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Document Number: ECP 11-0535 Version: 2.0 Date: 06/10/2016 THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE ENGINEERING COMMISSIONING PROCEDURE ECP 11-0535 LUCY GEMINI 3 TYPE E RTU COMMISSIONING PROCEDURE Network(s): EPN, LPN, SPN Summary: This procedure details the installation, testing and commissioning procedures for the Lucy Gemini 3 control unit connected to a UK Power Networks specification RTU, and old LPN specification RMU and an old EPN/SPN specification Lucy RMU, including the configuration of the remote terminal unit and communications Author: James Ford Date: 06/10/2016 Approved By: Paul Williams Approved Date: 01/11/2016 This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue. Applicable To UK Power Networks External All UK Power Networks G81 Website Asset Management Contractors Capital Programme ICPs/IDNOs Connections Meter Operators HSS&TT Network Operations UK Power Networks Services Other

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Page 1: ECP 11-0535 Lucy Gemini 3 Type E RTU …library.ukpowernetworks.co.uk/library/en/g81/Testing_and...5.5 The Gemini 3 uses the DNP3 IP protocol to provide communication with Power-On

Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

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ENGINEERING COMMISSIONING PROCEDURE

ECP 11-0535

LUCY GEMINI 3 TYPE E RTU COMMISSIONING PROCEDURE

Network(s): EPN, LPN, SPN

Summary: This procedure details the installation, testing and commissioning procedures for the Lucy Gemini 3 control unit connected to a UK Power Networks specification RTU, and old LPN specification RMU and an old EPN/SPN specification Lucy RMU, including the configuration of the remote terminal unit and communications

Author: James Ford Date: 06/10/2016

Approved By: Paul Williams Approved Date: 01/11/2016

This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue.

Applicable To

UK Power Networks External

All UK Power Networks G81 Website

Asset Management Contractors

Capital Programme ICPs/IDNOs

Connections Meter Operators

HSS&TT

Network Operations

UK Power Networks Services

Other

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

© UK Power Networks 2017 All rights reserved 2 of 64

Revision Record

Version 2.0 Review Date 01/11/2021

Date 06/10/2016 Author James Ford

Reason for update: First year review

What has changed: updated to include UKPN spec RMUs

Version 1.0 Review Date 24/12/2016

Date 24/11/2015 Author James Ford

Original

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

© UK Power Networks 2017 All rights reserved 3 of 64

Contents

1 Introduction ............................................................................................................. 6

2 Scope ....................................................................................................................... 6

3 References ............................................................................................................... 7

4 Definitions ................................................................................................................ 7

5 Description............................................................................................................... 8

6 Equipment .............................................................................................................. 10

7 Inspection .............................................................................................................. 10

8 RTU Installation ..................................................................................................... 12

9 RTU Additional Items Installation ......................................................................... 15

10 Gemini 3 Configuration ......................................................................................... 35

11 Local Commissioning Checks .............................................................................. 44

12 Power-On Commissioning of Controls, Alarms and Indications ....................... 49

13 On-Load Tests ....................................................................................................... 51

14 Final Checks .......................................................................................................... 51

15 Asset Data .............................................................................................................. 51

16 Test Equipment ..................................................................................................... 51

17 Certification ........................................................................................................... 51

Appendix A – RTU Software Update ................................................................................ 52

Appendix B – Status Information Screens ...................................................................... 56

B.1 Communications Monitor ......................................................................................... 56

Appendix C – Configuration Cable .................................................................................. 57

C.1 Configuration Cable ................................................................................................. 57

Appendix D –RMU Wiring Modification for LPN Specification Schneider RMUs .......... 58

Appendix E –Schneider Power Meter PM710 / PM5100 Comms Configuration ............ 60

Appendix F – Lucy Power Meter Comms Configuration ................................................ 63

Appendix G – EPN/SPN Spec Schneider RMU Adaptor Cable ....................................... 64

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

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Date: 06/10/2016

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Figures

Figure 1 – Gemini 3 RTU Cabinet Layout .............................................................................. 8

Figure 2 – Switch 1 and Switch 2 FPI CT Connections ........................................................ 9

Figure 3 – Sockets on Underside of RTU ............................................................................ 10

Figure 4 Unistrut Mounting Frame (brick substation) ........................................................... 12

Figure 5 RTU Cabinet Mounting Adaptors ........................................................................... 12

Figure 6 Hanging RTU onto Mounting Frame ...................................................................... 12

Figure 7 Unistrut Mounting Frame (GRP substation) ........................................................... 13

Figure 8 RTU Cabinet Mounting Adaptors ........................................................................... 13

Figure 9 Hanging RTU onto Mounting Frame ...................................................................... 13

Figure 10 – 1 x RMU and 1 x ACB Cable Connection Example ......................................... 16

Figure 11 – 2 x RMU Cable Connection Example .............................................................. 16

Figure 12 – LPN Retrofit Adaptor Box ................................................................................ 17

Figure 13 – 1 x RMU and 1 x ACB Cable Connection Example ......................................... 18

Figure 14 – 2 x RMU Cable Connection Example .............................................................. 19

Figure 15 – LPN Retrofit Adaptor Box Connections and Wiring Schedule .......................... 19

Figure 16 – LPN Spec RMU Plugs ..................................................................................... 20

Figure 17 – Umbilical Plug Polarising Pin Holes ................................................................. 23

Figure 18 – LV Cabinet Power Meter ................................................................................. 24

Figure 19 – LV Cabinet Power Meter Connection Terminals .............................................. 24

Figure 20 – External Power Meter and RJ45 Umbilical Cable ............................................ 26

Figure 21 – Power Meter and LV Cabinet Connections ...................................................... 26

Figure 22 – Power Meter Installation .................................................................................. 28

Figure 23 – CT/VT Connection ........................................................................................... 28

Figure 24 – CT/VT and Power Meter Connections .............................................................. 29

Figure 25 – Auxiliary I/O Box ............................................................................................... 31

Figure 26 – RJ45 Adaptor Box ........................................................................................... 32

Figure 27 – Comms Device DIN Rail Installation ................................................................ 33

Figure 28 – Comms Device Installed (DIGI WR21 3G/4G router shown) ............................ 34

Figure 29 – RTU configuration tool log in ............................................................................ 35

Figure 30 – Config and Software version number ............................................................... 36

Figure 31 – RTU Configuration Page .................................................................................. 37

Figure 32 – Starting Commissioning Wizard ....................................................................... 38

Figure 33 – Commissioning Wizard start page .................................................................... 39

Figure 34 – Commissioning Wizard switch setup page ....................................................... 39

Figure 35 – FPI ................................................................................................................... 40

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Figure 36 – FPI Settings Page ............................................................................................ 41

Figure 37 – Comms Type/Area Selection ............................................................................ 42

Figure 38 – Modbus Connected Devices............................................................................. 42

Figure 39 – Main Control Module (MCM) ........................................................................... 44

Figure 40 – Human Machine Interface (HMI) ..................................................................... 44

Figure 41 – Dual Switch Module (DSM) ............................................................................. 45

Tables

Table 1 – RJ45 umbilical termination in LV Cabinet ............................................................ 25

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

© UK Power Networks 2017 All rights reserved 6 of 64

1 Introduction

1.1 This procedure details the testing and commissioning procedures for the Lucy Gemini 3 control unit connected to UKPN spec RMUs and an old LPN specification RMU and an old EPN/SPN specification Lucy RMU, including the configuration of the remote terminal unit (RTU) and communications. These tests shall be satisfied before the unit can be accepted as fit for service.

1.2 The substation and RTU should be built on Power-On in advance of any RTU testing or commissioning being carried out.

1.3 The RTU/RMU should be fully tested and commissioned from Power-On to the RMU (except for analogues) before the RMU is made live.

1.4 If an old LPN specification Schneider RMU is to be used (this will be connected using the LPN Retrofit Adaptor Box), a wiring modification as detailed in Appendix D is required.

1.5 This procedure shall be carried out by the Commissioning Engineer or their appointed representative, who shall be an Authorised Person having appropriate training and experience.

1.6 This procedure shall be carried out in accordance with the requirements of the Distribution Safety Rules.

1.7 This procedure shall be carried out having regard to the requirements and recommendations of the manufacturer. If conflict exists between the requirements of the manufacturer and those of UK Power Networks the matter shall be referred to Asset Management.

