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HyCon™ Control System

Voith Hydro is one of the global leaders in hydropower from a single source to ensure complete service and to ensure
plant ­equipment and services for both new and modern- seamless availability for your hydropower plant and all of its
ization projects. components and systems.

Our reputation for excellence in products and services is Our automation solutions are based on a variety of
based on reliability, trust and commitment in long-lasting, subsystems that ensure a safe, reliable and cost-effective
Voith Hydro Holding GmbH & Co. KG partnering relationships with owners and operators around the operation through our long-term process know-how and
Alexanderstraße 11 world. control system expertise in hydropower applications.
89522 Heidenheim, Germany
Tel. +49 7321 37 0 This applies to overall plant engineering as well as to single From these systems, the control system is the central
Fax +49 7321 37 7828 component and system design in electrical and hydraulic interface between the operator and the hydropower genera-
www.voith.com machines, including the entire range of hydropower plant tion process. Our HyCon Control Systems offer perfect
control concepts and systems. We offer hydro automation solutions for safe and reliable hydropower control.
A Voith and Siemens Company
At a glance

The HyCon Control System family is tailor-made to meet the specific requirements of each hydropower plant. The HyCon Control System family is divided in two main releases fitting to different requirements in HyCon Control System, the intelligent choice.
It thus provides second to none reliability, functionality and safety. hydropower automation.

Proven technology meets highest quality and reliability Seamless Integration HyCon 300 Control System Family HyCon 400 Control System Family Investment protection Reliable operation
standards Today integration and smart handling of assets is becoming The Voith Hydro HyCon 300 control system solutions are The Voith Hydro HyCon 400 control system solutions are Voith wants to ensure the maximum benefit from your HyCon The proven operation philosophy applied in HyCon systems
Voith offers its portfolio of automation solutions under the more and more important. Integration of all digital and ­offering complete and comprehensive SCADA functionality for ­offering complete and comprehensive SCADA functionality for Control System installation. As there is a discrepancy between has been successfully implemented in hydropower plants of all
name HyCon. mechanical systems within the hydropower plant into one hydropower plants environment and are intended for use in all power plant environments. the life cycle of the power unit an the control system and an types and sizes all over the world. A cornerstone of this
control philosophy is a must. Within the HyCon family all Small-Medium hydropower plants. even more significant discrepancy between the lifetime of the ­concept is the fully object-oriented hydro block library using
The HyCon Control System family is based on the Siemens subsystems are fully integrated into the control system. This Our HyCon 400 solutions are based on the Siemens industrial PLC and the operator stations respectively the servers of the state-of-the-art faceplate technology for the operator station‘s
SIMATIC world which represents the worldwide most accept- includes not only turbine governor and voltage controller, but Our HyCon 300 solutions are running on HyCon Controllers S7-400 and WinCC products as well as PCS7 standards. control system, Voith is investing into clear strategies to pro- displays.
ed, widely-spread and well established industrial standard also electrical and mechanical protection. This is an invaluable based on Siemens high industrial quality devices and WinCC tect your investments. To handle these discrepancies in a
characterized by: advantage for our customers with regard to maintenance and HMI components. Third party SCADA systems can also be The main advantage of HyCon 400 is the full flexibility we technically feasible and economically intelligent way we offer a This technology and other features, like the sophisticated
spare part management. implemented via IEC communication p­ rotocols. guarantee in the engineering tool, and HyCon 400 is prepared clear migration and upgrade strategy to keep your control sys- ­sequence representation with special monitoring functions,
• Highest quality and reliability to fulfill all requirements of hydropower controls. tem efficiently up-to-date. This helps you to protect your in- make sure that the operator always has the overview on the
• Worldwide availability of spare parts and support HyCon is an uniform solution with seamless integration of all The main advantage of HyCon 300 is its effective working vestments. status of the process even in difficult situations requiring
• Approved technology applied in a wide range of industries systems. ­environment. Therefore we have defined an engineering tool The HyCon 400 solutions are also using our hydro specific special attention. Another feature to make the process
with highly demanding requirements and pre-configured templates to guarantee high efficiency and library of objects and therefore are fitting perfectly to hydro To support this strategy Voith is offering a wide range of transparent to the operator is the advanced fault tracking
Tailor-made Solutions speed of project implementation. The function scope is adapted applications. ­services tailored for HyCon Control Systems like: capabilities via picture tree and loop-in alarm.
To reach the goal to deliver a hydro specific solution fulfilling The HyCon object library with functions tailored to the hydro to fulfill the requirements of the Small-Medium hydropower
all demands of the control and supervision of a hydropower process deliver plenty of advantages including: plant environment. Our solutions are scalable over a wide range of applications, • Spare parts handling and supply
plant Voith developed specific Hydro library solutions that are from single station to distributed systems with different levels • Modification of system functionality
in line with market and customer necessities. • Flexibility for project specific modifications The HyCon 300 solutions are using our hydro specific library of redundancy. • Telephone hotline support

