FUTURE PROOF REMOTE MAINTENANCE

for TEM-Evo Engine Controllers

www.avat.de
 FUTURE PROOF
REMOTE MAINTENANCE
FUTURE PROOF REMOTE MAINTENANCE FOR
TEM-EVO ENGINE CONTROLLERS
Operators of power plants require high availability
from their engines, and as well as comprehensive
service, they need rapid response when faults arise.
The foundation of a successful service concept is
reliable remote service, which forms a basis for
securing existing service business and for building
new and sustainable service offerings.
For this reason, innovative companies are turning to
IP technology.
Modern remote maintenance solutions use Internet technology
2
Remote maintenance from the TEM-Evo specialists
For over 20 years AVAT has been a competent partner to the
gas engine industry and is the manufacturer of the TEM-Evo
engine controller which is in use on over 1000 engines.
AVAT’s remote maintenance solutions are based on current
Internet technology and have been specially conceived for
use with TEM-Evo. They enable safe and direct remote access
to the MWM engines under your supervision.
zz IP-based remote maintenance solutions adaptable to all
types of plant
zz Easy installation or conversion via TEM-Evo compatible
interfaces and device drivers
zz Permanent remote control and visualization of the engine
controller with the TEM-Evo PC software package (JView)
zz Other industrial controllers connectable to the VPN Router
Fast and competent remote diagnostics
The direct VPN connection to the on-site engine controller
enables quick and thorough diagnosis of alarms and mal-
functions as they occur. With the TEM-Evo software package
your specialist maintenance personnel can analyze the
condition of the engine and initiate appropriate measures.
zz Data analysis and fault detection
zz Alarm acknowledging and parameterization
zz Implementation of maintenance measures
zz Recommendations for plant optimizations
Efficient coordination of service work
With the Virtual Service Center (VSC) – a central rendezvous-
server on the Internet – you can manage your complete
engine-pool and all your service staff from a single location.
This is the ideal way to coordinate your service needs quickly
and efficiently.
Increase your service efficiency through the early planning of
fast, precisely targeted service measures. Avoid unnecessary
site visits when problems can be solved remotely.
zz Comprehensive overview of all monitored systems and
authorized employees
zz Secure implementation of VPN connections from the plant zz Use a turnkey modular system with VSC,
to remotely located service personnel
zz Quick access to service-related engine data
zz Central service planning, management and control of your
engine-pool
Make a direct connection to the TEM-Evo controller via remote access.
Analogue telephony is on the way out
By the end of 2018, Deutsche Telekom and other
telecommunications providers are planning to
convert from conventional telephone technology
to Internet-based communications. As a result,
analogue connection modules such as modems
will become obsolete and inoperative.
If you want to continue to use your existing
modem-based remote maintenance services,
convert to a modern Internet router in good time.
zz Make your installation future-proof now
VPN router and TEM-Evo connection
For more information visit: www.avat.de/vsc
or call: +49 7071 9735-69
www.avat.de 3
 REMOTE MAINTENANCE
SECURE AND RELIABLE

A RELIABLE CONNECTION
WITH INDUSTRIAL ROUTERS FROM AVAT

An essential element in a successful service Switch to secure remote maintenance

concept is a reliable remote connection to control
systems and engines at remote locations. An
important pre-condition is secure data exchange
protected from external threats.
With the Virtual Service Center (VSC) and industrial
routers from AVAT, you get a reliable solution that
meets your needs in terms of access security,
availability and data protection.
Do you want to readily access the engines you are responsible
for, at any time and from anywhere in the world? Connect
one or more local TEM-Evo engine controllers to VPN routers
and register yourself at AVAT’s Virtual Service Center (VSC).
If you are still using old analogue modems and want to upgrade
or convert to future-proof remote maintenance, then carry out
the following steps:
zz Establish an Internet connection via broadband using
the plant operator’s network or use a direct mobile
telephone connection
zz Connect the VPN router to the TEM-Evo controller
zz Register the router in the VSC
zz Setup Internet access at the remote workstation
zz Implement Remote Maintenance using the TEM Evo
PC software package (JView)

After successful authentication with the VSC, the router

establishes a secure VPN connection. VSC acts as a platform
(rendezvous-server) on which registered users can carry out
remote maintenance tasks at their globally located plants.