1.8 This procedure assumes that the unit has been installed in accordance with the appropriate procedures and that each circuit to be tested is isolated from the network.

1.9 The results of all observations, tests, adjustments and all relevant remarks shall be recorded on the associated test form.

2 Scope

2.1 This procedure and the associated test form apply to the Lucy Gemini 3 control unit. The Gemini 3 is used to provide remote control of all UK Power Networks approved secondary switchgear.

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3 References

3.1 This procedure shall be read in conjunction with the following references:

UK Power Networks Distribution Safety Rules.

EOS 05-9305 – Lucy Gemini 3 Control Unit and RTU.

Lucy Gemini 3 RTU Installation, Operation and Maintenance User Manual.

EDS 05-9005 - RTU Type E Ground Mounted Switchgear Interface.

EAS 05-9017 - Type E RTU Ancillary Items (Lucy Electric).

3.2 This procedure shall be used with the following procedures and test forms (where applicable):

ECP 11-0535c Lucy Gemini 3. Control Unit and RTU with DNP3 Test Form.

ECP 11-0535d Lucy Gemini Control Unit and RTU Power-On Commissioning Form.

ECP 11-0521 Nortroll Cabletroll 2350 FPI Installation and Commissioning Procedure.

ECP 11-0601 GPRS/3G/4G Comms Device Commissioning Procedure

ECP 11-0602 PAKNET Comms Device Commissioning Procedure

ECP 11-0603 xDSL Comms Device Commissioning Procedure

4 Definitions

4.1 The following abbreviations are used throughout this procedure.

Term Definition

ADSL Asynchronous Digital Subscriber Line

APN Access Point Name (secure access to mobile comms networks)

CT Current Transformer

DNP3 Distributed Network Protocol

Power-On Electricity Network Management and Control

ESN Electronic Serial Number

EFPI Earth Fault Passage Indicator

FPI Fault Passage Indicator

FSSI Forward Signal Strength Indication

GPRS/3G/4G Mobile Comms Networks (Vodafone and O2)

HMI Human Machine Interface

NUA Network User Address

RMU Ring Main Unit

RSSI Received Signal Strength Indication

RTU Remote Terminal Unit

SHDSL Symmetrical High-Speed Digital Subscriber Line

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5 Description

5.1 An overview of the main components of the Gemini 3 is shown Figure 1.

Figure 1 – Gemini 3 RTU Cabinet Layout

5.2 The Gemini 3 has remote control and monitoring facilities for up to four switches or circuit-breakers (or a mixture of both) using the DSM modules and is shown in Figure 1. Each switch/circuit breaker to be controlled and / or monitored needs an umbilical cable connection to the Gemini 3.

5.3 Local control and monitoring is provided using the HMI.

5.4 The Gemini 3 is mains powered with a battery back-up and is self-monitoring.

5.5 The Gemini 3 uses the DNP3 IP protocol to provide communication with Power-On network management system for remote control and monitoring. Any appropriate IP compliant comm system can be used, such as:

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O2 or Vodafone GPRS/3G networks via the dedicated UK Power Networks APNs.

Rented ADSL circuits.

UKPN SHDSL circuits.

5.6 The IP comms networks will also provide remote configuration and monitoring capability from UKPN offices.

5.7 The Gemini 3 is capable of providing two internal fault passage indicators (FPI) on the FPM module, driven via the 3 phase RMU FPI CT inputs (where available). Where RMU CT inputs cannot be provided to the RTU (old LPN spec RMUs for instance), or where additional FPIs are required, these can be facilitated using external FPI units.

Figure 2 – Switch 1 and Switch 2 FPI CT Connections

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5.8 Connections to plant and equipment are made using the sockets provided on the bottom of the RTU, see Figure 3.

Figure 3 – Sockets on Underside of RTU

6 Equipment

6.1 The following test equipment is required to carry out the tests detailed in this procedure:

A laptop PC running Windows 7 with the Lucy configuration software installed.

An Ethernet lead (not crossed) – see Appendix C.

Multi-meter.

Switchgear simulator (for testing the FPI).

Clamp Ammeter (for measuring the LV current).

7 Inspection

7.1 Record the substation, switchgear and control unit details on the test form.

7.2 Record the switches that are to be commissioned on the test form.

7.3 Carry out a visual inspection of the control unit to ensure that it is undamaged.

7.4 Check that the following parts are supplied with the RTU:

Fixing kit for the comms device.

RTU top ‘hook’ and bottom mounting plate.

Cable guard (where required).

Required number of umbilical cables with keying pins and cable tags.

LV Monitoring unit (where required).

RJ45 umbilical cable (where required).

RJ45 adaptor box (where required).

Correct RMU adaptor box (where required).

ACB umbilical cable (where required).

Auxiliary I/O box (where required).

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7.5 Ensure the correct comms device (such as GPRS/3G/4G modem) and where applicable, aerial is supplied.

7.6 Check that the correct batteries have been supplied.

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8 RTU Installation

8.1 Mounting RTU in a brick substation

8.1.1 Fix 2 x longer Unistrut to wall vertically with suitable fixings, wide enough apart so the 2 x shorter Unistrut will attach horizontally on top of the vertical unistrut, see Figure 4.

8.1.2 Fix 2 x shorter Unistrut to the 2 x longer Unistrut horizontally with suitable fixings, Figure 4.

8.1.3 The top horizontal Unistrut should be placed so the RTU will be placed at a suitable height.

8.1.4 The bottom horizontal Unistrut should be placed so the fixings at the bottom of the RTU can be secured.

8.1.5 Fit the hook mounting to the top of the RTU and the bottom plate to the bottom of the RTU, Figure 5.

8.1.6 Hang the RTU on the top horizontal Unistrut and secure the bottom of the RTU to the bottom horizontal Unistrut, Figure 6.

Figure 4 Unistrut Mounting Frame (brick substation)

Figure 5 RTU Cabinet Mounting Adaptors

Figure 6 Hanging RTU onto Mounting Frame

8.2 The RTU earth stud should be earthed to the substation earth using a minimum of 16mm2 earth cable. Fix the earth cable directly to the earth stud, do not introduce curls.

Wall fixing points

Wall fixing points

Shallow Unistrut

Horizontal unistrut bolted

on top of vertical unistrut

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8.3 Mounting RTU in GRP substation

8.3.1 Fix 2 x longer Unistrut to wall vertically with suitable fixings to the pre-installed fixing points in the GRP housing, see Figure 7.

8.3.2 Fix 2 x shorter Unistrut to the 2 x longer Unistrut horizontally with the ‘T’ Plate fixings, see Figure 7.

8.3.3 The top horizontal Unistrut should be placed so the RTU will be placed at a suitable height.

8.3.4 The bottom horizontal Unistrut should be placed so the fixings at the bottom of the RTU can be secured.

8.3.5 Fit the hook mounting to the top of the RTU and the bottom plate to the bottom of the RTU, see Figure 8.

8.3.6 Hang the RTU on the top horizontal Unistrut and secure the bottom of the RTU to the bottom horizontal Unistrut, see Figure 9.

Figure 7 Unistrut Mounting Frame (GRP substation)

Figure 8 RTU Cabinet Mounting Adaptors

Figure 9 Hanging RTU onto Mounting Frame

8.4 The RTU earth stud should be earthed to the substation earth using a minimum of 16mm2 earth cable. Fix the earth cable directly to the earth stud, do not introduce curls.

GRP fixing points

GRP fixing points

Shallow Unistrut

Horizontal unistrut bolted inside vertical

unistrut using T plates

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Date: 06/10/2016

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8.5 Mounting Using Floor Mounted Frame

8.5.1 Bolt the 2 x longer lengths of Unistrut to the feet.

8.5.2 Bolt the 2 x shorter lengths of Unistrut horizontally between the longer lengths using the T Plate fittings. One should be bolted at the top of the frame, and the other at a height to suite the lower bolt plate on the RTU cabinet.

8.5.3 Bolt the feet to the floor using suitable fixings.

8.5.4 Fit the hook mounting to the top of the RTU and the bottom plate to the bottom of the RTU.

8.5.5 Hang the RTU on the top horizontal Unistrut and secure the bottom of the RTU to the bottom horizontal Unistrut.

8.5.6 The RTU earth stud should be earthed to the substation earth using a minimum of 16mm2 earth cable. Fix the earth cable directly to the earth stud, do not introduce curls.