• Slim and modern design of objects and therefore are fitting perfectly to hydro applica- • Service contracts

• Voith Hydro ownership tions. • Remote diagnosis support

• Direct support up to third level • Regular maintenance of the equipment on site: e.g.

- Back-ups, check of all alarms, etc.

Voith guarantees and ensures an outstandingly high and - Start-up support after unit overhaul
­constant quality level for all projects due to our centralized
intensive system- and integration tests for all supported
­configurations.
Intensive factory testing in our automation center

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HyCon Control System, the better choice. HyCon Control Systems

Selected Highlights

Built-in Plant Safety The HyCon Control System family features Sequences – Plant Operation Event Matrix Independent local Operation Open Communication
The control system provides reliable operation and is a key The sequences build the brain of the control process of the State-of-the-art control systems ensure high reliability of the Open communication standards are an absolute must for a
factor for plant safety. Our hydro block library is designed to • IT security included, for example firewall and virus hydropower plant operation. With the help of the • Any signal can be integrated in the event matrix central control system level especially if the servers are modern power plant control system. HyCon supports a wide
meet the high level of safety standards embedded in all Voith ­scanner sequences the power units are started, stopped and operat- • Up to 32 responses can be defined (freely configurable provided as a redundant solution. However, the capability for range of open interfaces including IEC 60870-5-101/103/104
hydro products to guarantee an optimum of safety for the • Flexible remote access solutions ed. Here not only the technological know-how of Voith to without programming) ­local operation, for example at the unit control cabinet, which and IEC 61850. The Profibus DP is the preferred solution to
user, the capital equipment, and the environment. • Web interface operate hydropower units is required but also the best-in-class • In case of an event the causing signal and the response is completely independent of the central server, is a real communicate to decentralized I/Os, and is the most widely
• Messaging system support, for example pager and SMS programming to ensure safe and reliable operation in all is highlighted added value in each hydropower plant, for example for
­ used field bus system with more than 28 million installations
The mechanical protection is implemented in PLC (Program- • Control room equipment operating modes. • The causing signal is stored and must be reset manually commissioning, re-commissioning after maintenance work worldwide.
mable Logic Controller) technology. A sophisticated trip matrix • Hierarchically structured access control and in emergency cases. All HyCon Control Systems provide
concept allows high flexibility to define finely graduated • Parameter access and change without engineering tool • The documentation and definition of the sequences is ­independent local operation using operation panels or panel Voith is delivering highest quality. This includes certification for
responses to any abnormal events in mechanical subsystems. • Ergonomic screen design based on international standards done in one step, this avoids mismatches PCs. open communication standards to allow you a seamless
like IEC 60073 and others • The definition of the sequences is done graphically integration of our solutions into your existing e
­ nvironment. The
IT Security • Multiple language support (online switchable) • There is an enhanced display of the transitions according IEC protocol implementations provided by Voith have been
For all components of HyCon Control Systems measures are • Hard and software diagnosis in the PLC controller to the parameterization certified by KEMA/ TÜV Sued.
taken to safeguard protection from cyber attacks and system • Powerful trend and archiving system • Signal information within the sequences is shown as plain
hardening. This i­ncludes that all functions not necessarily re- • Central engineering tool with one central database text and signal status
quired for the o
­ peration of the system are deactivated or de- • Historian functionality • In case of a failure the signal states are stored for later on
leted (e.g. USB ports). Functions accessible over the network • Multi screen diagnostics
are reduced to a minimum and are individually adapted to the • Multi server
project specific needs. Thus the relevant international stan- • Multi clients
dards (like DIN ISO/IEC 27002; DIN 27009, IEC 62351, NERC
CIP-007-4) are met by our HyCon Control System family.

