Power Grids

RTU500 series - Remote Terminal Units

Part 1: Overview
Function Description Release 13
Revision

Document identity: 1KGT151095 V003 1

Revision: Date: Changes:
1 10/2020 Initial version
2 02/2021 Updated chapter 'Application' (PI#175987)
Added new module 530CID02 (PI#175252)
Added new module 530PTD01 (PI#172755)
Added chapter 'Cable Cross-Section' (PI#178851)
3 05/2021 Added new module 530AOD01 (PI#176345)
Contents

Contents

1 Introduction............................................................................................................................. 3

2 RTU500 Series Application and Features............................................................................5

2.1 Overview........................................................................................................................ 5
2.2 Application......................................................................................................................5
2.3 Features......................................................................................................................... 8
2.4 System Design...............................................................................................................9
2.5 System Concept.............................................................................................................9

3 System Overview.................................................................................................................. 11
3.1 Cyber Security............................................................................................................. 11
3.2 Telecontrol Functions................................................................................................... 11
3.3 External Communication..............................................................................................12
3.4 PLC Development System.......................................................................................... 13
3.5 System Redundancy....................................................................................................13
3.6 Status and Diagnostic Information.............................................................................. 14
3.7 Local Print and Local Archive..................................................................................... 14
3.8 Integrated Human Machine Interface (HMI)................................................................ 15

4 Safety Instructions............................................................................................................... 17
4.1 Introduction...................................................................................................................17
4.2 Safety Indication Symbols........................................................................................... 17
4.3 Applicable Standards and Directives for Installation and Operation........................... 18
4.4 Qualified Personnel......................................................................................................19
4.5 Intended Use................................................................................................................19
4.6 Warnings and Cautions............................................................................................... 19

5 Installation Instructions....................................................................................................... 21
5.1 Transport, Unpacking, Identification and Storage....................................................... 21
5.2 Documents and Instructions........................................................................................ 21
5.3 Cabinet Installation...................................................................................................... 21
5.4 Electrical Installation.................................................................................................... 22
5.4.1 Cable Grounding..........................................................................................22
5.4.2 Cable Cross-Section....................................................................................22
5.4.3 Cable Routing.............................................................................................. 23
5.5 Function Test................................................................................................................23
5.5.1 Tools and Devices....................................................................................... 23
5.5.2 Connection of Supply Voltage..................................................................... 23
5.5.3 Function Test............................................................................................... 23

6 RTU500 Series Documentation........................................................................................... 25

6.1 RTU500 Series Function Description.......................................................................... 25
6.2 Hardware Data Sheets................................................................................................ 27
6.3 Connections and Settings............................................................................................27
6.4 Host Communication Interfaces.................................................................................. 27
6.5 Subdevice Communication Interfaces......................................................................... 28

1KGT151095 V003 1 I
 Contents

6.6 User's Guides.............................................................................................................. 28

6.7 Security Documents.....................................................................................................28

7 Glossary.................................................................................................................................29

II 1KGT151095 V003 1
Introduction

1 Introduction
The RTU500 series is required to be configurable to nearly all demands made on remote stations in
networks for electrical substations, gas, oil, water or district heating.

The RTU500 series therefore provides a flexible and modular design with many integrated
functionalities covering a wide range of individual solutions suitable for transmission, distribution
substations, smart grid or feeder automation applications.

This document describes:

• Applications and features of the RTU500 series

• The applicable safety and installation instructions
• Structure and contents of the RTU500 series documentation

1KGT151095 V003 1 3
 Introduction

4 1KGT151095 V003 1
RTU500 Series Application and Features Overview

2 RTU500 Series Application and

Features

2.1 Overview
The task to monitor and to control the network for energy to reach an economical operation
control requests an ongoing penetration of the network down to the lowest levels. The increasing
requirements concerning the availability of energy and their distribution and transportation leads
to increasing demands on control systems. Improved and new communication possibilities with
a higher transmission bandwidth and new transmission media allow the telecontrol technology to
realize these tasks.

2.2 Application
The RTU500 series is required to be configurable to nearly all demands made on remote stations in
networks for electrical substations, gas, oil, water or district heating.

