Industrial IT

For bay control solutions

BCS 590 / BCS 593 GIS above 170 kV

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The essential first improvement step

The benefits of advanced power system

management require the automation of local
operations and the collection, evaluation and
forwarding of data from the primary equipment
to higher level systems.

In this context, the BCS590 and BCS593

solutions for bay-level control functions are
an integral part of systems for substation
automation mainly for sub-transmission and
transmission level substations. They belong
to the BCS family of modular pre-engineered
solutions and are dedicated for single and double-
busbar configurations. The ABB intelligent
electronic device REC316*4 with its
comprehensive control library is used as
the bay controller.

Typical applications of BCS590 and BCS593: Highlights

■ High safety standards

Power utilities, transmission level gas
isolated switchgear above 170kV
High voltage substations above 170kV for
installations with severe space constraints
or high aesthetic requirements, such as:
■ Metropolitan areas
■ Resort or environmentally protected areas
High voltage substations for installations
in heavily polluted environments, such as:
■ Petrochemical plants
■ Cement plants
■ Coastal Areas
Examples:
■ Modular scalable solutions
BCS593 modern control: ■ Fully integrated into the ABB SA System
local control cubicle for a new double- ■ Proven function packages
busbar indoor GIS substation with ■ Premium functionality
numerical protection including remote
connection to a Network Control Center.
BCS590 modern control:
local control cubicle to refurbish the
older generation secondary equipment
for a single busbar indoor GIS 220kV
transformer substation with numerical
protection and control equipment.

High voltage substations for installations BCS590 conventional control:

with high reliability requirements, such as: control panel for a new conventionally
■ Chip manufacturers controlled single busbar indoor GIS
■ Petrochemical plants substation. Remote control from the
■ Critical consumers (hospitals, hotels Network Control Center is made via a
casinos etc.) remote terminal unit RTU.

Industrial IT is the ABB commitment to the real time

integration of automation and information systems
across the business enterprise.