Direct access to the engine controller via VPN remote access with TEM-Evo PC Software

4
Comprehensive safety management
Today, data security, protection against viruses and manipu-
lation, and compliance with data regulations are challenges
for companies in all areas.
With the Virtual Service Center (VSC) you get a stable,
secure Internet connection and extensive server capacity
and computing power. Your plant and your services will be
protected from external threats by constantly updated
safety measures.
zz Industrial routers with integrated firewall
zz Secure connection via OpenVPN
zz Password-protected access to the VSC
zz Network availability of over 99%
zz High performance computer center in Germany with a
redundant link
VSC offers reliable technology with secure connection and high availability
Remote maintenance terminology
Analogue connection:
Refers to a telephone connection used to operate analogue
telecommunications equipment such as telephones, faxes
or modems. This technology is increasingly being replaced
by digital technology. Today, modern systems communica-
te via the Internet or mobile telephony.
Router:
Communicates digital data within networks and into the
Internet. Routers are used as a replacement for analogue
dial-up modems for Internet access, for linking networks
and for the secure connection of Web-portals via VPN.
VPN (Virtual Private Network):
Serves to create an Internet connection between partici-
pants in one self-contained network and those in another
self-contained network (VPN tunnel). Data are transmitted
in encoded form via the potentially insecure Internet so
that they cannot be intercepted or manipulated.
Firewall:
Protects a computer or a network against unauthorized
access. A router‘s firewall monitors the throughput of
data and restricts network access according to a set of
configurable rules stored in its memory. Firewalls usually
prevent any external access to the system.
Rendezvous-Server:
Is a central Internet platform where all the systems and all
the different users can connect via a secure VPN access.
The rendezvous server provides connections between
users and systems and allows secure data exchange.
www.avat.de 5
 REMOTE MAINTENANCE
MODERNIZED

MODERNIZED REMOTE ACCESS

ON TEM-EVO ENGINE CONTROLLERS

Are you still using analogue modems and planning
to convert to Internet-based services? Do you want
to equip existing installations with future-proof
access to remote maintenance?
With VPN routers from AVAT that are preconfigured
Upgrading and converting of TEM-Evo controllers
If you want to upgrade existing TEM-Evo controllers with a
remote maintenance function, you need a VPN router and an
interface converter (ModemKon) from AVAT.
First you connect the ModemKon to the function selection unit
(FAE) in the TEM-Evo cabinet. Then you connect the ModemKon
to the VPN router and establish the network connection.

for use with TEM-Evo controllers, you can execute In multi-engine installations, you connect the router directly
the changeover in a few easy steps. to the intelligent selection unit (IAE) which you will find in the
auxiliary equipment cabinet (HAS).

Upgrade to remote maintenance To convert existing analogue connections, replace the existing
To upgrade the TEM-Evo controller modem with a VPN router from AVAT.
carry out the following steps:

1. Connect the ModemKon to

FAE terminals in the TEM-Evo
2. Connect the VPN router to the
ModemKon and establish a
connection to the VSC

TEM-Evo without remote maintenance

Convert to remote maintenance

To convert the TEM-Evo controller
carry out the following steps:

1. Replace the eServ IP-Modem

with the VPN Router
2. Connect the VPN Router to the
ModemKon and establish a
connection to the VSC

TEM-Evo with remote maintenance via analogue modem TEM-Evo with remote maintenance via secure VPN access