Network Control Center Remote Maintenance Workplace

IEC 60870-5-101, IEC 60870-5-104

DNP 3.0, DNP 3.0 over WAN

Integrated Human Programmable Logic

Machine Interface Redundancy Scalability Controller

IEC 60870-5-103, DNP3, MODBUS IEC 61850

RTU540

Protection & Third Party Equipment Parallel I/Os RTU540 Third Party Protection &
Control IEDs Equipment Control IEDs

Figure 1: Typical configuration of a RTU560 telecontrol system

1KGT151095 V003 1 5
Application RTU500 Series Application and Features

Network Control Center Remote Maintenance Workplace

IEC 60870-5-101, IEC 60870-5-104

DNP 3.0, DNP 3.0 over WAN

Integrated Human Programmable Logic

Machine Interface Controller RTU540

Switch
IEC 60870-5-103 IEC 61850

Protection & Third Party Equipment Multimeter Protection & Control IEDs
Control IEDs

Figure 2: Typical configuration of a RTU540 telecontrol system

Figure 3: Typical configuration of a RTU530 telecontrol system

6 1KGT151095 V003 1
RTU500 Series Application and Features Application

Network Control Center Wireless communication Remote Maintenance Workplace

Process Voltage Fault passage

Measurements Regulation Control indication

Multimeter
Figure 4: Typical configuration of a RTU520 telecontrol system

The number of functions provided by decentralized and closed-loop control solutions is constantly
increasing. This also means that more functions can be executed directly in the station. The
RTU500 series supports this increase in functionality in two ways:

• The RTU500 series provides special PLC programs for carrying out control tasks.
• The RTU500 series products are able to communicate with external control units, protection
devices and monitoring units via serial lines. The RTU500 series products gather process
information from these units upon request. The information is then distributed to multiple network
control centers (NCC) in order to meet the requirements of station control and network control.

The RTU500 series uses a set of communication units (CMU) and I/O modules to build up
configurations that match the particular application and data point profiles of a station. Configuration
options range from multiple I/O process data points and a single communication unit for typical
small pump stations or ring main unit stations via medium-sized stations for distribution purposes up
to large stations on transmission grid level.

Engineering hours are a significant cost factor in most projects. Reducing or limiting these costs
requires standardization of the process data model and the use of state-of-the-art engineering tools.
These tools must meet the demands of communication networks for telecontrol, fulfill customer
requirements with regard to distributed stations, and support all configuration types that are possible
using the RTU500 series.

The RTUtil500 configuration software is used for engineering the process signals for the RTU500
series and for project engineering. In this context, project refers to a telecontrol network with several
remote stations that are combined with router stations, etc.. RTUtil500 supports process signal
routing from small stations on the lowest level up network control centers (NCC) on the topmost
level. Typically, it includes the conversion from one telecontrol protocol A to another telecontrol
protocol B, which is used on the following level, e.g., from DNP3 to IEC 60870-5-104. RTUtil500
generates all files which are necessary to run the RTU500 series.

RTUtil500 has been designed to work seamlessly with the RTU500 series. This integrated approach
allows the operator to download files to the RTU500 series components used in the stations via
intranet using common Web browser technology, or, if the protocol supports file transfer, via the
communication line. This user-friendly telecontrol approach helps reducing travel expenses and

1KGT151095 V003 1 7
Features RTU500 Series Application and Features

increases operator flexibility, e.g. by using configuration extensions or modifications to existing

configurations.

2.3 Features
The RTU500 series telecontrol system transmits process information in two directions:

• from the various units installed in a station to the control centers

• from the control centers to the addressed control units within the station

The RTU500 series is designed to perform the following tasks:

• Acquisition and processing of process signals sent via parallel wiring to the I/O-process interface
of the RTU500 series.
• Linking of serial communication routes within the station as well as to the higher control level.
The higher control level can be represented by another RTU500 series router station or a
network control center. Within the station, it is the connection of other existing additional control,
protection, or monitoring devices (so-called Intelligent Electronic Devices = IED) via serial
interface.

The RTU500 series concept allows for cost-effective adaptation to customer requirements with
regard to different serial links by cascading communication and processing units according to the
number of required serial interfaces.