2 ABB ABB 3
Bay control solution concept for BCS590 and BCS593
The bay Control Solution Concept is a
standardized comprehensive solution for control
cubicles for all the types of switchgear that can
occur in transmission and subtransmission and
busbar configurations.
Features
Common Features
BCS590 and BCS593 are two versions of
the Bay Control Solution concept comprising
control cubicles for high voltage gas isolated
switchgear (GIS) for voltage levels higher than
170kV.
The layout of the control cubicles and the
configuration of the devices as well as the main
functionality are identical for both solutions.
4 ABB
Modern and conventional control versions
of BCS590 and BCS593
For both of the applications, two control Single busbar Double busbar
GIS >170 kV GIS >170 kV
cubicle executions are defined:
■ Modern control Modern BCS590 BCS593
■ Conventional control
Conventional BCS590 BCS593
Specific features The modern control cubicle BCS590 modern control BCS593 modern control
is equipped with a microprocessor based Bay
■ The BCS590 is designed for a
Controller REC316*4 and a BCM800 mimic.
single busbar configuration
The performance characteristics of this solution are:
■ The BCS593 is designed for a ■ high functionality
■ simple integration in the ABB SA system via the
double busbar configuration.
LON bus
■ The main functional differences are in the ■ maximum reliability and availability.
complexity of the interlocking logic and in
the quantity of the high-voltage switchgear.
The conventional control cubicle BCS590 conventional control BCS593 conventional control
mainly differs from the modern by the replacement
of the REC316*4 Bay Controller by conventional
relay logic. The most important characteristics
of this solution are:
■ the basic functionality for the secure operation
of the plant,
■ local operation from the BCM800 mimic,
■ a parallel terminal block for the connection of
the remote controls.
ABB 5
Technical concept of the modern control
The diagram shows the structure of the control
cubicle in the modern control. The data
exchange between the components is shown
diagrammatically. The arrows represent the data
flow. The beginning and end of an arrow
represent an interface. Interfaces can be logical
or terminal blocks. The "Primary Interface
Solution" also comprises electromechanical
relays and the marshalling of the cables. The
concept is very flexibly and modularly designed
and permits customer specific adaptations to be
integrated very easily.
6 ABB
In LOCAL Mimic HMI mode the BCM800
mimic is used as an input device for the
REC316*4. Operator actions are first transmitted
to the REC316*4, and are checked there for
plausibility and for interlocking conditions. The
control command then goes from the REC316*4
via BCM800 to the Primary Interface Solution.
The Primary Interface Solution comprises the
output contactors for the control of the high
voltage switching devices.
In EMERGENCY Mimic HMI mode, the
switching commands go directly to the Primary
Interface Solution. The REC316*4 is bypassed.
The operator's comfort is therefore limited.
In this mode, the interlocking logic is made
conventionally in the Primary Interface Solution
with cabling.
Technical concept of the conventional control
The diagram shows the structure of the
conventional control. The main difference to the
modern control is the lack of the REC316*4 bay
controller. In place of the REC316*4 a parallel
terminal block is available that is used for the
remote connection to an RTU or station mimic.
The parallel interface uses exactly the same
terminals on the BCM800 as the REC316*4 bay
controller. The switching dialogs correspond to
the dialogs of the EMERGENCY Mimic HMI
mode for the modern control. Because of the
lack of the REC316*4 bay controller, all the
functions, with the exception of the alarm
handling and the Synchrocheck function are
conventionally implemented in the primary
interface solution block.
ABB 7
Function packaging for BCS590 and BCS593
The Bay Control Solution concept is based on
packaging. This enables customer specific
solutions to be made from predefined function
packages. A standardized interface concept
guarantees that the individual packages fit
together seamlessly.
Types of Packages
Base Package
The predefined scope of the functionality is
sufficient in order to locally control and monitor
a GIS station safely. This is the basic execution
to which extensions and modifications can be
made.
Add-On Package
The Add-On Packages extend the functionality
of the Base Package and can be used in any
combination.The predefined functions are
designed such that, starting from the basic
functionality, solutions can be made that fulfil
the highest requirements.
8 ABB
Customized Package
The customized package comprises any
customer specific functions and extensions that
are not in the Base Package or one of the Add-
On Packages. The flexible interface concept
allows customer specific functions to be
integrated, without influencing the functions
of the Base Package or one of the Add-On
Packages.
The modern control version for BCS590 and BCS593
The Modules
The REC316*4 Bay Controller
The functionality of the controls is significantly
increased by the use of the REC316*4 bay
controller, and at the same time the number of
terminals, cables, and electromechanical relays is
reduced, which contributes significantly to the
reliability of the complete control cubicle.
REC316*4
BCM800 Bay Control Mimic.
■ Intuitive operator guidance
is designed for maximum security; the status of
the plant is clearly displayed in a singleline
diagram.
■ Mimic Layout
The inscriptions on the mimic are made with
multi-color screen printing. The colors,
inscriptions, and the arrangement of the objects
are tailored for each customer. An easy to use
editor supports the user for the creation of the
mimic layout.
■ LOCAL Mimic HMI Mode
In LOCAL Mode the BCM800 mimic serves as the
input device for the REC313*4 controller. Inputs
are monitored by the REC316*4 controller and
checked for plausibility. Incorrect operation that
could lead to damage to the primary elements is Mimic BCM800
prevented both in own bay itself and also between
different bays by an interlocking and blocking
logic, that is implemented in the REC316*4.
■ EMERGENCY Mimic HMI Mode
If the REC316*4 bay controller is out of service
because of a fault, a change can be made at any
time to Emergency Mode. In this operation mode,
all the HV switching devices can be controlled.
The interlocking and blocking is conventionally
made with auxiliary contacts.
RIO580 (option)
To extend the number of the inputs and outputs
of the REC316*4 controller, a separate RIO580
device is used. This can be equipped with both
digital or analog inputs and outputs. This
concept enables any number of inputs and RIO580
outputs to be used with the REC316*4.
ABB 9
The modern control version for BCS590 and BCS593
Touchscreen (option)
The BCS590 and BCS593 cubicles can be exten-
ded with an additional touchscreen to make
maintenance and fault finding easier. The
touchscreen is provided with a comprehensive
application library.
Touchscreen integration concept
Touchscreen
10
Features
■ Protection and control information on one
screen.
■ Singleline diagram representation of the status
of the plant
■ Object orientated comprehensive alarm handling;
e.g. an SF6 gas alarm would be presented in the
gas compartment diagram physically related
visually and with text.
■ Clear presentation of measurands
■ Customer specific representation of protection
fault data, e.g. distance to the fault location
■ Execution of control sequences
– earthing of a bay
– changing bus bars
ABB
Characteristics
■ The hybrid combination LOCAL Mimic Mode and
EMERGENCY Mimic Mode
forms a secure solution, that enables both the
leaded operation by the bay controller, and also
operation of the bay on the failure of the bay
controller.
■ The hybrid controls REC316*4 with BCM800
form a logical bay control unit with which up to 7
high voltage switching devices can be monitored
and controlled in the basic version. As an option,
up to 8 high voltage switching devices are
supported.
■ Integration in the ABB station controls
is made via the LON BUS. This flexible concept
also supports the later connection to a remote
gateway or station control workplace without
additional engineering effort in the bay controller.
Therefore, the investment is secure for the future
in the case of a later extension of the station.
With this concept, benefits arise from the modern
ABB Station Automation and the higher-level
systems (ABB Advanced Power System
Management) both today and in future.
■ High functionality
The modern REC316*4 controller is provided with
a comprehensive library of functions. The
synchrocheck, the programming possibilities, and
various protection functions offer special
potential for applications.
BCS 593 base package
ABB 11
The conventional control version for BCS 590 and BCS 593 Functional description of the base package