6
Simple installation and commissioning Technical data VPN router
Pre-configured connection cables are supplied for connecting
the ModemKon or IAE to the VPN router. Operating voltage 10 - 30 VDC
Current rating max. 1,3 A
The VPN routers are connected to the Internet via the
plant-side broadband connection or via a mobile telephone. Protection class IP 20
The existing analogue telephone connection is no longer Operating temp. 0 ° to 50 °C
needed. Storage temp. -20 ° to +60 °C
Humidity 0 to 95% non-cond.
Installation
Follow a few simple steps to install the VPN router: Weight appr. 650g
Dimensions (HxBxT) 124 x 48 x 124 (in mm)
zz Install Router in the auxiliary equipment cabinet Fixation Top hat rail
zz Connecting to the company network or prepare for mobile
telephone via SIM card
zz Connect the power supply and earth (ground) connection

Commissioning without specialist IT knowledge

In a few steps, you can connect to the Virtual Service Center
(VSC). Installation is implemented using the USB flash drive
included in the scope-of-supply.

zz Check the connection by means of the Check-Software

zz Start VSC and install the router via the Dial-Up Software
zz Transfer the communication data from VSC to the router
using the USB
zz Remote access becomes functional after system restart

Do you have questions about configuration?

We’ll be glad to help. Contact us on css@avat.de or
by telephone on +49 7071 9735-69.

VPN router MDH 814 with LAN interfaces and mobile telephone antenna

www.avat.de 7
 VPN ROUTERS
FEATURES

VPN-ROUTERS FOR REMOTE MAINTENANCE

OPTIMIZED FOR TEM-EVO CONTROLLERS

All routers feature:

4 x LAN ports (Ethernet), 4 x digital inputs (low 0-3,2V, high 8-30V DC), 2 x digital outputs
(50mA, 12V / 100mA, 24V) for use in case of alarm messages, 1 x USB port (host 2.0) usable for
configuration and as an external data storage, preconfigured for up to 2 TEM-Evo controllers

Order No.

For use with plant-side Internet connection (DSL)

VPN-Router MDH 810 3200 101
zz WAN interface to broadband connection (DSL)
zz 2x RS-232/485 seriell interface pre-set for use with TEM
zz Remote access via virtual COM-port

For use with Internet connection via mobile telephony

VPN-Router MDH 814 3200 102
zz UMTS modem for connection via mobile telephony
zz 2 SIM card slots with Failover* functionality
zz WAN interface to broadband connection (DSL)
zz 2x RS-232/485 seriell interface pre-set for use with TEM
zz Remote access via virtual COM-port

Interface overview of all available routers

Internal External
Serial LAN Analogue GSM/UMTS WAN
MDH 810
MDH 814
MDH 816
MDH 819
available
not available

*If one of the mobile networks fails, the system switches to the network of the second SIM card. The plant still remains available.

8
Accessories
For fast and simple router installation you will receive the
following accessories:

Bestell-Nr.
ModemKon 4500 091
zz Converts from RS 232 to TTY interface
zz Required for cable length over 5m

Connecting cable FAE/ModemKon-VPN-Router 3200 120

zz Serial connecting cable
zz Connects VPN-Router (in the auxiliary equipment cabinet) via
ModemKon to the functions selection unit FAE* in the TEM cabinet

Connecting cable IAE-VPN-Router 3200 125

zz Serial connecting cable
zz For connection between VPN Router und IAE** in the
auxiliary equipment cabinet
USB-Stick, 4GB 3200 111
zz Used for router configuration and as a data storage device
zz Contents: VPN Router manual, Declaration of Conformity,
DIALUP and CHECK-Software

* The function selection unit (FAE) allows manual switching between local control of the TEM-Evo system and remote access.
** The intelligent selection unit (IAE) automatically switches the connection from the router and/or modem to one of the connected
TEM-Evo systems.