The RTU500 series provides the following features to meet customer requirements with regard to
remote control stations:

• A broad range of telecontrol functions

• PLC capabilities to execute control and closed-loop control applications for pump stations, hydro
power plants, station interlocking for electrical substations, etc.
• Archival of process and station events in a sequence of event lists in the flash memory,
accessible via intranet or equivalent independent network
• Archival of Integrated Totals (ITI) and Analog Measured Values (AMI) in the flash memory,
accessible via intranet or equivalent independent network
• Reading and archival of disturbance files from protection relays upon request by the protection
relay; reading of disturbance files via file transfer over a separate communication network (e.g.
intranet) upon user request; independent and direct deployment of new disturbance files to the
disturbance file archive to the NCC
• Creation of group alarms and a PLC program for typical alarm messages
• Interfacing with nearly all types and to large numbers of IEDs in a station via serial telecontrol
protocols, such as IEC 60870-5-103, Modbus, SPAbus, or DNP3, or via Ethernet-based
protocols, such as IEC 60870-5-104 or IEC 61850
• Marshaling and filtering of process events to connected NCCs, decoupling transaction
sequences and delay times to different NCCs by using a separate process database for each
NCC link
• Remote access for diagnostic purposes via Web browser and Internet or intranet with detailed
information down to each process signal
• An integrated HMI (Human Machine Interface) for process supervision and control, via web
browser and Internet or intranet
• Sophisticated security features for user account management, user activity logging and
protection against unexpected attacks

8 1KGT151095 V003 1
RTU500 Series Application and Features System Design

2.4 System Design

The RTU500 series consists of the following product lines:

• RTU560 product line: rack-based RTU solution with scalable, modular platform and redundancy
concept
• RTU540 product line: DIN rail RTU in metal housing
• RTU530 product line: DIN rail RTU in compact housing
• RTU520 product line: DIN rail RTU in compact housing

The features of the RTU560 product line are described in Function Description, Part 2: Rack
Solutions. The features of the RTU540, RTU530 and RTU520 product lines are described in Part 3:
DIN Rail Solutions (see chapter RTU500 Series Function Description).

Rack-mounted and DIN rail-mounted components (with the exception of the RTU530 components)
can be used together in one RTU560 system.

2.5 System Concept

Different network control systems

CMU CMU CMU CMU

RTU560 System bus

CMU CMU CMU CMU

I/O modules
IED Sub-RTU
I/O modules

IED Sub-RTU I/O modules

I/O modules

Figure 5: RTU500 series concept, rack mounting

The figure above shows the basic concepts of the RTU500 series. The RTU500 series is based
on a communication node, an approach that provides high flexibility. The number of CMU boards

1KGT151095 V003 1 9
System Concept RTU500 Series Application and Features

depends on the requirements of a particular station or router RTU. Single CMU solutions are also
available in the DIN rail RTU product lines.

Each CMU type has a number of serial interfaces to connect serial communication links. These
interfaces can use up to four different communication protocols and therefore act either as a Host
Communication Interface (HCI= Slave protocol) or as a Subdevice Communication Interface (SCI =
Master protocol).

This approach allows cascading the required number of to meet the demands of different protocols
and interfaces.

Another main feature of the RTU500 series is its method of internal communication. All process
information, regardless of the source interface from which it is received, is converted to an internal
representation and distributed to all CMUs via the RTU500 series' own system bus. This approach
eliminates the need of combining multiple conversions. Each protocol module needs only one
conversion: into or from the RTU's internal representation.

This approach requires each protocol module to maintain its own process database for signal
processing, etc.

The following list shows the key features of the RTU500 series:

• Multi-processor technology for the communication modules (only rack-mounted variants)

• Redundant communication units with warm standby performance (rack-mounted variants)
• Redundant power supplies for most of the racks (only rack-mounted variants)
• Redundant communication links for serial line and Ethernet, can be combined on one CMU
• Archival of process event on flash memory
• Archival of disturbance files on flash memory, with directory organization per protection relay,
and autonomous read-out of the disturbance files
• Remote diagnostics for the complete RTU500 product line via Web browser
• Up to 5 000 process data points within a single RTU of the RTU500 series, including all direct
connected process signals and all signals via serial links
• Increasing performance of event access via the RTU500 series peripheral bus by splitting the I/
O-racks into different bus segments. A maximum of 32 bus segments is possible (only RTU560
rack-mounted variants).
• The system's core design is field-proven and has demonstrated its stability in a large number of
installations world-wide.
• Possibility to run multiple PLC programs in parallel
• Small number of different hardware modules
• High availability
• One engineering tool (RTUtil500) for the entire RTU500 series
• The firmware and configuration data of archives are protected against voltage loss (CF card, SD
card and eMMC)