BCM800 Mimic Terminal block for the protection recorded with mechanical counters. A total of 6
The BCM800 mimic is the key component of In the control cubicle, there is a terminal block counters are available. For the modern control,
the conventional control. In the basic execution for the connection of Trip Main1, Trip Main2, the switching operations and pump starts are
up to 7 high voltage switching devices can be and Autoreclosure (AR). This simplifies the additionally acquired in the REC316*4 controller
monitored and controlled. As an option, up to protection cubicle. and are transmitted via the LON interface.
8 high voltage switching devices can be
monitored and controlled. Operations counters for circuit Pump control
breakers and pumps Automatic control of the hydraulic pump or
Characteristics The single or three pole switching operations of compressor for maintaining the necessary
■ Local control
the power switches and the start-up of the operating pressure.
is identical with the EMERGENCY Mimic mode
pump in the case of a hydraulic drive are
of the modern controls.

■ Remote control

the higher level components are connected via

a terminal block.

■ The functionality

is designed to control and monitor the main

equipment safely and reliably. Interlocking, alarm
annunciation, display of measurands and
operation counters for the power switches and List of functions of the base package for BCS590 and BCS593
the pumps are all part of the basic functionality.
The following list gives the functionality of the base package for both types of controls:

BCS 590 base package Function Modern Conventional

control control
Terminal block for the protection Yes Yes
Operations counters for circuit breakers and pumps Yes Yes

