storage
of event records, counters, etc.
Clock
1ppm Real-time Clock
Optional Integrated GPS Receiver
1PPS/1PPM input
1PPS output
The flash memory on the unit is used for storage
of configuration files, log files, disturbance records,
metering profiles, etc.
The NVRAM is backed up by a 3V coin-cell,
which provides retentive storage of events,
counters, etc., in case of loss of input power.
Miscellaneous
2x Add-on Module slots
2 line LCD Character Display (Optional)
2x general purpose inputs (24/48VDC)
1x general purpose output (24/48VDC)
Real-time Clock (RTC)
A real-time clock of 1ppm accuracy is provided
on board for maintaining the calendar date-time
of the unit. This RTC can be synchronized with
multiple time sources.
Power
18-60VDC Input Power
230VAC Input Power (Optional)
Redundant Power Supplies (Optional)
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As a factory-fitted option, the unit can be
equipped with a GPS receiver for providing an
accurate source of time. When this option is
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installed, the unit can also provide 1PPS pulse
output to synchronize external devices.
For fault-tolerant applications, two iCG units
can be networked over this expansion bus in
hot-standby configuration.
Serial Interfaces
Additionally, HUSKY RTU 6049-E70 I/O racks
can be connected to the iCG unit on this
expansion bus for providing local/distributed
I/O. The I/O racks can be placed in the field
equipment bays/kiosks and connected with the
iCG unit over a fiber-optic link.
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Up to sixteen Serial Ports
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RS232 (TX, RX, RTS, CTS). Two ports
support modem signals (DCD, DSR, DTR)
also through jumper selection
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RS232 Transmitter tri-state option allows
connecting two RS232 serial ports together
as fall-back switch arrangement
Add-on Modules
Two add-on modules slots are provided on the
iCG, which can be used for providing additional
interfaces –
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2-wire RS485
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RJ45 connector with Tx/Rx LED indicators
?
2.5kV Isolation
?
2-port 100FX Fiber-optic Ethernet
?
Surge-Protected as per IEC 60870-2-1 Level 4
?
4-port 10/100 Ethernet Switch
?
2-port 10/100/1000 Ethernet
Ethernet Interfaces
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2-port Fiber-optic serial ports (Rx/Tx)
?
Four built-in 10/100 Ethernet Ports
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1-port Fiber-optic LON Interface
?
Three independent MAC Addresses
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I/O Module – 16-channel Digital Input +
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One two-port switch with Rapid Spanning
6-channel Digital Output + 4-channel
Analog Input + 1-channel Analog Output
Tree Protocol (RSTP) for daisy-chained or
dual-homed topologies
?
IEEE1588 (PTP) v2 Support
Miscellaneous
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RJ45 connector with Link+Activity/Speed LED
The iCG optionally provides a 2-line, 20character wide LCD display. This display can
be used for monitoring the unit status and
other vital information (IP Address, Unit
Address, etc.).
indicators
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Optical Fiber-ports through add-on modules
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1.5kV Isolation
?
Surge-Protected as per IEC 60870-2-1 Level 4
The iCG also provides a watchdog NO contact
(24/48VDC @ 0.1A) which can be connected to
an external system (e.g., annunciation panel) for
monitoring the health of the iCG unit.
Expansion Capability (Optional)
The iCG architecture provides for expandability
of the system, by inter-networking multiple
units. This is achieved through a dedicated
high-speed bus on the unit, based on industrystandard ARCNet protocol. This bus is available
in both RS485 as well as fiber-optic
(POF/HCS) versions.
Two general purpose inputs capable of
sensing 24/48VDC externally wetted contacts
are provided which can be used for
implementing custom logics. One general
purpose NO contact (24/48VDC @ 0.1A) is
also provided, which can be activated
through user-defined logics.
For applications where the number of
interfaces required is more than what is
offered by a single unit, multiple units can be
daisy-chained together.
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SOFTWARE FUNCTIONS
Core
the existing infrastructure, and thereby leading
to lesser system downtime, and preserving the
existing investment.
iCG5125 employs a pre-emptive real-time
operating system (RTOS) for providing reliable
and time-critical performance. The RTOS has
been specifically customized to take advantage
of the special features/enhancements
provided by the hardware.
Gateway / Protocol
Converter / Data
Concentrator Function
Router Function
In some applications, a change/upgrade
in the control center
IEC 870-5-101 system or
Link Layer
communication
Management
network requires
IEC 870-5-101
Slave
IEC 870-5
ASDUs
Typically in an existing
application, a variety of devices
exist that operate on different and
possibly proprietary protocols. In such
cases, there is a general need to
collate data from these devices and
convert them to a standard protocol
that a higher order system supports.
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IEC 870-5-104
APCI Layer
iCG5125 with
IEC104-IEC101 Router Function
IEC 870-5-104
Master
The iCG provides this function using the
wide array of protocols that it supports
for interfacing with different devices
for data acquisition and control
requirements. The iCG
therefore allows existing
TELECOM
older generation
NETWORK
systems to be easily
migration to a new protocol for
communication between the field devices
and a control center system. Often,
such a change requires reconfiguration/
replacement of field devices to
accommodate this change. Typical
example of such a scenario is where
older systems operating on IEC 870-5101 or DNP3.0 Serial protocol need to
be upgraded to IEC 870-5-104 or
DNP3.0 LAN/WAN protocol.
CONTROL
CENTRE
IEC 870-5-10x
DNP 3.0
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Data Concentrator
The router function of the
iCG allows this
migration to be easily
MFT
IEC
870-5-103
implemented without
NUMERICAL
Auxiliary
RELAY
Plant I/O
MFT
requiring any change in
BCU
BPCU
TMU
BCU
NUMERICAL
the existing field devices.