10 1KGT151095 V003 1
System Overview Cyber Security

3 System Overview

3.1 Cyber Security

A set of security features is available to fulfill basic requirements of the following security standards:
• NERC /CIP
North American Electric Reliability Corporation – Critical Infrastructure Protection
• IEC 62351
Power systems management and associated information exchange – Data and communications
security
• IEEE 1686-2007
Standard for Substation Intelligent Electronic Devices (IEDs) Cyber Security Capabilities

The above-mentioned standards require the following security features:

Security feature Function

Confidentiality Secure communication links
Availability Robustness of external interfaces
Authentication, authorization Verify the identity of a user
Auditability Logging of user activities
Table 1: Security features of security standards

The RTU500 series includes the following security functions:

• User Activity Logging (UAL) on the CompactFlash® or SD Memory Card of the CMU
• Closing of unused TCP/IP ports
• Enabling and disabling services (e. g. web server) for each ethernet port individually
• Virtual Private Network (VPN) communication
• HTTPS support for integrated web server
• Support of Syslog and ArcSight Server
• Security Events and Alarms via telecontrol protocols

3.2 Telecontrol Functions

The telecontrol functions (SCADA) in monitoring direction are executed on the following boards:

Binary input modules:

• 560BIR01
• 23BE40
• 23BE50
• 520BID01
• 530BID01

Analog input modules:

• 560AIR01
• 560AIR02
• 520AID01
• 520PTD01 (PT100 interface)
• 530AID01

1KGT151095 V003 1 11
External Communication System Overview

• 530PTD01 (PT100 interface)

Combined binary input output modules:

• 530IOD01 (binary input and binary output)

Base modules with integrated I/Os:

• 540CID01 (binary input, binary output, analog input and command output supervision)
• 530CID01 (binary input and binary output)
• 530CID02 (binary input and binary output)

Multimeter modules:
• 560CVD03
• 500CVD90

SCADA functions in command direction are defined for the following boards:

Binary output modules:

• 560BOR01
• 23BA23 (command output supervision)
• 23BA40
• 520BOD01
• 520CSD01 (command output with command output supervision)
• 530BOD01

Analog output modules:

• 23AA21
• 520AOD01
• 530AOD01

Combined binary input output modules:

• 530IOD01 (binary input and binary output)

Base modules with integrated I/Os:

• 540CID01 (binary input, binary output, analog input and command output supervision)
• 530CID01 (binary input and binary output)
• 530CID02 (binary input and binary output)

Telecontrol functions are described in RTU500 Series Function Description - Part 5: SCADA
functions (1KGT151099).

3.3 External Communication

The RTU500 series allows communication with up to 16 different host systems by using the
communication interfaces provided by the CMUs.

Different instances of host communication interfaces do not have any dependencies between each
other. Each instance has its own set of configuration parameters and runs independently.

Because of the different requirements of protocols supported by the RTU, this chapter describes
only the general functionalities and principles of host communication interfaces. For more detailed
information, refer to the corresponding Protocol Description manual.

12 1KGT151095 V003 1
System Overview PLC Development System

The subdevice communication interface is used for communication between the RTU and
subordinated devices. Subordinate devices can be other RTUs of the RTU500 series or, in general,
other intelligent electronic devices (IED).

The communication of multiple IEDs with different communication protocols is one of the basic
concepts of the RTU500 series.

The sub-device communication interface (SCI) supports various communication protocols. The
protocol-specific configuration parameters are described in additional documents.

Configuration of the SCIs and communication lines with their protocols is carried out in RTUtil500.
No hardware switches need to be set in order to configure the interfaces.

The communication features are described in RTU500 Series Function Description - Part 6:
RTU500 functions (1KGT151100).

3.4 PLC Development System

This chapter describes the PLC function, the RTU500 series runtime system for control
applications. It has been designed according to IEC 61131-3 and is engineered with the
programming and debugging system MULTIPROG.

The PLC function is a licensed software package that generally enables the CMU to run PLC
applications and to communicate with MULTIPROG for loading and debugging applications. It is
started at boot time of the CMU if a PLC function is added to the configuration.