Benefits of the BCS590 and BCS593 concept Pump control Yes Yes
Anti-pumping Yes Yes
Pump start cascading Yes Yes
■ Proven packages ■ Seamless integration in the ABB station controls
Pump supervision Yes Yes
there are proven packages that can be assembled (modern control only)
Operating pressure supervision Yes Yes
to form a solution based on modular principles. and in the ABB advanced power system
Pole discrepancy monitoring and trip function Yes Yes
This reduces the commissioning time to a minimum. management higher level systems enable unlimited
Alarm annunciation Yes Yes
access to process data and its processing into
■ Clear scope of supply
Interlocking and blocking Yes Yes
information that is of vital significance for the
already at the offer stage, the exact scope of the Mechanics RESP 97 series Yes Yes
efficient operation of a power network.
functionality is defined and documented. Measurand display Yes Yes
The bay control solutions (BCS) are integrated via
This saves the customer time and resoures for LOCAL mimic HMI mode Yes No
a LON BUS in one of the ABB SAS systems from
project management. EMERGENCY mimic HMI mode Yes Yes*
SAS510 to SAS570.
SA integration Yes No**.
■ Standardized interfaces Interlocking and blocking display Yes No
■ Modifications are possible later
enable the integration of application specific Synchrocheck Yes No***
(modern control only)
extensions without the need to make corresponding Event list Yes No
if for operational reasons, e.g. a manned station
modifications to the standard packages. Breaker position indication per phase Yes No
is to be converted to a remote controlled station,
this does not require any modifications to the Transmission of measurands
■ Scalable solutions from conventional to modern
control cubicle configuration. to the higher station level (SA system) Yes No
support a very wide range of applications.
A later upgrade of the functionality is very easily
■ High quality standards *) The local mimic HMI of the conventional control is the same as the EMERGENY mimic HMI mode
possible. In this way, a conventional control can be
every component used such as auxiliary relays of the modern control.
upgraded to a modern one later.
and intelligent electronic devices IEDs are proved **) A parallel terminal interface is available.
and fulfil the high ABB quality requirements. ***) The synchrocheck is implemented with a synchrocheck relay. This is available as an add-on package.