www.avat.de 9
 CENTRAL
DATA
QUALIFIED STATUS- AND ALARM MESSAGES
IN THE VIRTUAL SERVICE CENTER (VSC)
To ensure the economic viability of energy
production plants it is essential to guarantee
high availability. Current machine status is an
important indicator of this.
With the Virtual Service Center, AVAT now offers an
expanded range of engine monitoring functions.
You receive constantly updated status and alarm
messages from connected gas engines equipped
with TEM-Evo engine controllers.
In the case of a malfunction an e-mail containing the most important data
will be sent to the smartphone
10
MANAGEMENT
Qualified alarm management
In addition to active remote monitoring an efficient alarm
management is crucial in order to minimize engine down-
time. The VSC informs you on the current status of your
system, either continuously or on demand.
zz Automated e-mail notification of warnings, malfunctions
and status changes.
zz On-call status selectable for each e-mail recipient
zz Configuration/storage of alarm profiles at the VSC
zz List of alarm messages with acknowledgment status
Automatic status notification
In addition to the alarm messages operating and status
data are continuously reported to the Virtual Service Center
and visualized there.
zz Connection Status
zz Operating Status
zz Power and rpm
zz Operating hours with planning recommendations for main-
tenance work according to predetermined service intervals
zz Configuration, analysis and reporting via Internet browser
zz Automatic data communication every 5 seconds
Web-oriented visualization
Monitor task-specific screen displays direct in your web
browser, at your PC workstation and via your smartphone or
tablet.
zz Cockpit: major performance and status messages,
engines grouped by plant and operator
zz Fault Monitor: alarm list with current status and
responsible employees
zz Configuration of signalling profiles in the VSC
zz Service Monitor: Operating hour meter with indication
of service intervals and forecasts
The VSC Cockpit is the control center for all additional monitor views
Data management of the future
A success factor for future service models is the
high quantity of data available in the plant and
its controls.
Values for power, speed, number of starts,
temperatures, pressures, voltages, fluid levels
and the status of actuators and valves, are
continuously monitored. These operating data
are stored and already partly evaluated by the
control system.
Allow these data to be acquired by on-site
control systems and transmitted to the data
center. Via the visualization of the temporal
sequences of different engines and equipment,
you obtain an efficient tool for optimising
running time and maintenance.
By means of automated analysis processes,
patterns are quickly identified and interpreted,
leading to the early recognition of critical
conditions.
zz Permanent condition monitoring of your
entire engine pool
zz Systematic early fault recognition and
engine optimization
zz Predictive maintenance and replacement
planning
zz Continuous forecast of availability and
profitability
zz Long-term storage of operating logs, history
and parameters
www.avat.de 11
 REMOTE MAINTENANCE
CUSTOMER-ORIENTED
CUSTOMER-ORIENTED REMOTE MAINTENANCE
WITH THE VIRTUAL SERVICE CENTER
Investing in large gas engines for energy production
carries considerable risks. Protect the operator’s
earnings by guaranteeing high plant availability
and keeping down operating and service costs.
Engine controllers and remote service tools from
AVAT enable you to organize engine operation and
servicing, in advance and according to a well-
planned, economic schedule.
Efficient engine control in combination with professional remote maintenance
guarantees long-term earnings
12
Efficient coordination
With AVAT remote services you can plan your work even
more precisely. Trained staff at the control center decide on
the basis of received status messages if a site visit is
necessary or if the fault can be corrected by remote inter-
vention. By reducing travel time you reduce your service
costs and ensure the economic viability of the plants you
manage.
zz Central overview of all managed systems
zz Rapid remote diagnosis
zz Site visits are reduced, travel costs minimized
zz Management of all systems and users from the VSC
(Virtual Service Center)
Increase plant availability
AVAT remote services provide targeted engine control,
predictive maintenance and rapid fault corrections.
Pro-actively prevent engine downtimes shutdowns by
quickly identifying and eliminating potential malfunctions.
zz Fast reaction to outages via direct alarms
zz Smaller faults corrected remotely from the control center
zz Targeted planning of site visits via qualified
alarm messages
zz Reliable and secure data connections via high system
availability at the VSC (Virtual Service Center)
Simple modernization Future-proof remote maintenance
Easily replace your installed analog modems with Internet-
based VPN routers from AVAT. Plants which are equipped with via VPN Router and the
TEM-Evo gas engine control systems and do not presently have Virtual Service Centre (VSC)
remote access can be updated simply by adding suitable
routers.
For more information visit:
zz Updating and conversion solutions for remote www.avat.de/vsc
maintenance directly from the manufacturer of TEM-Evo
or call: +49 7071 9735-69
zz A range of router variants for every application case
zz Commissioning without special IT knowledge
zz DIN top-hat rail mounting in the auxiliary equipment
cabinet
zz Ready-made cables available for connection of the
VPN router to TEM-Evo