Once started on a CMU, the PLC function is running in shared mode with lower priority compared to
the SCADA software.

It is possible to design a configuration with PLC function and SCADA activities running on different
CMUs. Since both communicate via internal communication, the PLC function can run on any CMU
within the RTU500 series. This provides maximum processor power for each of the activities.

The PLC development system is described in RTU500 Series Function Description - Part 6:
RTU500 functions (1KGT151100).

3.5 System Redundancy

Retaining accessibility to stations in energy transmission and distribution networks is a key
requirement.

The RTU500 product line fulfills this requirement by providing a sophisticated redundancy concept,
which includes the following features:

• Redundant power supply units

• Redundant communication lines or links
• Redundant communication units (CMU)

The main concept for redundant CMUs is to have one or more pairs of CMU modules for any
communication lines and functions that are critical to the operation of the station. In the event of an
error, the RTU will switch over to the redundant standby CMU which immediately starts to take over
the tasks after a warm start. Other redundant sets of CMUs in the configuration will not be affected
in operation.

1KGT151095 V003 1 13
Status and Diagnostic Information System Overview

System redundancy is described in RTU500 Series Function Description - Part 2: Rack mounted
solutions (1KGT151096) and RTU500 Series Function Description - Part 6: RTU500 functions
(1KGT151100).

3.6 Status and Diagnostic Information

The RTU500 series reports the system status and error states to the NCC via system events (SEV).
System events are part of the System Data Interface (SDI).

System events are internally processed and provided as single-point information. The message
types and message identifications used to send system events to an NCC depend on the
communication protocol used on the host interface.

The web server of the RTU500 series is the common interface to an RTU. It is used for carrying out
maintenance and diagnostic tasks on the RTU and its components. For more information, refer to
the RTU500 series Web Server User's Guide.

Status and diagnostic functions are described in RTU500 Series Function Description - Part 6:
RTU500 functions (1KGT151100).

3.7 Local Print and Local Archive

The Local Print and Process Archive functions are optional features, which provide the following
local outputs:
• Permanent output to a printing device connected to a serial interface of the RTU500 series
• Output to a printer as backup function to regular host communication, i.e., printing is started only
when all host connections of an RTU are in the off-line state
• Output to archive files in CSV format. The archive files are stored in the flash memory file
system of a CMU of the RTU500 series. Archive files can be downloaded to a PC. The contents
of archive files can also be displayed using the web server of the RTU500 series.

Local printout or storage to an archive file, respectively, is possible for the following data categories:
• Process and system events, commands in command direction, login/logout
• Measured values (AMI)
• Integrated totals (ITI)
• Security events

Protection equipment is limited in memory. Therefore, only a small amount of disturbance records
can be stored in protection equipment memory before they are overwritten. In order to simplify
the analysis of disturbances and to reduce response time, it is necessary to collect them in a
centralized archive. This archive is provided by the RTU.

Uploaded files are stored on the RTU500 series file system. A file administration function is included
which allows the operator to manage the storage space of the RTU500 series file system's flash
memory.

Uploaded disturbance data files are accessible through the archive displayed by the Web server of
the RTU500 series. It is also possible to manually upload files to the Web server.

Disturbance data from protection equipment connected to Sub-RTUs can be uploaded using the file
transfer function with the communication protocols IEC 60870-5-101 or IEC 60870-5-104.

Local print and archive functions are described in RTU500 Series Function Description - Part 7:
Archive functions (1KGT151101).

14 1KGT151095 V003 1
System Overview Integrated Human Machine Interface (HMI)

3.8 Integrated Human Machine Interface (HMI)

The function Integrated HMI consists of two parts:
• An editor for the offline configuration
• A runtime system installed on a CMU of the RTU500 series

The offline editor is used to create customer-specific interface pages using the components
provided in a library package.

Dynamic components can be linked to individual RTU data points. To this end, the editor reads the
data point list from the RTU500 configuration file.

The editor generates one HMI project file per CMU with Integrated HMI function. This additional
configuration file needs to be uploaded to RTU.

An RTU can be connected to a PC using one of the following connection options:

• Local area network (LAN)
• Wide area network (WAN)
• Dial-up or modem connection (PPP)
• Direct serial connection (PPP)
• USB network

The Integrated HMI is described in RTU500 Series Function Description - Part 8: Integrated HMI
(1KGT151102).

