SCADA Hardware and Software

SCADA Hardware and Software
by Editorial Staff
A SCADA system consists of a number of remote terminal units (RTU)
collecting field data and sending that data back to a master station,
via a communication system. The master station displays the acquired
data and allows the operator to perform remote control tasks.
The accurate and timely data allows for optimization of the plant
operation and process. Other benefits include more efficient, reliable
and most importantly, safer operations. This results in a lower cost of
operation compared to earlier non-automated systems.
SCADA system essentially has five levels or hierarchies, as

listed below
1. Field instrumentation and control devices: These analog and

digital sensors situated at each remote site
2. Marshalling terminals and RTUs: These provides an interface to

the field devices
3. Communications system: Communications systems form the

backbone of SCADA. The widely used systems are wire, fiber optic,
radio, telephone line, microwave and possibly even satellite. Specific
protocols and error detection techniques are used for efficient and
optimum transfer of data pathway for communications between the
master station and the remote sites
4. The master station(s): The master stations gather data from the
various RTUs provide an operator interface for display of information
and control of the remote sites
5. Information Technology (IT) Applications: The commercial
information technology (IT) or data processing department computer
system.
Table of Contents
 SCADA Hardware Functions
 Remote Terminal Units (RTU)
 RTU Hardware
 SCADA RTU
 RTU Software functions
 Basic operation
 RTU Standards
 Difference between PLC and RTU
SCADA Hardware Functions

There are many functions of SCADA; some of them are listed below.
Data Collection: collecting of the information via a RTU (remote

terminal unit)
Data Transfer: transferring it to the central site
Data Processing: Carrying out any necessary analysis and control
Information Display: Displaying that information on operator screens

or displays
Control Actions: Required control actions are then conveyed back to

the process
Remote Terminal Units (RTU)

An RTU (sometimes referred to as a remote telemetry unit) as the title
implies, is a standalone data acquisition and control unit, generally
microprocessor based, which monitors and controls equipment at
some remote location from the central station.
Its primary task is to control and acquire data from process equipment
at the remote location and to transfer this data back to a central
station. It generally also has the facility for having its configuration and
control programs dynamically downloaded from some central station.
There is also a facility to be configured locally by some RTU
programming unit. Although traditionally the RTU communicates back
to some central station, it is also possible to communicate on a peer-
to-peer basis with other RTUs.
The RTU can also act as a relay station (sometimes referred to as a

store and forward station) to another RTU, which may not be
accessible from the central station.
The RTU provides an interface to the field analog and digital sensors
situated at each remote site. The communications system provides the
pathway for communication between the master station and the
remote sites. This communication system can be wire, fiber optic,
radio, telephone line, microwave and possibly even satellite.
Specific protocols and error detection philosophies are used for

efficient and optimum transfer of data. The master station (or sub-
masters) gather data from the various RTUs and generally provide an
operator interface for display of information and control of the remote
sites.
In large telemetry systems, sub-master sites gather information from

remote sites and act as a relay back to the control master station.
Small sized RTUs generally have less than 10 to 20 analog and digital
signals, medium sized RTUs have 100 digital and 30 to 40 analog
inputs. RTUs, having a capacity greater than this can be classified as
large.
RTU Hardware:
The RTU Hardware consists of a set on inputs, outputs, memory and
communications.
There are further classified as following
Inputs
 Analog inputs (AI)

 Counter inputs (CI)
 Digital inputs (DI)
Outputs
 Analog outputs (AO)

 Digital outputs (DO)
Memory
 Static and Dynamic Memory
 Control processor and associated memory
Communications and Other modules
 Communication interface(s)
 Power supply
 RTU rack and enclosure
SCADA RTU
The SCADA RTU is a small rugged computer which provides
intelligence in the field, and allows the central SCADA master to
communicate with the field instruments. It is a stand alone data
acquisition and control unit. Its function is to control process
equipment at the remote site, acquire data from the equipment, and
transfer the data back to the central SCADA system.
There are two basic types of RTU – the “single board RTU” which is
compact, and contains all I/O on a single board, and the “modular
RTU” which has a separate CPU module, and can have other modules
added, normally by plugging into a common “backplane” (a bit like a
PC motherboard and plug in peripheral cards).
A typical single board RTU
The single board RTU normally has fixed I/O eg 16 digital inputs, 8
digital outputs, 8 analogue inputs, and say 4 analogue outputs. It is
normally not possible to expand its capability. The modular RTU is
designed to be expanded by adding additional modules.
Typical modules may be an 8 analog in module, a 8 digital out

module. Some specialized modules such as a GPS time stamp module
may be available.
Hardware functionality in an RTU
The SCADA RTU is a small rugged computer. It has the following

hardware features:
Memory
 CPU and volatile memory.