12 ABB ABB 13
Functional description of the base package
Anti-pumping
Anti-pumping control prevents the repeated,
undesired closing of a circuit breaker in the case
of a persisting CLOSE command followed by
an OPEN command. The circuit breaker
remains in the OPEN position, and the close
command is ignored.
Pump-start cascading
Too many simultaneous pump starts would
drain the station DC battery too much.
Therefore, only one pump can run at a time.
Pump supervision
The number of pump or compressor starts and
the running time is supervised in order to
obtain an early indication of problems with the
hydraulic or pneumatic circuits. In the case of an
oil or air leak, the pump starts more frequently
to restore the operating pressure. If the pump
running time until the oil pressure is restored is
shorter, this may be an indication of a nitrogen
gas leak in the gas compartment of the hydraulic
accumulator. In this case, preventive
maintenance can be made before the gas
pressure is too low for safe CB operation.
Operating pressure supervision
The operating pressure control functions are
executed in the REC316*4, to supervise the
operating pressure of a hydraulic or pneumatic
operating mechanism. It is a basic safety rule,
that a CB operating mechanism must have
sufficient operating pressure for opening if it
was accidentally closed onto a fault. In the case
of low pressure, first the AUTO-RECLOSURE
operation is blocked, and then the closing
operation and finally the opening operation are
blocked.
14
Pole discrepancy monitoring
and trip function
The circuit breaker pole discrepancy monitoring
function detects a discrepancy in the pole
positions during a closing operation and after a
defined time delay, it actuates the three-phase
opening operation of the breaker poles that are
in the closed position. If the three CB poles are
mechanically coupled such that pole discrepancy
cannot occur, this function is not operational.
Alarm annunciation
In the modern control the 14 LEDs of the
REC316*4 are used to indicate alarms. For the
conventional control, an alarm annunciation
device is provided. The alarm add-on package
extends the alarm handling functions of the base
package.
Interlocking and blocking
In order to prevent incorrect operation by the
operator, a blocking and interlocking logic is
implemented. Blocking conditions are defined
for all types of switching device. For example, a
circuit breaker must not be closed as long as a
protection trip exists, or a disconnector must
not be switched, as long as the associated circuit
breaker is closed or the manual operation crank
is in position. The interlocking logic determines
the release of the switching operations based on
the high-voltage switchgear position signals.
For this, both the positions of the high-voltage
switching devices in its own bay (bay
interlocking) and also the positions of the other
bays (interbay interlocking) are taken into
account. An example of interbay interlocking is:
a busbar disconnector must not be closed if the
corresponding busbar earthing switch is closed.
In order that the interlocking is also provided in
emergency operation if the Bay Controller has
failed, the blocking logic and the interlocking
logic are made conventionally with relay logic
and cabling.
ABB
Mechanics
Terminal blocks
The base package is equipped with terminal
blocks for bolted cable connections (1.5 sq. mm).
If plugs or other cross sections are used the
corresponding add-on package has to be selected.
The RESP 97 series supports many additional
features that can be selected by using the
Customized Package, e.g. color, hygrostatic or
thermal heating etc.
Paneling
The standard door at the front of the cubicles has
a glass window so that the front of the REC316*4
is always visible for the alarm LEDs and display,
the tapchanger REGSys TM HMI and the
BCM800 HMI.
Features
■ Dimensions 2200x800x800
(height, width, depth) (used if the primary cables
are connected via terminal connectors)
■ Standard protection conforming to class IP 40
according to EN 60529. Other protection classes
are available with the customized package IP 43,
IP50, IP54.
■ Normally with convection cooling via louvres
in the lower part of the door and the outlet around
the roof.
■ Can be supplied with a right or left opening door.
■ Lighting is activated by a door switch, lamp E27
■ Colors NCS 1704-Y15R, RAL7032, RAL7035
(other colors are available by selecting the
customized package)
BCS 593 modern bay control solution
ABB 15
Functional description of the base package
Measurand display
A digital instrument display is integrated in the
BCM800 mimic. All the measurands that are
important for operation, such as currents,
voltages, and active and reactive power are
displayed.
Interlocking and blocking display
In LOCAL Mimic HMI mode, the operator is
informed about possible interlocking and
blocking conditions when the corresponding
high voltage switchgear is selected. In the case
of an interlock condition, the execution of the
switching command is blocked in order to
prevent damage to the switchgear and
endangering personnel. The complete operator
guidance is designed for maximum comfort and
safety.
Synchrocheck
The Synchrocheck is included in the Base
Package and is implemented in the REC316*4
controller. Therefore, an additional relay for the
Synchrocheck is not required. The integrated
Synchrocheck increases the reliability and
therefore the availability, as the fewer the
number of components that are required for a
function, the higher is the total availability.
Event list
The REC316*4 maintains an event list where all
