⚡ NTPC – AMR Hardware & Software Protocol
Smart Metering Infrastructure | NTPC Mouda – 647 Nodes | End-to-End Data Automation
Project Overview
ASW Technologies Pvt. Ltd. developed a cutting-edge Automatic Meter Reading (AMR) system for NTPC Mouda, integrating advanced hardware and communication protocols to automate energy data collection across 647 power meters. The solution enables remote energy monitoring, accurate data analytics, and minimal human intervention for billing and maintenance operations.
Project Info
- Domain: Energy Monitoring & Utility Automation
- Technology: IOT, Modbus Communication, Embedded Hardware Design, Cloud-Based Data Management, Web Dashboard, Automatic Meter Reading (AMR) System
Data Concentrator Unit (DCU)
The Data Concentrator Unit acts as the system’s intelligent master controller, aggregating real-time readings from multiple meters and pushing them securely to a remote acquisition server. Equipped with robust I/O interfaces and edge analytics, it ensures uninterrupted operation even during communication loss.
- Controls up to 16 meters per DCU with automatic fault detection
- Local data buffering during network downtime
- Built-in RS232, RS485, Ethernet & USB 2.0 ports
- LED indicators for live status and diagnostics
- Embedded web interface for remote monitoring
Technical Specifications:
- Processor: ARM Cortex-A53 64-bit Quad-Core @ 1 GHz
- Memory: 512 MB LPDDR2 RAM
- Wireless: Dual-Band Wi-Fi 802.11ac + Bluetooth 4.2
- Interfaces: RS232 | RS485 | Ethernet | USB 2.0
- Power Input: 5 V DC 2.5 A
- Protection: ±15 kV ESD, 3 kV isolation + surge suppressors
- Operating System: Embedded Linux
Meter Communication Card (MCC)
Each MCC interfaces directly with its respective energy meter, handling data conversion from the proprietary meter protocol to Modbus RTU/ASCII for seamless communication with the DCU. Designed for industrial reliability, the MCC ensures precise data exchange and plug-and-play deployment.
- Industrial-grade RS232 ↔ RS485 conversion
- Configurable Slave IDs with protocol mapping
- Auto-fetch of Serial No. and kWh data
- Diagnostic LEDs for testing and fault isolation
- Compact, wall-mountable design
Technical Specifications:
- Processor: 8-bit MCU @ 16 MHz
- Power Supply: 12 V DC 0.5 A
- Communication: 9600 bps Modbus RTU/ASCII
- Temperature Range: -10 °C to +70 °C
- Mounting: Screw / DIN Rail
AMR Network Topology
The complete system follows a BUS communication topology in which a single DCU communicates with up to 16 MCCs per loop. This modular design facilitates scalability and uniform data acquisition across all 49 buildings and utility zones within the NTPC Mouda complex.
Communication Protocol
The communication framework is based on the Genus Proprietary Protocol, optimized for reliability and accuracy in industrial environments. It incorporates CRC checksums, secure handshake authentication, and dynamic addressing for each meter node.
- DLMS → Modbus conversion layer for data translation
- Bidirectional command handling and error recovery
- Optimized data packets (9600 bps) for low-latency response
- Checksum and byte-sequence validation per frame
Project Outcome
The AMR deployment at NTPC Mouda successfully established a fully automated, real-time energy monitoring network for over 49 residential and industrial buildings. The solution reduced manual data collection time by 90%, increased transparency in energy usage analytics, and set a benchmark for smart-grid readiness across NTPC installations.