 Non volatile memory for storing programs and data.
Interface
 I/O interfaces to DI/DO/AI/AO’s.

 Real time clock.
Communications
 Communications capability either through serial port(s) or

sometimes with an on board modem.
Power Equipment
 Secure Power supply with battery backup.
 Watchdog timer to ensure the RTU restarts if something fails.
RTU Software functions
All RTU’s require the following functionality. In many RTU’s these may
be intermingled and not necessarily identifiable as separate modules.
Real time operating system, which can be a specific RTOS, or it may be
code that started out life as one big loop scanning the inputs, and
monitoring the communications ports. Driver for the communications
system, which is the link to the SCADA Master. Device drivers for
the I/O system connecting to the field devices.
SCADA applications like scanning of inputs, processing and storing of

data, responding to requests from the SCADA master over the
communications network. Some method to allow the user applications
to be configured in the RTU.
This may be simple parameter setting, enabling or disabling specific

I/O’s or it may represent a complete user programming environment.
Diagnostics. Some RTU’s may have a file system with support for file
downloads. This supports user programs, and configuration files.
Basic operation
The RTU will operate scanning its inputs, normally at a fairly fast rate. It
may do some processing such as change of state processing, time
stamping of changes, and storage of the data awaiting polling from
the SCADA master. Some RTU’s have the ability to initiate reporting to
the SCADA master, although more common is the situation where the
SCADA master polls the RTU’s asking for changes.
The RTU may do some alarm processing. When polled by the SCADA
master, the RTU must respond to the request, which may be as simple
as “give me all your data”, to a complex control function to be
executed. RTU’s are specialty devices manufactured often by small
suppliers in batches of as little as one hundred. They are made for
niche markets, and at the smaller end can be subject to intense cost
pressures.
Therefore not all RTU’s support all functionality. Larger RTU’s may be
capable of processing hundreds of inputs, and even controlling
smaller “sub RTU’s”. These are obviously more expensive. The
processing power of an RTU ranges from small 8 bit processors with
minimal memory to larger sophisticated RTU’s capable of time
stamping data to millisecond accuracy.
RTU Standards
As indicated RTU’s are specialty devices. There has been a lack of
standards, especially in the communications area, and generally RTU’s
from one supplier cannot be mixed with RTU’s from another supplier.
An industry has grown up developing protocol converters and
emulators.
Recently some standards have begun to emerge for RTU’s. Some

standards are
1. DNPs and IEC870 for communications and

2. IEC1131-3 for programming RTU’s.
Difference between PLC and RTU
A PLC (programmable logic controller) is a small industrial computer
which originally replaced relay logicWhat is Relay Logic ?. It had inputs
and outputs similar to those an RTU has. It contained a program which
executed a loop, scanning the inputs and taking actions based on
these inputs.
Originally the PLC had no communications capability, but they began

to be used in situations where communications was a desirable
feature. Communications modules were developed for PLC’s,
supporting Ethernet (for use in distributed control systems) and
the Modbus communications protocol for use over dedicated (wire)
links. As time goes on we will see PLC’s support more sophisticated
communications protocols.
RTU’s have always been used in situations where the communications

are more difficult, and the RTU’s strength was its ability to handle
difficult communications. RTU’s originally had poor programmability in
comparison to PLC’s. As time has gone on, the programmability of the
RTU has increased.

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SCADA Hardware and Software

SCADA system essentially has five levels or hierarchies, as

1. Field instrumentation and control devices: These analog and

2. Marshalling terminals and RTUs: These provides an interface to

3. Communications system: Communications systems form the

SCADA Hardware Functions

Data Collection: collecting of the information via a RTU (remote

Data Transfer: transferring it to the central site

Data Processing: Carrying out any necessary analysis and control

Information Display: Displaying that information on operator screens

Control Actions: Required control actions are then conveyed back to

Remote Terminal Units (RTU)

The RTU can also act as a relay station (sometimes referred to as a

Specific protocols and error detection philosophies are used for

In large telemetry systems, sub-master sites gather information from

There are further classified as following

 Analog inputs (AI)

 Analog outputs (AO)

A typical single board RTU

Typical modules may be an 8 analog in module, a 8 digital out

Hardware functionality in an RTU

The SCADA RTU is a small rugged computer. It has the following

 CPU and volatile memory.

 I/O interfaces to DI/DO/AI/AO’s.

 Communications capability either through serial port(s) or

SCADA applications like scanning of inputs, processing and storing of

This may be simple parameter setting, enabling or disabling specific

Recently some standards have begun to emerge for RTU’s. Some

1. DNPs and IEC870 for communications and

Originally the PLC had no communications capability, but they began

RTU’s have always been used in situations where the communications

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