8.5.7 The steel angle uprights will be replaced with deep Unistrut in the near future. When the deep Unistrut is used the RTU will fix to the frame in the same way as the wall mounted frame using the hook and bolt plates.

8.6 Install Power Cable and Batteries and Power Up the RTU

8.6.1 An un-switched fuse spur unit should be installed close to the RTU.

8.6.2 Install a suitable cable from the un-switched fuse spur unit to the RTU. The cable should enter the RTU via a stuffing gland installed on the RTU gland plate and connect into the incoming supply power terminals in the RTU. Do not connect the earth wire from the supply cable to the RTU, the RTU is earthed to the substation earth via the RTU earth stud using a minimum of 16mm2 earth cable.

8.6.3 Plug the battery connection cable into the battery connection module.

8.6.4 Connect the battery leads to the battery terminals outside of the RTU.

8.6.5 Install the rear battery in the RTU cabinet and plug the battery lead into the battery connection cable.

8.6.6 Install the front battery in the RTU cabinet and plug the battery lead into the battery connection cable.

8.6.7 Fit the battery securing strap.

8.6.8 Ensure the power supply fuse and batter fuse are fitted and switch on the RTU power switch, see Figure 1. The RTU should now power up.

8.6.9 Ensure the AC supply LED and the Batt Health LED on the PSM are showing green.

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9 RTU Additional Items Installation

9.1 UKPN Spec RMU Umbilical Cables

9.1.1 All UKPN specification RMUs have Cannon/Trident sockets installed for each ring switch and the circuit breaker.

9.1.2 Any ring switch or circuit breaker that requires automation or any I/O to be connected to Power-On requires an umbilical cable to be installed between the RTU and RMU.

9.1.3 Any RTU switch can be connected to any RMU switch/circuit breaker. However, it must be remembered that only RTU switch 1 and RTU switch 2 can provide the FPI functionality or voltage loss indication for the PLTU.

9.1.4 The ring switch on the left hand side of the RMU is designated RMU ‘x’ Switch 1, the ring switch on the right hand side of the RMU is designated RMU ‘x’ Switch 2 and the circuit breaker is designated RMU ‘x’ Switch 3.

9.1.5 Where the RTU is controlling a single RMU, RMU ‘x’ will be RMU 1. If the RMU is connected to two RMUs, one RMU will be designated RMU1 and the other RMU 2.

9.1.6 Polarising pins need be installed on the umbilicals to ensure they can only be plugged into specific RMU and RTU sockets to ensure that if they are unplugged after the site has been commissioned they will be plugged back into the correct sockets.

9.1.7 The cables should be labelled at each end with the RTU switch number, and RMU number/switch number. If there is only one RMU in use, it should still be labelled RMU1. For example:

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1 x RMU and 1 x ACB (see Figure 10)

Cable 1 label - RTU end: Sw1, RMU end: Sw1.

Cable 2 label - RTU end Sw2, RMU end: Sw2.

Cable 3 label - RTU end: Sw3, RMU end: Sw3.

Cable 4 label - RTU end Sw4, no label required.

Figure 10 – 1 x RMU and 1 x ACB Cable Connection Example

2 x RMUs (see Figure 11):

Cable 1 label - RTU end: Sw1, RMU end: Sw2.

Cable 2 label - RTU end: Sw2, RMU end: Sw1.

Cable 3 label - RTU end: Sw3, RMU end: Sw3.

Cable 4 label - RTU end: Sw4, RMU end: Sw2.

Figure 11 – 2 x RMU Cable Connection Example

Note: The umbilical cables do not have to be connected to the RTU/RMU switches as shown in the above examples, any RTU switch can be connected to any RMU switch/ACB. The examples are to illustrate the umbilical cable labelling convention to be used. However, it must be remembered that only RTU switch 1 and RTU switch 2 can provide the FPI functionality or voltage loss indication for the PLTU.

RTUACB1

RMU1 Sw1 RMU1 Sw2

RMU1 Sw3RTUSw1

RTUSw4

RTUSw3

RTUSw2

Cable 1

Cable 3

Cable 4

Cable 2

RTU

RMU2 Sw1 RMU2 Sw2

RMU2 Sw3RTUSw1

RTUSw4

RTUSw3

RTUSw2

RMU1 Sw1 RMU1 Sw2

RMU1 Sw3

Cable 1

Cable 3

Cable 4

Cable 2

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9.2 EPN/SPN Spec Schneider RMU Umbilical Cables

9.2.1 An adaptor cable is available from Lucy Automation to connect an old EPN or SPN specification Schneider RMU to a Type E RTU. The cable has the Cannon/Trident plugs on the RTU end of the cable and the Schneider plugs on the RMU end of the cable.

9.2.2 The installation procedure and details are contained in Appendix G.

9.3 LPN ‘Retrofit’ Adaptor Box (Old LPN Spec RMUs only)

9.3.1 In order to be able to connect the new RTUs to the old LPN specification RMUs, an adaptor box has been developed. See Figure 12.

Figure 12 – LPN Retrofit Adaptor Box

9.3.2 When used with an LPN specification Schneider RMU, a wiring modification needs to be made to the RMU itself, these are detailed in Appendix D. The modification is required to change the way the Schneider RMU actuator is powered to remove the risk of an unplanned operation of the actuator. The modification is only required when using an old LPN specification Schneider RMU with a new Type E RTU (Lucy Gemini 3 or Remsdaq Callisto NX) via an LPN Retrofit Adaptor box. No modifications are required for any other manufacturers RMU or when using a new UKPN specification RMU connected directly to the RTU with umbilical cables.

9.3.3 The adaptor box is equipped with 3 x cables with RTU plugs on the end which are to be connected to the RTU.

9.3.4 For a ‘Retrofit’ installation, the cables and plugs associated with the RMU will already exist on site. The cables will be removed from the old Callisto 1 RTU, installed into the Adaptor Box, and connected as directed by the connection diagram in the Adaptor Box. RMU cable/plug connection for new LPN Spec RMU installations are detailed in section 9.4.

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9.3.5 Where the RTU is controlling a single RMU the adaptor box should be connected to the following plugs on the RTU: switch 1, switch 2 and switch 3.

9.3.6 Where the RTU is controlling two RMUs, two adaptor boxes will be required. An example of how the two adaptor boxes can be connected as shown in Figure 14. It should be noted that the polarising pins in the RTU Cannon/Trident plugs may need to be altered to match the installation requirements. The pins can be removed using pliers and re-inserted in the appropriate positions for the relevant RTU switch.

9.3.7 Further example of how to connect various equipment within the substation can be found in EOS 05-9305 ‘Lucy Gemini 3 Control Unit and RTU’.

9.3.8 The cables should be labelled at each end with the RTU switch number, and RMU number/switch number. If there is only one RMU in use, it should still be labelled RMU1. For example:

1 x RMU and 1 x ACB (see Figure 13)

Cable 1 label - RTU end: Sw1, RMU end: Sw1.

Cable 2 label - RTU end Sw2, RMU end: Sw2.

Cable 3 label - RTU end: Sw3, RMU end: Sw3.

Cable 4 label - RTU end Sw4, no label required.

Figure 13 – 1 x RMU and 1 x ACB Cable Connection Example

Adaptor Box 1 (RMU1)

RMU1 Sw1

RMU1 Sw2

RMU1 Sw2

RTU

RTU Sw1

RTU Sw2

RTU Sw3

RTU Sw4

Cable 1

Cable 3

Cable 4

Cable 2

RMU1 Sw1

RMU1 Sw3

RMU1 Sw3

ACB1

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2 x RMUs (see Figure 14):

Cable 1 label - RTU end: Sw1, RMU end: Sw2.

Cable 2 label - RTU end: Sw2, RMU end: Sw1.

Cable 3 label - RTU end: Sw3, RMU end: Sw3.

Cable 4 label - RTU end: Sw4, RMU end: Sw2.

In this example, the polarising pins will need to be inserted in the following positions:

RMU1 Adaptor Box Sw2 cable, Neptune connector power pin terminal 1 (RTU Sw 1 socket).

RMU1 Adaptor Box Sw3 cable, Neptune connector power pin terminal 3 (RTU Sw 3 socket).

RMU2 Adaptor Box Sw1 cable, Neptune connector power pin terminal 2 (RTU Sw 2 socket).

RMU2 Adaptor Box Sw2 cable, Neptune connector power pin terminal 4 (RTU Sw 4 socket).