RELAY
This feature of the iCG
IEC 61850 / IEC 870-5-10x / LON / SPA
NUMERICAL
automatically
and
RELAY
transparently handles the
differences
in the two protocols,
interfaced with newer generation systems
without using any intermediate data buffers.
without incurring the cost of replacement of
MFT
MODBUS
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M2M Gateway Function
The iCG can also be used an M2M (Machine
-2- Machine Communications) gateway. In this
case, the M2M communications is normally
achieved in conjunction with Synergy Systems &
Solutions’ Secure Wireless Gateways (SWG).
Alternatively, RFC2217 (Telnet Com Port Control
Option) is also supported which allows any
RFC2217-compliant host system application to
access and manage the serial ports of the
iCG unit.
The iCG when acting as an M2M gateway is
typically connected to the Internet via a highspeed link (ADSL Broadband, etc.), and the
SWGs connect to this gateway through wireless
networks like 2G/3G/CDMA.
Time Synchronization
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Internet
(ISP)
Broadband
Router
SWG
RS-232 / Ethernet
iCG supports time synchronization of its own
RTC from multiple sources. The iCG has also
support for IEEE1588 ordinary clock, which
allows its RTC to be synchronized to a highly
accurate external clock.
Optionally, a GPS receiver
can be installed as a time
reference for the unit.
M2M Gateway
at Central Location
The iCG can also synchronize
other devices over their
communication protocols. When fitted
with a GPS receiver, SNTP server support
is also available.
GPRS / EDGE
(NSP)
I/O Device
SWG
Cyber Security
Central Server
With the proliferation of public communication
networks like Internet, GPRS, etc. in SCADA
applications, many IEDs are now directly
connected to these networks. Therefore securing
these devices is a major requirement in order to
prevent cyber attacks which compromise the
entire application being controlled by the SCADA
system.
RS-232 / Ethernet
I/O Device
The M2M gateway and SWG combined
together offer a secure and transparent
channel between the control center and field
devices over a public wireless network.
iCG can deployed as an electronic security
perimeter (ESP) that acts like a firewall between the
public networks and the IEDs. The iCG provides
the following functions to achieve a cyber-secure
network –
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Firewall that allows only specific hosts to connect
with the gateway
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Audit Logs for user actions, connection attempts,
connection denials, etc.
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SSL/TLS encrypted communications
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Secure Execution Environment which prevents
execution of malware or third-party applications
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Authenticated pass-through channels
Serial Device Server Function
For applications where multiple serial devices
are required to be connected to a host
system, the iCG can provide such connectivity
with serial devices over Ethernet.
The iCG supports TCP server mode where
each serial port on the unit is assigned a
unique IP:Port combination. The host system
makes a TCP connection to this address and
communicates with the serial device(s)
connected on that serial port using this TCP
channel.
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ORDERING INFORMATION
Data Logging
Data logging function is provided in iCG for
storage of events and analog measurements in a
time-stamped manner for future retrieval.
Measurements can be logged on cyclical or
exception basis in the logs.
Field
1
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Further, logging function also provides support for
storage and retrieval of disturbance logs, and
metering profiles acquired by the protocol tasks
running inside iCG.
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These logs can be acquired by an external system
either through the configuration and diagnostics
tool, or over a protocol that supports file transfer
mechanism.
Logic Programming
iCG also provides a ladder-logic based
programming environment for implementing
custom logics like conversions, interlocks, etc.
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Configuration & Diagnostics
TM
The iCG is configured using a Windows based configuration tool. The tool supports
configuration of protocol parameters, mapping
of variables between protocols, and iCG
hardware parameters.
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The same tool can also be used to check the
status of various modules functioning inside the
iCG, as well to monitor status of different
hardware elements.
Ordering Info
Base Model (128MB RAM, 128MB Flash)
Enhanced Model (256MB RAM, 1GB Flash)
Eight RS232/RS485 Serial Ports
Sixteen RS232/RS485 Serial Ports
PSU1 - AC Input Power
PSU1 - 18-60V DC Input Power
PSU2 - AC Input Power
PSU2 - 18-60V DC Input Power
PSU2 - None
GPS Receiver
LCD Character Display
Expansion Option
Add on Module #1
None
2-port 100FX Fiber-optic Ethernet
4-port 10/100 Ethernet Switch
2-port 10/100/1000 Ethernet
2-port Fiber-optic serial ports (Rx/Tx)
1-port Fiber-optic LON Interface
I/O Module - 16x DI, 6x DO, 4x AI,
1x AO (Occupies both slots)
Add on Module #2
None
2-port 100FX Fiber-optic Ethernet
4-port 10/100 Ethernet Switch
2-port 10/100/1000 Ethernet
2-port Fiber-optic serial ports (Rx/Tx)
1-port Fiber-optic LON Interface
Software Options
Protocol Converter / Data Concentrator
IEC104<->IEC101 Router
M2M Gateway
Serial Device Server
Protocol Options (include all required options)
IEC 870-5-101 Master
IEC 870-5-101 Slave
IEC 870-5-103 Master
IEC 870-5-104 Client
IEC 870-5-104 Server
IEC 61850-8-1 Client
DNP 3.0 Master/Client
DNP 3.0 Slave/Server
SPA Bus Master
RP-570 Master
Proteus 2000 Master
Proteus 2000 Slave
EQUINODE Master
EQUINODE Slave
SPORT Slave
Synergy Systems & Solutions
A-1526, Green Fields Colony, Faridabad - 121001, India
Phone : +91-129-2510501, 2, 3 Fax : +91-129-2510399
Email : sales@s3india.com
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