Overview Screen for electrical unit presentation Auxiliary Turbine Systems Sequence Overview Typical Single Sequence Local Operation

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Built-in Flexibility Operation Intelligent Alarm Management
Even though HyCon automation products are designed to In mixed mode not all units must be assigned to the Joint The Voith control system family is always pursuing one goal: An intelligent alarm management helps to keep cool when
provide an integrated overall automation system, all compo- Control (however units in manual mode are considered in total We want to provide a comprehensive operation functionality there are unforeseen events. Our intelligent alarm manage-
nents may be used as stand-alone systems as well. HyCon power balancing). for reliable control of the hydropower plant process. ment delivers the right alarms to the right person at the right
Control Systems have been delivered for all types of hydraulic time. We can ensure this by several options:
machines and generators. Due to the flexible concepts and HyCon Plant Optimization We reach this goal by providing an intuitive and flexible
the process expertise of Voith, the systems can be used for An intelligent add-on extension of the HyCon Joint Control is navigation for fast information access, e.g. you can jump from Intelligent Limiting of Active Alarms
new plants as well as for modernization projects. ­ HyCon our HyCon PO – Plant Optimization module which is offering group alarm display straight to graphical representation and
­Control Systems can be perfectly matched for any ­existing a highly sophisticated method for optimizing and increasing therefore have all information available on one click. • Removes “non-relevant” alarms
power plant in the world. It is our mission to have a solution the plant efficiency. The HyCon PO optimizes the load • Filters “nuisance” alarms
for any challenge in hydropower automation. Several add-on distribution between several units in a plant or even in a • Suppresses alarms without defined “operator reaction“
functionalities can easily be integrated into our control system multi-plant model in that way, that the efficiency is at its
helping you to optimize the plant output. maximum. Alarm Prioritization

Joint Control HyCon Water Management Control • Important alarms are always shown in the alarm line first
The HyCon JC – Joint Control is an integral part of the HyCon Another valuable extension of the HyCon Control System • A warning of the generator is more important than an alarm
Control System library. It allows you to distribute the active family is the HyCon WMC – Water Management Control, an from another plant item
and reactive power to all units within the power plant. The intelligent river control module.
calculation of the optimal unit configuration is based on
efficiency curves stored and processed in the PLC. This allows
easy and safe operation of the complete plant. There are
several additional features included like definition of a spinning
reserve as a constraint.

Plant Overview including Joint Control Status Generator Capability Chart

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 Communication: Web Client
Intranet, Internet
Ethernet, Office LAN

Mobile Client WAN

Industrial
WAN Voith Remote
Wireless LAN
Support
Firewall
Video Wall
OS Single Station / Redundant HyCon MD OS Client Web Archive Server Engineering Open PCS7 / OS
Station Server Single / Redundant Station Client
Network IEC60870-5-104
printer IEC60870-5-101
Modbus RTU
DNP3
OPC
Others

Industrial Ethernet,
Terminal Bus, Single / Redundant
GPS GPS
…OS Server… Satellite

Industrial Ethernet, Plant Bus,

Single / Redundant / IEC61850 / IEC60870-5-104

A.S Fault-Tolerant
S7-400 / HyCon Communication
HyCon Controller Controller

S7-400H / Protection

Profibus DP
HyCon Controller HMI HMI
Client / DELPHIN Single Station HMI TP Protective Relay
Single Station
HyCon MD
ET 200M / SOE OLM
1ms Scalance ET 200M