the events are stored with millisecond accuracy.
The event list can be presented on the
REC316*4 display.
Breaker position indication perphase
The REC316*4 receives the circuit breaker
position signals separately for each phase.
Changes of position are stored with millisecond
accuracy in the internal event list and are also
sent to the LON interface. They are therefore
available to the higher level SA applications.
16
Transmission of measurands to the
higher station level (SA system)
The REC316*4 Bay Controller acquires all the
currents, voltages, frequencies, and phase angles
and calculates the active and reactive power. All
these values are transmitted via the LON bus
interface, and are therefore available to the
higher level applications.
ABB
Functional description of the add-on packages
Plug connection
The plug connection package is designed to
connect the primary equipment with plugs
instead of terminals. It contains all the parts and
material that are necessary for the plug
connection. An important requirement is the
increased space requirements for the plugs.
The control cubicle is therefore extended by an
additional half cubicle and has the dimensions
2200x1200x800 (height, width, depth).
SF 6 alarm Features / Benefits
The base package includes two group alarms ■ Up to 30 alarms for SF 6 alarms per cubicle,
5 chambers * 2 alarms * 3 phases
only (refill and urgent) for the entire bay. The
■ Integrated in the SA interface (LON interface)
SF6 alarm package allows the SF6 gas alarm
(option for the modern solution only)
functionality to be extended by monitoring each ■ Display of the alarms on the alarm unit
gas compartment separately. Two alarm levels
per gas compartment are defined, (refill and
urgent). Refill is a low-pressure warning and
signifies the need for gas replenishment. The
insulation capability and switching capacity of
the GIS is still maintained. The urgent alarm
indicates an unsafe operating condition, which
causes the corresponding switchgear to be
blocked.
List of the add-on packages for BCS590 and BCS593
Name Available for the modern Available for the conventional
control control
Plug connection Yes Yes
SF6 alarm Yes Yes
Tap changer Yes Yes*
Not integrated in the SA system
Touchscreen Yes No
Comfort Yes No
Protection and recording Yes No
ABB 17
Functional description of the add-on packages
Tap changer
The tap changer package is designed for
transformer regulation. The kernel of this
TM
package is the REGSys tapchanger controller
that is equipped with a LON interface and that
can be easily integrated in the higher level SA
System with the modern control.
REGSys tapchanger controller
Comfort
This package comprises a complete range of
functions that are a useful extension of the
functions of the base package. The kernel of the
package is an RIO580 that extends the
REC316*4 by an additional 32 digital inputs /
outputs.
18
Functions: Protection and Recording Scope of the Protection Functions
■ Regulation of tap-changer transformers This package uses the different possibilities of ■ Definite time over/ undervoltage protection
■ Integrated statistical function of all tap-changer ■ High set over/ undervoltage protection
the REC316*4 bay controller. This function
movements (total number of changes, number of ■ Definite time overcurrent protection with inrush
package comprises various protection and
changes under load / per tap) detection
■ Recording of voltage and visualization via the
monitoring functions. ■ High set overcurrent protection
regulator display or PC ■ Inverse time overcurrent protection
■ Dynamic transformer group assignment according ■ Thermal overload protection
to the busbar image ■ Frequency protection
■ up to 3 transformers ■ Rate-of-frequency change
■ double busbar ■ The product range of the complete function
■ 1 bus coupler, 2 section couplers library of the RE.316 is available for customer
■ Current inputs (-20mA...0…+20mA) for specific solutions
transformer monitoring (J, P, ...) ■ Four independent, user-selectable setting groups
■ Current output (-20mA...0…+20mA) for set point ■ Multi-activation facility for the available functions
output, strip chart recorder
■ Interface to the SA IBB bus (LON Bus)
Disturbance Recording
Disturbance recording of freely selectable analog
inputs
Sequence of events recorder
With a resolution of 1 ms
Functions:
■ 8 BCM800 mimic LEDs
The BCM800 is equipped with 8 LEDs. These
LEDs are used for alarm annunciation for the high
voltage switching devices. The LEDs are
positioned on the mimic such that there is a clear
association of the alarm to the switching device.
Position indication
and alarm LEDs
■ Three-pole Position Acquisition for the Fast
Earthing Switch.
In the Base Package the position of the fast
earthing switch is acquired for each fast earthing
switch. With this option the position signal is
acquired for each pole and is made available to
the SA interface (LON interface).
■ Pump alarm indicator and acknowledgement
pushbutton on the BCM800 mimic.
An additional alarm indicator and
acknowledgement pushbutton for the pump
alarms is installed on the BCM800 mimic. The
pushbutton indicates a pump alarm. By pressing
the button, the alarm is acknowledged and the
control of the pumps is enabled.
ABB ABB 19
 2000 - 12.01 - Printed in Switzerland

ABB Switzerland Ltd

Utility Automation
Brown Boveri Strasse 6
1KHA - 000 732 - SEN

CH-5400 Baden/Switzerland
Phone +41- 58 - 585 77 44
Fax +41- 58 - 585 55 77
e.Mail substation.automation@ch.abb.com

www.abb.com/substationautomation

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