Figure 14 – 2 x RMU Cable Connection Example

9.3.9 The existing 2 x RMU connection cables are inserted into the adaptor box using the 2 x stuffing glands provided and are wired into the appropriate terminals as per the wiring diagram included in the adaptor box, see Figure 15. The RMU Harting plugs are connected to the RMU in the usual way.

Figure 15 – LPN Retrofit Adaptor Box Connections and Wiring Schedule

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9.4 LPN Specification RMU Plugs (new installations of old LPN spec RMUs)

9.4.1 Where the Lucy Gemini 3 RTU is being connected to a current LPN specification RMU for a new installation (ie. The cables/plugs associated with the RMU do not exist) the following procedure will need to be followed to connect the Adaptor Box to the RMU.

9.4.2 The connection between the cables from the Adaptor Box and the RMU use two plugs and sockets. The RMU is delivered with the sockets installed by the manufacturer – the 16-way plug/socket is used for the indications/control initiation pulses and the 6-way way plug/socket is used for 24V supplies/indication common.

9.4.3 The plugs and sockets use a stuffing gland to secure the sheath of the screened cable and the screening should be cut back and insulated using PVC tape as shown below.

Figure 16 – LPN Spec RMU Plugs

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9.4.4 The 16-way plug uses an 18 core 16/02 cable which has colour coded cores and 6-way plug uses a 7 core 2.5mm cable cores are numbered 1 to 6, the seventh core is an earth cable. The two spare cores should be cut back and insulated.

9.4.5 The earth cable should be cut back in the plug and insulated.

9.4.6 Terminate the 7c 2.5mm2 cable into the 6-way plug and the Adaptor Box as shown below.

6-way Plug Pin No

Cable Core No

Description Adaptor Box Connection

1 1 +24 Volt DC supply As detailed in the connection diagram in the Adaptor Box

2 2 +24 Volt DC supply switched As detailed in the connection diagram in the Adaptor Box

3 3 EFPI reset common As detailed in the connection diagram in the Adaptor Box

4 4 0 volt DC supply As detailed in the connection diagram in the Adaptor Box

5 5 Switch indication common As detailed in the connection diagram in the Adaptor Box

6 6 EFPI indication common As detailed in the connection diagram in the Adaptor Box

7 Cut back & insulate both ends As detailed in the connection diagram in the Adaptor Box

9.4.7 Terminate the 18c 16/0.2mm2 cable into the 16-way plug and the Adaptor Box as shown below.

16-way Plug Pin No

Cable Core Colour

Description Adaptor Box Connection

1 Red Switch 1 open indication As detailed in the connection diagram in the Adaptor Box

2 Blue Switch 2 open indication As detailed in the connection diagram in the Adaptor Box

3 Green CB 3 open indication As detailed in the connection diagram in the Adaptor Box

4 Yellow EFPI 1 indication As detailed in the connection diagram in the Adaptor Box

5 White EFPI 3 indication As detailed in the connection diagram in the Adaptor Box

6 Black Open switch 1 command As detailed in the connection diagram in the Adaptor Box

7 Brown Open switch 2 command As detailed in the connection diagram in the Adaptor Box

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16-way Plug Pin No

Cable Core Colour

Description Adaptor Box Connection

8 Violet Open CB3 command As detailed in the connection diagram in the Adaptor Box

9 Orange Switch 1 close indication As detailed in the connection diagram in the Adaptor Box

10 Pink Switch 2 close indication As detailed in the connection diagram in the Adaptor Box

11 Turquoise CB 3 close indication As detailed in the connection diagram in the Adaptor Box

12 Grey EFPI 2 indication As detailed in the connection diagram in the Adaptor Box

13 Red/Blue Reset EFPIs command As detailed in the connection diagram in the Adaptor Box

14 Green/Red Close switch 1 command As detailed in the connection diagram in the Adaptor Box

15 Yellow/Red Close switch 2 command As detailed in the connection diagram in the Adaptor Box

16 White/Red Close CB3 command As detailed in the connection diagram in the Adaptor Box

Red/Black Cut back & insulate both ends

Red/Brown Cut back & insulate both ends

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9.5 Umbilical Cable Polarising Pins

9.5.1 Polarising Pins are provided with each Umbilical Cable. Fit the Polarising Pins into the plugs at each end of the Umbilical cable:

For RTU or RMU switch 1 insert a pin in the hole labelled ‘1’

For RTU or RMU switch 2 insert a pin in the hole labelled ‘2’

For RTU or RMU switch 3 insert a pin in the hole labelled ‘3’

For RTU or RMU switch 4 insert a pin in the hole labelled ‘4’

Figure 17 – Umbilical Plug Polarising Pin Holes

9.5.2 To verify which hole in the Umbilical plug to install the polarising pin check the appropriate socket and install the polarising pin in whichever hole is empty on the socket.

9.5.3 This will ensure that if removed, the plug can only be re-inserted into the relevant socket.

Hole 1 Hole 2

Hole 3 Hole 4

Socket on RTU or RMU polarised for switch 1

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9.6 Transformer LV Monitoring via Schneider LV Cabinet Power Meter

9.6.1 Monitoring of the transformer LV way can be facilitated by connection to the power meter installed in the Schneider LV cabinet, see Figure 18, and connected back to the RTU using a comms bus (RJ45 umbilical).

Figure 18 – LV Cabinet Power Meter

9.6.2 The RJ45 umbilical plug at the LV cabinet end will need to be cut off and the cable terminated onto the relevant terminals within the LV cabinet, see Figure 19. The umbilical cable should enter the LV cabinet through a suitable sized stuffing gland in the cabinet gland plate.

Figure 19 – LV Cabinet Power Meter Connection Terminals

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9.6.3 The RJ45 umbilical cable cores should be terminated as described in Table 1. The White/Orange and Orange/White cores of the RJ45 umbilical cable need to be connected to the Blue/White cables in the LV Cabinet and the White/Green core of the RJ45 umbilical cable connected to the remaining cable in the LV cabinet.

Existing wiring to PM

RJ45 cable to RTU Description

Blue/White White/Orange RS485A (+)

White/Blue Orange/White RS485B (-)

Screen White/Green RS485 ground

n/a Blue/White 24V+ from RTU (not used) should be insulated using bootlace crimp

n/a White/Blue 24V+ from RTU (not used) should be insulated using bootlace crimp

n/a White/Brown 0V from RTU (not used) should be insulated using bootlace crimp

n/a Brown/White 0V from RTU (not used) should be insulated using bootlace crimp

Table 1 – RJ45 umbilical termination in LV Cabinet

9.6.4 The baud rate of the Power Meter should be set to 9600 baud, 8 data bits, no parity and 1 stop bit. Appendix E details how to set up the Power Meter comms parameters.

9.6.5 If a single Power Meter is connected to the RTU (either meter installed in the LV board, a separate unit or a combination) the Power Meter must be set with a Modbus address of 1. If two Power Meters are used, one must be set to a Modbus Address of 1 and one to a Modbus address of 2. Appendix E details how to set up the Power Meter comms parameters.

9.6.6 The orientation of the connections between the RJ45 umbilical cable and the LV cabinet connections may vary, if the output of the Power Meter is not being read by the RTU then the RJ45 umbilical White/Orange and Orange/White cores should be swapped.

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9.7 Transformer LV Monitoring via Schneider LV Cabinet (No Power Meter installed in cabinet)

9.7.1 Some LV cabinets do not have a Power Meter installed, but do have terminals for the LV voltage and currents.

9.7.2 If a Power Meter is not already installed in the Schneider LV cabinet, monitoring of the transformer LV way can be facilitated by the use of an external Power Meter which can be installed close to the LV board and connected back to the RTU using a comms bus (RJ45 umbilical), see Figure 20.

Figure 20 – External Power Meter and RJ45 Umbilical Cable

9.7.3 Mount a power meter on the wall, and run two cables from the power meter to the LV cabinet and connect the cores as detailed in Figure 21.