1KGT151095 V003 1 15
Integrated Human Machine Interface (HMI) System Overview

16 1KGT151095 V003 1
Safety Instructions Introduction

4 Safety Instructions

4.1 Introduction
Read the following chapter before mounting and commissioning a system or device of the RTU500
series.

4.2 Safety Indication Symbols

The following safety indication symbols are used in this documentation:

DANGER
Hazardous situation which, if not avoided, will result in death or serious injury of the operating
personnel. The provided information is necessary to know, if you configure a RTU500
series device. The safety indication informs about a restriction etc.

WARNING
Hazardous situation which, if not avoided, could result in death or serious injury of operating
personnel.

CAUTION
Hazardous situation, which, if not avoided, could result in minor or moderate injury.

ADVICE
Important information not related to personal injury but that should be observed. This symbol
is used to indicate restrictions, prerequisites, and other information that is important for
configuration.

The following safety indication symbols are used on RTU500 series devices:

Symbol Type Level of danger

Danger Hazardous voltage. Contact with live circuits will cause electric
shock or burn. Verify that all terminals feeding dangerous contact
voltages (supply voltage, input or output channels) is in secure
OFF state before connecting or withdrawing the terminals.
Warning Hazardous situation, read documentation (data sheets and con-
nection and settings documents)

Table 2: Safety indication symbols on RTU500 series devices

1KGT151095 V003 1 17
Applicable Standards and Directives for Installation and Opera- Safety Instructions
tion

4.3 Applicable Standards and Directives for

Installation and Operation
The devices of the Hitachi ABB Power Grids RTU500 series are produced in compliance with the
relevant regulations and standards.

According to IEC 60664-1 (DIN VDE 0110-1) Insulation coordination for equipment within low-
voltage systems – Part 1: Principles, requirements and tests, classification of the RTU500 series is
as follows:
• Pollution degree 2
Only non-conductive pollution occurs except that occasionally a temporary conductivity caused
by condensation is to be expected.
• Overvoltage category II
in accordance with the definitions in IEC 60364-4-44.

The owner of the devices and components is responsible to ensure that they are installed safely
and in compliance with the applicable local laws and regulations.

Standard Explanation
DIN VDE 0100 Erection of power installations with nominal voltages up to 1000
V AC or 1500 V DC.
EN 50274 (DIN VDE 0660-514) Low-voltage switchgear and controlgear assemblies.

Protection against electric shock - Protection against uninten-

tional direct contact with hazardous live parts.
IEC/EN 60204 (DIN VDE 0113) Safety of machinery; Electrical equipment of machines.

Part 1: General requirements

EN 50178 (DIN VDE 0160) Electronic equipment for use in electrical power installations and
their assembly into electrical power installations.
EN 50310 (DIN VDE Application of equipotential bonding and earthing in buildings
0800-2-310) with information technology equipment.
Table 3: Standards

Mounting into cabinet is mandatory due to fire protection.

If devices of the RTU500 series are coupled with or supplied through power-frequency voltage
networks of overvoltage category III, take suitable protective action, such as installing surge voltage
protectors, to guarantee that overvoltage category II (1500 V max. transient) according to DIN VDE
0110 applies at the terminal connectors. The secondary circuit should be connected to protective
terminal.

WARNING
For detailed installation instructions of the individual devices refer to the respective connections
and settings.

18 1KGT151095 V003 1
Safety Instructions Qualified Personnel

4.4 Qualified Personnel

DANGER
The connectors or terminals of some components of the RTU500 series conduct dangerous
contact voltages.

Touching parts with live current will result in death or serious injury.

Installation, commissioning and maintenance of such systems must be carried out only by
qualified personnel with knowledge of the following information:
• Dealing with dangerous voltages
• Application of the relevant specifications, standards, and regulations, in particular of the
applicable EN (VDE) standards and occupational safety regulations aiming at the prevention
of accidents

4.5 Intended Use

The RTU500 series was developed, manufactured, tested, and documented observing the relevant
standards.

If the applicable regulations for installation, commissioning, and maintenance are observed, the
product does not pose a danger to health, life, safety, or property under normal circumstances.