ET 200M / SOE 1ms IEC60870-5-104

IEC60870-5-101
1 ms (SOE) 1 ms (SOE) DISPATCH
Profibus DP

Profibus DP

IEC 61850
DNP3
CENTER

Profinet

Profinet
IEC 61850
PAC3000
Y-Link
Y-Link
OLM ET 200M

PAC3000 PAC3000

ET 200M
Thyricon Thyricon
(Voith Excitation) (Voith Excitation) AS-I Bus
HyCon GC Hycon GC
S7-300 HMI TP (Voith Governor) S7-300 HMI TP (Voith Governor) DELPHIN
Temperature Temperature HyCon MD
OLM Monitoring Monitoring

Scalance ET 200M
AS-I Bus Thyricon
(Voith Excitation)
S7-300 HMI TP HyCon GC
ET 200M
AS-I Bus Scalance (Voith Governor)
ET 200M Temperature
Monitoring

DELPHIN IEC60870- IEC60870-

HyCon MD 5-104 5-104
S7-300 S7-300

Thyricon
HMI TP HMI TP (Voith Excitation)
HyCon GC
(Voith Governor)
Ethernet Ethernet
S7-300 S7-300 Temperature
Monitoring
Modbus Modbus
AS-I AS-!
Others Others

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HyCon 400

High-end solution to satisfy all your needs. Selected features

Major features in detail Redundancy Concepts

HyCon 400 is designed to fulfill ambitious requirements such • Scalable archiving system with separate archive server as To increase the availability of the control system several
as the automation of pumped storage plants with very • Based on Siemens SIMATIC PCS7 an option redundancy concepts are available within the HyCon 400
­
challenging demands regarding safety, reliability and stabiliza- • Scalable redundancy (hot stand-by) for PLCs, network, • Flexible reporting tool based on MS Excel® control system family, such as PLC redundancy, OS redun-
tion of the grid. These are features which are especially crucial server • Central time synchronization server dancy and network redundancy.
for power plants contributing to the primary control of the grid. • Distributed server configurations for multi-unit plants, (GPS, Siemens optimized NTP synchronization)
very complex auxiliaries and others • Alarm and messaging system supporting efficient
The HyCon 400 control system is designed to cover a • Transparent user guidance and intuitive operation using disturbance analysis and fault tracking
considerable range of requirements. For this purpose, HyCon faceplate technology • SOE for all messages like alarms and events
400 is extremely scalable and – due to the modular design – • Ergonomically designed process screens which help to • Clear and transparent concepts for administration of user
the system can grow with the demands. Starting from a cost- focus the user attention to what is most relevant rights, interlocking of control locations and integrated alarm
­effective all-in-one concept up to distributed architectures and • Local operation completely independent of the central acknowledgement that is effective system wide
redundancy in all levels of the system, HyCon 400 is prepared ­server using the same screens and faceplates like in the
to meet all your requirements. central control room. Local server functionality provided if
central server or communication fails
Furthermore, a broad spectrum of standard interfaces allows • Powerful and highly flexible representation of step se-
the integration of existing components into the control system quences (optionally branched) including special monitoring
– this is especially valuable for modernization projects. functions for failure analysis. This concept is designed in
particular to handle complex transitions for pump-turbines

Transformer Screen Turbine Guide Bearing

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HyCon 300

A complete system in compact design combining leading-edge technology with economic efficiency.

Our HyCon 300 control system not only sets new standards in This simple, reliable and robust tool offers the following Integration into all automation strategies
terms of functionality, quality and reliability, but stands for an ­additional advantages
outstanding value for money. It can be seamlessly • Various process busses are supported
incorporated as a standard component in new plants and • Short delivery times (Profibus, Ethernet, IEC, etc.)
modernization projects alike. The basis is a preconfigured sys- • Clearly defined scope of delivery
tem which is basically running right out of the box. • Full pre-testing of the system before shipping • Non-proprietary communication standards:
• Rapid commissioning - PROFIBUS DP, PROFINET
HyCon 300 is a pre-tested system which guarantees highest • High availability - IEC 60870-5-104
quality. • Flawless operation - IEC 61850
• Easy maintenance - OPC UA
Economic efficiency is assured by innovative, standardized
concepts, which enable us to offer you an outstanding high- • Communication to third party PLC’s via HyCon
quality and efficient product due to the use of durable, reliable communication standards
components, complying with exacting industrial standards.
Advanced software engineering, systematic standardization
and application of modular principles, as well as the specific
focus on the requirements of hydroelectric power stations
­afford an excellent price performance ratio.