Figure 21 – Power Meter and LV Cabinet Connections

1E50

5C12

2E30

3E10

4H2

6C11

7C32

8C31

9C52

10C51

Schneider LV Board Terminals

Voltage Connections

Current Connections (0-340mV)

Blu

e

Yello

w

Red

Gre

en

4 core 16/0.2

8 core 16/0.2 (black and green cores spare)

Bro

wn

Red

Wh

ite

Yello

w

Vio

let

Blu

e

NB: Please install the wires into the bottom terminals in the LV Cabinet

Power Meter Schneider LV Board Cable Core Colour

1 4 4 core 16/0.2 Green

2 1 4 core 16/0.2 Blue

3 2 4 core 16/0.2 Yellow

4 3 4 core 16/0.2 Red

15 9 8 core 16/0.2 Violet

16 10 8 core 16/0.2 Blue

17 7 8 core 16/0.2 White

18 8 8 core 16/0.2 Yellow

19 5 8 core 16/0.2 Brown

20 6 8 core 16/0.2 Red

Wiring Schedule

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9.7.4 The current terminals in the Schneider LV board give a mV output. For an LV cabinet with 1600A busbars, the output is 340mV for a current of 1674A. For an LV cabinet with 800A busbars the output is 340mV for a current of 837A.

9.7.5 Set CT1 of the power meter to 1674A for an LV cabinet with 1600A busbars, or 837A for a cabinet with 800A busbars and set CT2 to 0.34V.

9.7.6 Set the display to show real time voltage or current using the button labelled ‘V/A’ or ‘U/I’. The display should NOT be set to show MD (Maximum Demand) values.

9.7.7 Check that power meter displays correct current and voltage, and make sure the kW reading for each phase is correct (assuming the is some load on the LV board).

9.7.8 If a single Power Meter is connected to the RTU (either meter installed in the LV board, a separate unit or a combination) the Power Meter must be set with a Modbus address of 1. If two Power Meters are used, one must be set to a Modbus Address of 1 and one to a Modbus address of 2. Appendix E details how to set up the Lucy Power Meter comms parameters.

9.7.9 All parameters are pre-set and do not need to be changed, unless it is the second Power Meter installed on the bus, in which case the Modbus address will need to be changed to 2.

9.7.10 Connect the Power Meter to the RTU using an RJ45 Umbilical cable, and if required an RJ45 adaptor box.

9.7.11 The Power Meter is powered from the RJ45 Umbilical cable and does not need any external power supply.

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9.8 Transformer LV Monitoring via Additional Monitoring Unit

9.8.1 If a Power Meter is not already installed in the LV cabinet, or no LV cabinet is connected, monitoring of the transformer LV way can be facilitated by the use of an external Power Meter which can be installed close to the LV board and connected back to the RTU using a comms bus (RJ45 umbilical), see Figure 22.

Figure 22 – Power Meter Installation

9.8.2 The Power Meter is connected to the transformer tails using clip on CTs and ‘cable sheath piercing’ fuse ways. If the transformer LV cables uses two cores per phase, then a CT should be installed on each core (6 CTs in total), and the outputs of the two CTs for a given phase paralleled, see Figure 23.

Figure 23 – CT/VT Connection

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9.8.3 The CT and VT connections are detailed in Figure 24.

Figure 24 – CT/VT and Power Meter Connections

9.8.4 The CTs and fuse links should be fitted as close to the LV board/ACB as possible.

9.8.5 Check the LV cables are dead before carrying out this work.

9.8.6 Attach three clip-on CTs (or six if two cores per phase) to the LV phase cables as shown in Figure 23, with P1 towards the transformer/ACB (supply) and P2 towards the LV board (load). Fit a ‘DO NOT REMOVE’ label on each clip-on CT.

Note: The correct CTs are of a voltage output type, designated by the label ‘..xx V output’, and may safely be unclipped without shorting the outputs.

9.8.7 Attach four fuse carriers directly to the LV phase and neutral cables, as shown in Figure 23, using a self-tapping screw (drill size 3mm).

Note: Do not install the fuses/links at this stage – they should be left locked in the RTU cabinet for installation during commissioning. A solid link is fitted to the neutral.

4 core 16/0.2

3 X 2 core cables for single LV phase cable

6 x 2 core cables for dual LV phase cables

L1

N

L3

L2

From cable sheath piercing fuse ways

From L1 phase CTs

From L2 phase CTs

From L3 phase CTs

Fit 2 A fuse to each phase fuse way and a solid link to the neutral fuse way

Power Meter CTs/VTs Cable Core Colour

1 N (V) 4 core 16/0.2 Green

2 L1 (V) 4 core 16/0.2 Red

3 L2 (V) 4 core 16/0.2 Yellow

4 L3 (V) 4 core 16/0.2 Blue

15 L3 (A) 2 core

16 L3 (A) 2 core

17 L2 (A) 2 core

18 L2 (A) 2 core

19 L1 (A) 2 core

20 L1 (A) 2 core

15 L3 (A) 2 core

16 L3 (A) 2 core

17 L2 (A) 2 core

18 L2 (A) 2 core

19 L1 (A) 2 core

20 L1 (A) 2 core

Wiring Schedule

If the transformer LV tails have two cables per phase install a 2nd

set of CTs and additional cable to the Power Meter and parallel

the connections on the Power Meter terminals

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9.8.8 Carry out an insulation test of the fuse carry cabling using an appropriate tester.

9.8.9 The CT cables should not be attached to the power cables in any way.

9.8.10 Set the power meter CT primary current (CT1 in the menu) to 1000A if it is a single LV run with one clamp CT per phase, or 2000A if it is a double run with two clamp CTs per phase.

9.8.11 If a single Power Meter is connected to the RTU (either meter installed in the LV board, a separate unit or a combination) the Power Meter must be set with a Modbus address of 1. If two Power Meters are used, one must be set to a Modbus Address of 1 and one to a Modbus address of 2. Appendix F details how to set up the Lucy Power Meter comms parameters.

9.8.12 All parameters are pre-set and do not need to be changed, unless it is the second Power Meter installed on the bus, in which case the Modbus address will need to be changed to 2.

9.8.13 Connect the Power Meter to the RTU using an RJ45 Umbilical cable, and if required an RJ45 adaptor box.

9.8.14 The Power Meter is powered from the RJ45 Umbilical cable and does not need any external power supply.

9.9 Anti-Vandal Guard

9.9.1 An Anti-Vandal guard is available for use in areas where vandalism is considered possible, or where protection from livestock is required.

9.10 Umbilical Cable Mechanical Protection

9.10.1 Where mechanical protection of the Umbilical cables is required, this is provided by the use of split flexible conduit. The split flexible conduit is available from stores and RS Components:

RS part number: 755-9029 - CR PP Flexible, Split Conduit Black 32mm 10m

RS part number: 875-0255 - CR PP Flexible, Split Conduit Black 32mm 50m

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9.11 Auxiliary I/O Box

9.11.1 The RTU has been designed to be ‘plug and play’ and to accommodate the I/O required for the majority of UK Power Networks substations. However there may be additional I/O requirements from some substations, in order to facilitate the connections of this I/O an external Auxiliary I/O box can be used, see Figure 25.

9.11.2 The I/O box connects to the RTU using the 12 pin socket on the bottom of the RTU, see Figure 3.

9.11.3 The following I/O has been hard wired into the RTU:

Terminal Function

1 +24V DC (permanent power supply)

2 0V (for above)

3 General Alarm/Indication Common

4 Intruder Alarm (n/c contact)

5 Flood Alarm (n/c contact)

6 Transformer 1 Temperature Pos (20mA analogue)

7 Transformer 1 Temperature Neg (20mA analogue)

8 Transformer 2 Temperature Pos (20mA analogue)

9 Transformer 2 Temperature Neg (20mA analogue)

10 Spare - Wired in RTU (unconnected in RTU)

11 Spare - Wired in RTU (unconnected in RTU)

Figure 25 – Auxiliary I/O Box

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9.12 RJ45 Adaptor Box

9.12.1 The RTU is equipped with a single RJ45 socket on the bottom of the cabinet to facilitate the connection of the comms bus. Most of the plant that would be connected to the comms bus in the substation will also only have a single RJ45 socket, in order to ‘daisy chain’ more than one item of plant onto the comms bus an RJ45 adaptor box have been developed.

9.12.2 The adaptor box has 3 x RJ45 sockets to enable any item of plant to be tee’d into the comms bus, see Figure 26.

9.12.3 The RTU has a termination resistor fitted. No termination resistors should be included in any of the plant connected to the bus.

Figure 26 – RJ45 Adaptor Box

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9.13 ACB Umbilical Cable

9.13.1 To facilitate the connection of an ACB to the RTU a dedicated umbilical cable is available.

9.13.2 The umbilical cable will plug into the RTU using the Cannon/Trident plug and into the ACB using the Harting plug.

9.14 Comms Device Installation

9.14.1 Ensure the Comms Device mounting DIN rail is installed in the appropriate position for the Comms Device to be installed as shown in Figure 27. NB, the DIN rail may need to be repositioned depending on the Comms Device being fitted.