"Intended use of the product" means that the components of the RTU500 series are operated and
maintained exclusively in the form described in the product documentation. In particular, intended
use of the product requires observing the technical specifications of the process circuits and power
supply.

Hitachi ABB Power Grids does not accept any responsibility whatsoever for injury or damage
resulting from improper use or unauthorized repair.

4.6 Warnings and Cautions

ADVICE
Connect the 6.3 mm Faston connector to protective earth before connecting any power to the
device.

Ensure that the device is entirely without power supply before removing the earth protection.

Observe the earthing principles for the Serial Peripheral Bus (direct or capacitive earthing).

DANGER
Hazardous voltage.

Contact with live circuits will cause electric shock or burn.

Verify that all terminals feeding dangerous contact voltages (supply voltage, input or output
channels) is in secure OFF state before connecting or withdrawing the terminals.

1KGT151095 V003 1 19
Warnings and Cautions Safety Instructions

ADVICE
Protect the device from dampness, dirt and damage during transport, storage and operation. The
device does not normally need to be cleaned.

CAUTION
Do not operate the device outside the limits defined in the Technical Specifications.

CAUTION
Operate the device according to the conditions defined for the IP 20 protection class.

If these conditions cannot be met due to environmental conditions at the installation location,
install the device in a closed cabinet or rack.

CAUTION
Do not obstruct the cooling ventilation.

Do not cover the ventilation slots with cables or wires.

CAUTION
Route signal lines and power lines separately.

Route cables at a suitable distance and avoid crossing cables in order to prevent capacitive or
inductive interference of the power lines with signal lines.

CAUTION
Use overvoltage protection in cables to outdoor antenna.

20 1KGT151095 V003 1
Installation Instructions Transport, Unpacking, Identification and Storage

5 Installation Instructions

5.1 Transport, Unpacking, Identification and

Storage
Check the goods against the delivery documents upon receipt.
Inform Hitachi ABB Power Grids immediately of any damage or deficiencies to avoid delay in the
installation.
The packaging of the cabinets is suitable for the means of transport. Do not remove the
packaging of the cabinets until the cabinets are located in their intended position.
If the cabinets cannot be installed immediately on arrival at the site, store them in a dry location.
Make sure that their packaging is not removed and protect them from dust.
If the cabinets are delivered strapped on pallets, keep them strapped on the pallets during
transport.
Do not remove the transport bars before the cabinet is in its intended position.
Use a fork-lift truck to transport the pallets with the cabinets. If a travelling crane is available at
the site, use the lifting eyes of the cabinet. Use suitable spreaders with the lifting straps.

A plate shows the system designation is usually fixed to the upper front of the cabinet. A nameplate
with stamped identification information (including the order number) is fixed to the bottom of the
cabinet. The order number and station name are included on the terminal diagram, assembly
drawing and other order-specific documentation for the cabinet.

5.2 Documents and Instructions

The assembly drawing shows the location of the racks, the connection units and other units in the
cabinet and the location of the modules included in the different racks.

The assembly drawing also shows all units of the respective system.

The terminal diagram is a set of drawings showing all points at which connections are made to the
terminal.

Each circuit board type is presented on one or several sheets. The process environment in which
the RTU system will be integrated is normally set up and connected by the client beforehand.
Therefore, the terminal diagram is supplied to the customer prior to shipping the terminal.

5.3 Cabinet Installation

If the electronics cabinet to be installed will have direct physical contact with another cabinet
containing electronics equipment only, you can omit the side panels between cabinets. However,
in order to protect the electronics from interference, the side panels between electronics
cabinets and relay cabinets must remain in place.
If the cabinet is not welded to a steel deck or similar, fasten the electronics cabinet to the floor
using floor screws.
Use a duct for incoming and outgoing cables.
Connect the cabinet to protective earth and test earth protection before welding it to a steel deck
or similar surfaces.