Simple updating of a VPN router via mounting on a top-hat rail

www.avat.de 13
 PATH
TO SUCCESS
TWO BUSINESS AREAS – ONE GOAL
AVAT stands for competence in automation and
process control technology. In the field of engine
management systems for cogeneration plants,
with AVAT as a partner you are dealing with a
global leader in this area of technology.
As a partner of municipal and private energy
producers and plant engineering companies, AVAT
pursues an holistic approach, consisting of well
thought-out concepts and sustainable solutions in
supply and process engineering.
AVAT’s overriding aim is always to use our growing
fund of know-how to make the most recent project
the best, to maximize the benefit to our customers.
AVAT’s offering encompasses consultation and the implementation
of product objectives right up to the commissioning stage
14
Automation and control systems
AVAT implements and manages sophisticated automation
projects through all their phases. Involvement ranges from
specification of project objectives to equipment commissioning.
You benefit from a comprehensive offering, from the process
control system to the on-site equipment, from the highly complex
control software to a completely assembled control cabinet.
Engine management systems for cogeneration gas engines
AVAT is a long-term development partner of leading interna-
tional manufacturers of gas engines, whom we accompany
from the idea to the concept and on to series production.
An holistic approach to the gas engine and close collabora-
tion with research institutions and engine developers have
led to interdisciplinary expertise in engine technology and
in-depth knowledge of combustion processes.
This all-round proficiency has made AVAT today’s technology
leader in highly efficient engine management systems.
More than 25 years of experience in the development of gas engine controls
flows into every new project.
Our products and services
As a partner of municipal and private utilities and equipment
manufacturers, we develop innovative concepts in automation
and control technology:
zz Sector-specific solutions for heat, electricity, gas and water
zz CHP Automation - highly efficient distributed power
generation
zz Tools for the liberalized energy market (electricity/gas)
zz Renewable energy: biogas plants, biomass power plants,
syngas production
A highly flexible approach results in tailored solutions, closely
adapted to different customer requirements and plant sizes in
the following areas:
zz Measuring, control and regulation technology
zz Remote control systems, data and communications technology
zz Process control in visualization, observation, monitoring,
alarms, logging, archiving
zz Concepts for increasing efficiency and reducing emissions
zz Solutions for energy and load management (Smart Grids /
virtual power plants / virtual power storage)
Our Expertise - Your Benefits
zz Over 25 years’ experience in the development
of gas engine control systems
zz Innovative automation solutions for supply
and process engineering
zz Technology leader in control systems for
large gas engines
zz More than AVAT 6,500 engine controllers
in use worldwide
zz Over 7,000 MW of installed electrical power
using AVAT technology
zz About 80 highly qualified employees in
interdisciplinary engineering teams

Expertise and systems solutions competence

At AVAT you get automation solutions resulting from extensive
expertise in several disciplines:
zz Engineering / CAD
zz S
 oftware development at control and plant management
levels
zz System integration of hardware/software/peripherals
zz C
 ontrol cabinet construction, electrical assembly and
commissioning
zz Service, support and remote maintenance

www.avat.de 15
AVAT Automation GmbH
Derendinger Straße 40
D-72072 Tübingen

Tel +49 7071 9735-0

Fax +49 7071 9735-55

E-Mail: avat@avat.de
Web: www.avat.de
Presented by:

© 2015 AVAT Automation GmbH

Subject to technical changes at any time PB_VSC_E_1509