Figure 27 – Comms Device DIN Rail Installation

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9.14.2 Mount the Comms Device on the DIN rail as shown in Figure 28.

Figure 28 – Comms Device Installed (DIGI WR21 3G/4G router shown)

9.14.3 Connect the Comms Device power lead into the PSM ‘DC outputs’ connector on terminals ‘DC 1+’ and ‘DC 1-‘.

9.14.4 Connect the Comms Device power lead to the Comms Device.

9.14.5 If using GPRS/3G/4G Comms: Connect the ethernet patch lead to ‘ETH0’ of the ‘MCM’ and to the comms device Ethernet port.

9.14.6 If using PAKNET Comms: Connect the comms lead to the port labelled either ‘Comm 1’ or ‘RS232 A’ of the ‘MCM’ and to the comms device serial port.

9.14.7 If a risk assessment of the location allows, the aerial should be mounted outdoors, however if not the aerial should be mounted as high as possible within the substation.

9.14.8 If the substation is underground, every effort should be made to place the aerial at street level, or as close as reasonably practicable.

9.14.9 If using GPRS/3G/4G Comms: The Aerial feeder should be passed through one of the stuffing glands already installed on the RTU. The aerial feeder cable may need to be packed out (with insulating tape or something suitable) to ensure the stuffing gland can be tightened to form a good seal around the feeder cable. If the aerial feeder cable only has a single connector, connect it to the connection on the right hand side of the front of the router (next to the 9 pin serial port).

9.14.10 If using PAKNET Comms: The Aerial should be supplied with a stuffing gland already installed on the cable. Feed the cable and stuffing gland through one of the blanked 20mm holes on the bottom of the RTU.

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10 Gemini 3 Configuration

10.1 The Gemini 3 RTU is pre-configured for the ‘hardwired’ I/O points and only requires configuration for the additional options that may be installed on a site by site basis, and the site specific RTU address.

10.2 The Gemini 3 ‘Gemini 3 Configuration Tool’ software is used to configure the RTU, set up the DNP3 address and IP addresses, etc, and to check the status of the RTU.

10.3 Ensure the Laptop is to set to obtain an IP address automatically (DHCP Client).

10.4 Connect a laptop PC to the ‘ETH-1’ Ethernet port on the ‘MCM’ module using a suitable Ethernet Patch cable (refer to Appendix C for details of the software and cable requirements).

10.5 Start the Gemini 3 Configuration Tool program.

10.6 Input the User Name ‘ukpn’, Password ‘<deliberately not shown in this document>, and IP Address ‘192.168.2.1’ and select ‘Login’. See Figure 29.

Figure 29 – RTU configuration tool log in

10.7 The configuration program may give a message stating “You are trying to read the configuration from the RTU. Any changes that have been made locally will be lost. Are you sure?” Select Yes.

10.8 Maximize the page on the screen.

10.9 Check the RTU has the correct latest software version installed (as available on Alfresco) in the ‘Software Information’ section, see Error! Reference source not found.. You may need to scroll down the page using scroll the bar on the right.

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Figure 30 – Config and Software version number

10.10 If the software version or config version is incorrect, upgrade the software and/or config.

10.11 If the software needs upgrading, follow the procedure detailed in Appendix A.

10.12 If the Config needs to be updated, follow 10.15 to 10.16.

10.13 All Software/Firmware, Configs and PC Config Software can be downloaded from Alfresco at the following location:

Home Page > Policies, Procedures & Forms > Engineering > Reference Library > Link to: Reference Library > Relay and RTU Software > Lucy > Gemini 3

10.14 If both Config and Software are up to date skip to 10.19.

10.15 Load the RTU configuration into the RTU. Select ‘Configuration’ from the left hand menu. Select ‘Configuration’ from the tree menu. Select the ‘down arrow’ next to ‘New’, then select ‘Load from a File’, you may get a message “You are trying to open a configuration. Any changes that have been made locally will be lost. Are you sure?” Select ‘Yes’. See Figure 31.

Browse to locate the RTU Config file on your Laptop.

Select the file and click ‘Open’.

From the ‘RTU Configuration’ section, select ‘Write’.

When prompted, click ‘Activate Now’ and ‘Restart Now’.

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Figure 31 – RTU Configuration Page

10.16 Check the RTU now has the correct latest config and software version installed (as available on Alfresco).

10.17 Select ‘Realtime Monitor’ from the left hand menu.

10.18 Check the Config and Software Version is now correct (see Figure 31Error! Reference source not found.).

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10.19 Select Commissioning from the left hand menu, then select Wizard, then select Start Commissioning’ see Figure 33.

Figure 32 – Starting Commissioning Wizard

10.20 Step 1: Input the RTU Site Name into the appropriate box (site name specified by Power-On commissioning engineer). The IP address, Submask and Gateway should be pre-configured to 192.168.1.11, 255.255.255.0 and 192.168.1.1 respectively. Enter the RTU DNP3 Address (as specified by the Power-On commissioning engineer) into the ‘DNP3 RTU Address’ box. See Figure 33.

10.21 If more than one RTU is being connected to a single Comms Device:

The second RTU IP Address should be changed to 192.168.1.12.

The third RTU IP Address should be changed to 192.168.1.13.

The forth RTU IP Address should be changed to 192.168.1.14.

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Figure 33 – Commissioning Wizard start page

10.22 Select Next.

10.23 Step 2: Select which RTU switch is connected to which RMU manufacturer switch/circuit breaker (for instance RTU Sw1, Lucy Electric RMU (switch)). If no switch is connected select ‘Disabled’. See Figure 34.

Figure 34 – Commissioning Wizard switch setup page

10.24 Select Next.

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10.25 Step 3: Select whether the Internal FPI functionality needs to be Enabled or Disabled. See Figure 35. Wherever an LPN RMU Adaptor Box is used, this will need to be set to ‘Internal FPI Disabled’. Please note, the internal FPIs are connected to RTU Switch 1 and RTU Switch 2, therefore any RMU switch/circuit breaker that needs to use the internal FPI functionality must be connected to either RTU Switch 1 or RTU Switch 2.

Figure 35 – FPI

10.26 If the Internal FPI is used, input the required FPI settings, an example is shown in Figure 36.

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Figure 36 – FPI Settings Page

Please note, the standard FPI settings for use with the Type E RTU internal FPIs for EPN, LPN and SPN are: Phase Fault 600A 50ms and Earth Fault 90A 50ms. These values can be overwritten if site specific values have been calculated.

10.27 Select Next.

50

90

50

90

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10.28 Step 4: Select the region the RTU is to be installed within (which Power-On system the RTU will communicate to) and the comms type it will use. See Figure 37.Error! Reference source not found.

Figure 37 – Comms Type/Area Selection

10.29 Select Next.

10.30 Step 5: Select the appropriate Modbus connected device (such as a Power Meters or Protection relays). If no Modbus device is connected select Disabled. See Figure

38.

Figure 38 – Modbus Connected Devices

10.31 Please note, the Modbus address of the devices installed on the comms bus must match the Modbus address detailed in the configuration tool.

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10.32 Select Next.

10.33 Step 6: Internal PLTU, tick the box to enable the PLTU functionality, leave the box unticked to disable the PLTU logic. Wherever an LPN RMU Adaptor Box is used, this will need to be set to ‘Disabled’ (leave box unticked).

10.34 Select Next.

10.35 Step 7: Select Finish to write the configuration to the RTU. The RTU will restart. Once the RTU has restarted successfully, a message with state ‘The RTU has been configured successfully’, click ‘OK’.

10.36 Select Exit from the top right corner of the screen.

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11 Local Commissioning Checks

11.1 Switch/Circuit Breaker Controls

11.1.1 Set the RTU to ‘Local’ using the HMI (Press and hold the ‘Mode’ button for 1 seconds then release). The status will only change once the button is released.

11.1.2 Check the MCM Module LED shows ‘Local’ (see Figure 39) and the HMI shows ‘Local’ (see Figure 40).

11.1.3 Check that each automated switch or circuit-breaker can be opened and closed using the controls on the HMI. In both positions the indicator LEDs on the DSM module (see Figure 41) and HMI description should correspond with the physical position of the switch or circuit-breaker.