Typical all-in-on automation solution

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 1 2 3 4 5

6 7 8 9 10 11

1 La Muela II 10 Peixe Angical

2 Frades II 11 Estreito
3 Cannelton 12 Baglihar
4 Ohio River 13 Omkareshwar
5 Willow Island
6 Rheinfelden
7 Herdecke

12 13 8 Foyers
9 Aimores

Asia Africa 2006 Herdecke, Germany: 2010 Säckingen, Germany: 2010 Indaia Grande, Brazil: 2012 Las Lajas (Alto Maipo), Chile:
2001 Baglihar, India: 2005 Gilgel Gibe II, Ethiopia: HyCon 400 HyCon 300 HyCon 300 HyCon 400
HyCon 400 HyCon 400 1 Pump turbine unit (1 x 150 MW) 4 Kaplan units (4 x 18 MW) 3 Kaplan units (3 x 7 MW) 2 Pelton units (2 x 135.2 MW)
6 Francis units (6 x 168 MW) 4 Pelton units (4 x 125 MW)
2007 La Muela II, Spain: South America 2010 Queixada, Brazil: North America / Canada
2002 Tai An, China: 2008 Ingula, South Africa: HyCon 400 2002 Peixe Angical, Brazil: HyCon 300 2002 Conowingo, Maryland:
HyCon 400 HyCon 400 4 Pump turbine (4 x 213 MW) HyCon 400 4 Francis units (4 x 7.5 MW) HyCon PCS7
4 Pump turbine units (4 x 250 MW) 4 Pump turbine units (4 x 342 MW) 3 Kaplan units (3 x 169 MW) 11 Francis units (11 x 50 MW)
2008 Rheinfelden, Germany: 2011 Belo Monte, Brazil:
2003 Cameron Highlands, Malaysia: 2012 Kakobola, DR Congo: HyCon 400 2007 Estreito, Brazil: HyCon 400 2008 Cannelton, Kentucky:
HyCon 400 HyCon 300 4 Bulb turbine units (4 x 25 MW) HyCon 400 18 Francis units (18 x 611 MW) HyCon 400
for several plants 3 Francis units (3 x 3.5 MW) 8 Kaplan units (8 x 138 MW) 3 Kaplan bulb units (3 x 29 MW)
2010 Frades II, Portugal: 2011 Indaiazinho, Brazil:
2003 Omkareshwar, India: Europe HyCon 400 2008 Amoya, Columbia: HyCon 300 2008 Smithland, Kentucky:
HyCon 400 2002 Enguri, Georgia: 2 VarSpeed Pump turbine units HyCon 300 2 Kaplan units (2 x 6.5 MW) HyCon 400
8 Francis units (8 x 65 MW) HyCon 300 (2 x 380 MW) 2 Pelton units (2 x 40 MW) 3 Kaplan bulb units (3 x 25 MW)
3 Francis units (3 x 250 MW) 2011 Teles Pires, Brazil:
2009 Sarobi, Afganistan: 2009 Palo Viejo, Guatemala: HyCon 400 2008 Willow Island, West Virginia:
HyCon 300 2004 Foyers, United Kingdom: HyCon 400 5 Francis units (5 x 370 MW) HyCon 400
2 Francis units (2 x 12.5 MW) HyCon 400 2 Francis units (2 x 43 MW) 2 Kaplan bulb units (2 x 21 MW)
2 Pump turbine units (2 x 150 MW) 2012 Alfalfal II (Alto Maipo), Chile:
2010 Cubujuqui, Brazil: HyCon 400 2013 Churchill Falls, Canada
HyCon 300 2 Pelton units (2 x 135.6 MW) 11 Francis units (11 x 494 MW)
2 Franics units (2 x 11 MW)

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