Press the ‘Menu’ button.

Using the Arrow keys, select the desired Switch/Circuit Breaker and press ‘OK’.

Using the Arrow Keys select ‘Control’ in the menu and press ‘OK’.

Using the Arrow Keys select ‘RTU SW’x’’ in the menu and press ‘OK’.

Press and hold the ‘Act’ button together with either the ‘Open’ or ‘Close’ buttons for approx. 5 seconds. When the HMI display shows ‘Operating’, release the buttons.

If the switchgear being operated is an RN2C there will be a delay of up to 5 seconds before the actuator starts operating, all other switchgear will operate immediately.

After the delay (if any), the appropriate switch/CB should operate and the indication on the HMI will show ‘Operation Finished’ and ‘Open’ or ‘Closed’ and the LED on the relevant DSM Module will indicate the correct switch position.

Pressing the ‘Menu’ button at any time will take you back to the start page of the HMI.

Figure 39 – Main Control Module (MCM) Figure 40 – Human Machine Interface (HMI)

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Figure 41 – Dual Switch Module (DSM)

11.2 Switch/Circuit Breaker Alarms

11.2.1 To navigate to the Switch/Circuit Breaker Alarms page on the HMI:

Press the ‘Menu’ button.

Using the Arrow keys, select the desired Switch/Circuit Breaker and press ‘OK’.

Using the Arrow Keys scroll down and select ‘Alarms’ in the menu and press ‘OK’.

Step through the alarms using the arrow keys and make sure they are all displaying ‘0’ (not operated) except for ‘Sw’x’ Act Dis’ which will display ‘1’.

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11.3 Internal FPI Testing

11.3.1 To navigate to the FPI page on the HMI:

Press the ‘Menu’ button.

Using the arrow keys, select the desired Switch that the FPI is associated with and press ‘OK’.

Using the arrow keys scroll down and select ‘FPI’ and press ‘OK’.

This page displays the status of the FPI.

11.3.2 Use a plant simulator to inject current to test the FPI and EFPI functionality.

11.3.3 Send an ‘FPI Reset’ control from the HMI.

Press the ‘Menu’ button.

Using the arrow keys, select the desired Switch that the FPI is associated with and press ‘OK’.

Using the arrow keys select ‘Controls’ and press ‘OK’.

Using the arrow keys select ‘FPI Reset’ and press ‘OK’.

Press and hold the ‘Act’ and either the ‘Open’ or ‘Close’ buttons for approx. 5 seconds.

11.3.4 The ‘FPI Operated’ indication should clear.

11.3.5 Repeat for all connected FPIs.

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11.4 External FPI Testing

11.4.1 For FPI installation, please refer to ECP 11-0521 (Nortroll Cabletroll 2350 FPI Installation and Commissioning Procedure).

11.4.2 To navigate to the FPI page on the HMI:

Press the ‘Menu’ button.

Using the arrow keys, select the desired Switch that the FPI is associated with and press ‘OK’.

Using the arrow keys scroll down and select ‘FPI’ and press ‘OK’.

This page displays the status of the FPI.

11.4.3 When using an external FPI, Ignore ‘FPI E’ and ‘FPI P’. The FPI status is shown on ‘SW’x’ FPI’.

11.4.4 Press the ‘Test’ button on the front of the FPI. The relevant FPI should show a ‘1’ indication on the correct switch/EFPI/FPI designation on the HMI.

11.4.5 Send an ‘FPI Reset’ control from the HMI.

Press the ‘Menu’ button.

Using the arrow keys, select the desired Switch that the FPI is associated with and press ‘OK’.

Using the arrow keys select ‘Controls’ and press ‘OK’.

Using the arrow keys select ‘FPI Reset’ and press ‘OK’.

Press and hold the ‘Act’ and either the ‘Open’ or ‘Close’ buttons for approx. 5 seconds.

11.4.6 The ‘FPI Operated’ indication should clear on the external FPI unit(s).

11.4.7 Repeat for all connected FPIs.

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11.5 External Power Meter

11.5.1 To navigate to the LV Power Meter page on the HMI:

Press the ‘Menu’ button.

Using the arrow keys, scroll down and select the desired TX that the Power Meter is associated with and press ‘OK’.

Step through the pages using the arrow keys and check the information displayed is correct (as shown on the Power Meter and through measurement of the values using a multi meter).

On the last page, check the Power Meter is showing as ‘Offline 0’.

11.5.2 Repeat for all connected Power Meters.

11.6 RTU General Alarms

11.6.1 To navigate to the RTU General Alarms page on the HMI:

Press the ‘Menu’ button.

Using the arrow keys, select ‘RTU & General’ and press ‘OK’.

Using the arrow keys, select ‘RTU Alarms’ and press ‘OK’.

Step through the pages using the arrow keys and check the information displayed is correct.

Step through the alarms using the arrow keys and make sure they are all displaying ‘0’ (not operated), except for the following:

Door Alarm (this will show ‘1’ as the door is open).

Flood Alarm (this will show ‘1’ if there is no flood alarm is fitted, or ‘0’ if one is fitted).

Intruder Alarm (this will show ‘1’ if there is no flood alarm is fitted, or ‘0’ if one is fitted).

11.7 Circuit Description Form

Complete the circuits description form (supplied with form ECP 11-0535c) and install within the RTU close to the HMI so it is easily visible.

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12 Power-On Commissioning of Controls, Alarms and Indications

12.1 These tests should be carried out from Power-On to the RMU before the RMU is made live. However, if the RMU has been made live the tests should be carried out to a suitable plant simulator.

12.2 Check the comms device Ethernet cable is plugged into the ETH0 port of the MCM.

12.3 Supply site/comms/battery/circuit details for Power-On commissioning form as requested by Power-On Commissioning Engineer.

12.4 Ensure the RTU is set to Local and no communications is established with Power-On.

12.5 Select Remote and confirm with the Commissioning Operator that the unit has successfully dialled in.

12.6 Confirm that the RTU status and Switch/CB statuses are correctly shown on Power-On.

12.7 Once the call has dropped ask the Commissioning Operator to operate the dummy circuit-breaker from Power-On and confirm that the change of state is shown both on Power-On and locally on the RTU HMI and MCM.

12.8 Providing communications have been established in both directions carry out the Power-On commissioning as detailed below.

12.9 Ensure the RTU is set to ‘Remote’.

12.10 Carry out the checks detailed below for each remotely controlled switch and circuit-breaker from Power-On. (refer to 12.1)

Switch State Command Switch Action

Open Close from NMS Closes

Closed Open from NMS Opens

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12.11 Ensure the RTU is selected to ‘Remote’ and confirm the following status changes for each switch or circuit-breaker are received correctly on Power-On.

Action Power-On Indication/Alarm1

HMI Indication

Press FPI Test button (repeat test for each FPI)

FPI Operated (for appropriate switch)

SW’x’ FPI 1

Reset FPI from NMS All FPIs Reset SW’x’ FPI 0

Observe air temp on NMS Power-On displays correct air temp

Initiate flood alarm (if fitted) Flood Alarm Flood Alarm 1

Reset flood alarm (if fitted) Flood Alarm Reset Flood Alarm 0

Initiate intruder alarm (if fitted) Intruder Alarm Int Alarm 1

Reset intruder alarm (if fitted) Intruder Alarm Reset Int Alarm 0

Unplug the RJ45 cable from the Power Meter and wait up to 20 seconds (repeat test for each Power Meter in turn)

Transformer ‘#’ Power Meter Comms Fail (ensure the correct transformer number if shown on Power-On)

Power Meter Offline

Plug the RJ45 cable back into the Power Meter

Relevant alarm will clear Power Meter Online

Turn off mains supply to RTU (RTU should continue to run on batteries)

Mains fail alarm LV AC Off 1

Reconnect mains supply Mains fail alarm reset LV AC Off 0

1 The actual indication/alarm description in ENMAC may vary to ones shown below.

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13 On-Load Tests

13.1 Carry out the following tests after the switchgear is connected to the network and energised. These tests are used to ensure the correct analogue readings are being displayed on Power-On.

13.2 Measure the current in each phase of the Transformer LV tails using a tong tester. If there are two cores per phase try and measure both cores at the same time, if this is not possible measure them individually and add the results together.

13.3 For each phase, check the correct current value is displayed on the Power Meter, and on Power-On. The values should be within 3%.

13.4 Measure the phase to neutral voltage on the LV board for each phase with a multi-meter, check the correct values are displayed on the Power Meter, and on Power-On. The values should be within 0.5%.

13.5 Check the kW analogues for each phase on Power-On are showing a +ve power flow from the Transformer/ACB to the LV Board.

14 Final Checks

14.1 Check all umbilical cables are clearly identified and labelled on the Gemini 3 and plant.

14.2 Check all connections/plugs are secure.

14.3 Check that Gemini 3 is set to ‘Remote’.

14.4 Check all ‘OK’ LEDs are flashing green, the ‘PWR’ LEDs are solid green and the ‘CAN’ LEDs are flashing green on the RTU modules.

14.5 Close and secure the RTU door.

14.6 Check all outstanding Power-On alarms are cleared.

15 Asset Data

15.1 Complete the asset data form and either send it to the Asset Registration Team or email it to the appropriate mailbox (ART.EPN, ART.LPN or ART.SPN).

16 Test Equipment

16.1 Record the purpose, make, type and serial number of all test equipment used during commissioning on the test form.

17 Certification

17.1 When the commissioning has been satisfactorily completed, sign and date the test form. The test form shall be left on-site, in a plastic wallet, in the control unit.

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Appendix A – RTU Software Update

Download the latest version of the Software from Alfresco:

Open Alfresco from the Intranet Home page:

Home Page > Applications (from right hand menu) > CDL, DMS, Cloudman, iCass, LMS (half way

down page under HSS&TT Apps)

Select ‘Engineering Documents’

(from the left hand menu) Documents > Engineering > Reference Library (then select Link to:

Reference Library) > Relay and RTU Software > Lucy > Gemini 3 > Lucy G3 Software

Download both the ‘SDP’ and ‘SDP Bootloader’ zip files to a suitable folder on your laptop.

The Gemini 3 software is upgraded using Gemini 3 Configuration Tool as follows:

1. Select Utilities from the left hand menu.

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2. Select Upgrade from the left hand menu.

3. From the ‘1. Select Software Distribution Package File(.zip)’ menu, ‘select the file to be uploaded’ (this will be the ‘SDP bootloader’ file) by browsing to the folder you downloaded the files to from Alfresco. This may take a few minutes.

4. From the ‘2. Select Software Version for MCM’ menu, select the version required (this will be the version with the highest number, if they are the same select the ‘MCMBoard.zip’ version).

5. Select ‘Start Upgrade’.

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6. You will see a ‘Confirm Upgrade’ box appear, select ‘Yes’.

7. You will then see the following boxes appear as the Software goes through the upgrade process.

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8. Once the upgrade process has completed you will see the following box, select ‘OK’.

9. The process will then need to be repeated to load the ‘SDP’ file.

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Appendix B – Status Information Screens

The Gemini 3 Configuration Tool program also provides an HMI to enable the communications, digital alarms/indications, analogues and events to be viewed and the controls to be actioned, to assist with the commissioning and testing of the Gemini 3. The procedure to access the Mimic page is as follows:

1. Follow the procedure detailed in 10.2 to 10.8. 2. Select Commissioning from the left hand menu. 3. Select Mimic from the left hand menu.

B.1 Communications Monitor

Within the Gemini 3 Configuration Tool is the facility to monitor RTU Events and RTU Alarms using two tabs within the configuration tool Realtime Monitor.

The RTU Events tab enables the display of historical and real-time time-stamped events (including SCADA protocol events & system events) to be reported to the SCADA.

The RTU Alarms tab enables the display of the current alarm state of each module in the system.

The procedure to access the Mimic page is as follows:

1. Follow the procedure detailed in 10.2 to 10.8. 2. Select Realtime Monitor from the left hand menu. 3. Select the desired tab Events or Alarms from the bottom of the screen.

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Appendix C – Configuration Cable

C.1 Configuration Cable

If the Laptop supports auto-crossover a standard Ethernet Patch Cable may be used to connect a laptop PC to the Gemini 3 for configuration, if not a crossover Ethernet cable is required.

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Appendix D –RMU Wiring Modification for LPN Specification Schneider RMUs

The modification is required to change the way the Schneider RMU actuator is powered to remove the risk of an unplanned operation of the actuator. The modification is only required when using an old LPN specification Schneider RMU with a new Lucy Gemini 3 or Remsdaq CallistoNX RTU via an LPN Retrofit Adaptor box. No modifications are required for any other manufacturers RMU or when using a new UKPN specification RMU connected directly to the RTU with umbilical cables.

Modification Procedure

1. Remove the 4 off M8 bolts from each side of the RMU Harting socket cabinet.

2. Cut the mastic seal between the RMU Harting cabinet front cover and the cabinet body. Once the seal is broken remove the front plate, this will allow access to the terminal block KP2 and Polarity conversion relays.

Fig.1 - Harting Socket Cabinet with Front Plate Removed

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3. Fit one new terminal on the right hand side of existing terminals at rail KP2.

Fig.2 – Klippon Rail KP2 Showing New Terminal Position

4. Remove wires K43 at the top position of terminal 2. There are two wires at this location, one is connected directly to the six pin Harting Socket SKA-3 and the other is directly connected to rail KP4/14. The former should be connected to the top position of the new terminal. The latter should be connected to the bottom position of the new terminal.

5. Remove any dry mastic remaining on the body or the front plate of the Harting Socket Cabinet. Re-fit the front plate using the M8 bolts removed in step 1. Use mastic to reseal between the front plate and the cabinet body.

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Appendix E –Schneider Power Meter PM710 / PM5100 Comms Configuration

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

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Date: 06/10/2016

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

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• Configure the comms settings:

– Modbus Address – 1 (if connecting to 2 Power Meters from a single RTU, set the second Power Meter address to 2)

– Baud Rate – 9600

– No Parity

– 1 Stop Bit

• The default password is “00000” (five zeros).

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

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Appendix F – Lucy Power Meter Comms Configuration

This procedure is only required if the Power Meter is the second Power meter set up in the RTU configuration tool (Modbus address 2). The Power Meter is pre-set to Modbus address 1.

Long press on E to get into password entry display

Short press on up arrow to display 1000

Long press on E to accept password

The Modbus address is displayed.

Long press on E to enter address change mode

Two short presses on E to select the right hand digit

Short press on Up arrow or Down arrow to change the address (set to 2)

Long press on E to save the change

The display will revert to displaying AC values if not touched for a minute or so.

Once completed, the display should NOT be set to show MD values. Use the button labelled ‘V/A’ or ‘U/I’ to see real time voltage and current.

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Lucy Gemini 3 Type E RTU Commissioning Procedure Document Number: ECP 11-0535

Version: 2.0

Date: 06/10/2016

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Appendix G – EPN/SPN Spec Schneider RMU Adaptor Cable

The universal umbilical is modified so that it can connect to a standard Schneider RN2C (EPN & SPN)

This umbilical will work with switch 1 and switch 2 of RN2C and RN6C EPN/SPN type units.

The standard automated Schneider ringmain is equipped on each automated way with an initial "T" wiring loom piece to accommodate an actuator removed alarm relay.

Commence by fitting the umbilical to the ring main unit before connecting to the RTU.

When the umbilical is installed into the ring main unit landing gland plate (splits to allow access of connector plugs etc.) the loom splits in the following way:

1) 8 cores are made off into a 12 way plug(female pins). This connects into one end of the "actuator removed" "T" piece loom.

2) 1 core [Y/G] connects direct to the A1 terminal of the "T" piece relay base. The existing H5 wire loop should be completely removed; it loops to the adjacent No.16 terminal connector on the "T" piece.

3) 4 cores - CT wiring - go direct to the inbuilt CT shorting block(may need to remove the wires going to the EFPI unit if fitted). On commissioning the CT shorting block must be checked so that the links are opened.

It is intended that an automatic electronic CT shorting block should be mounted imbetween the inbuilt CT shorting block and the outgoing cores to RTU CT wires. This will mount on the Din rail. If supplied the wiring will be obvious; 4 wires in and 4 wires out.

4) The alarm sense on the contacts of the "T" piece relay must be changed. Move wire L15 from terminal 12(NC) to 14 (NO).

5) All other cores in the new umbilical should be insulated and coiled out of the way.

6) Umbilical should be numbered externally with the switch circuit designation at both ends.

7) Fit location pin in RTU umbilical plug to agree with circuit in use.