1KGT151095 V003 1 21
Electrical Installation Installation Instructions

If the cabinet needs to be installed with its rear against a wall, provide a minimum clear space of
1 m in front of the cabinet to leave a passage while the cabinet door is open.
When installing cabinets with a hinged frame, provide sufficient clear space to the left of the row
of cabinets to allow the doors and frames of the cabinets to be opened entirely.
Provide a clear space of 0.5 m above the cabinet to ensure ventilation in the cabinet.
If the equipment to be installed is distributed across multiple cabinets, make sure interference
is limited to a minimum. Connect the cabinets at ten or more positions evenly spread across the
entire area of contact. Use the supplied screws and washers to ensure electrical contact.
Verify that the cabinets are properly connected to protective earth to ensure normal function and
safety of the operating personnel.
Verify that the protective earth connection consists of a copper conductor with a minimum cross-
section of 10 mm that is connected to the earthing bar in the enclosure.
If the equipment to be installed is distributed across multiple cabinets, connect the horizontal
earthing bars from enclosure to enclosure and connect the cabinets to the plant's earthing
system at a location allowing the shortest possible conductor.

5.4 Electrical Installation

Before electrical installation, take the following precautionary steps:

Ensure that the main switch in the cabinet is in the OFF position.
Open all input and output circuits to ensure that no circuits in the cabinet are live when voltage is
applied to other plant sections.

DANGER
Hazardous voltage.

Contact with live circuits will cause electric shock or burn.

Before the beginning of electrical installation, turn off main switch and open all input and output
circuits to ensure that no circuits in the cabinet are live when voltage is applied to other plant
sections.

5.4.1 Cable Grounding

Connect the shield of all process and signal cables leaving or entering the cabinet to protective
earth to ensure the required EMC/EMI protection.
Connect the cable shield to the earthing of the cabinet. Use a position close to the cabinet entry
for that connection.
Install appropriate earthing bars close to protective earthing conductors.
When connecting the cable shields to the earthing bar, ensure a sufficient contact area.

5.4.2 Cable Cross-Section

ADVICE
The cable cross-section and the cable insulation must be dimensioned according to the expected
load.

22 1KGT151095 V003 1
Installation Instructions Electrical Installation

5.4.3 Cable Routing

Use cable shields for cables transmitting process signals.

Connect the cable shields to the earthing bar of the cabinet at a location allowing the shortest
possible conductor (max. 10 cm).
Route signal cables as far as possible from other cables to make sure interference is limited to a
minimum.
Ensure a minimum distance of 0.3 m to power cables carrying phase voltages greater than 250
V and running in parallel over a length greater than 3.0 m.
Ensure that the protective earthing lines follow the signal cables in the cable ducts.

5.5 Function Test

5.5.1 Tools and Devices

Ensure that the following tools are available:

• General hand tools, e.g. screw drivers, tweezers and soldering iron.
• A PC running the program RTUtil500 and a web browser e.g. Google Chrome.
• Level meter (selective).
• Digital display multi-meter, 4 digits, AC and DC, accuracy better than 0.2 %.
• Variable DC voltage supply unit for simulation of analog measured values (±20 mA DC, 0...10 V
DC).
• Oscilloscope or level-indicating instrument for introducing transmission channels to service.
• Display for DC voltage supply (±20 mA DC, 0...10 V DC).

5.5.2 Connection of Supply Voltage

Ensure that the supply voltages to the power supply boards are distributed correctly.
Set the switches on the power supply board in each rack to OFF.
Set the switch on the main switch unit to OFF.
Connect the supply voltage to the input terminal of the RTU500 series.
Ensure that the operating supply voltage at the input terminal is correct.
Set the switch on the main switch unit to ON.
Ensure that the correct voltage is available at the primary voltage poles on the power supply
boards.
Set the switches on the power supply boards to ON.

5.5.3 Function Test

Connect the PC that is running a web browser to the remote terminal station as described in the
Web Server User’s Guide.
Ensure that the configuration to be tested is already installed. If the configuration is not installed,
use a web browser to upload the required configuration files as distributed by data engineering
of the PC running RTUtil500 to the RTU. For more information on uploading configuration files,
refer to the Web Server User's Guide.
Start the RTU by setting the main switch on the power supply unit to ON.

After power-up, the ST LED of each board is ON for several seconds. The LED turns OFF once the
respective board has completed initialization. RTU530 I/O modules do not have an ERR LED. A
failure is detected and signalized by the communication unit.

1KGT151095 V003 1 23
Function Test Installation Instructions

Ensure that no red ST LED remains ON. For LED display status definitions, refer to Part 6 of the
Function Description.
A web browser can be used to ensure correct operation for process I/O signals. For more
information, refer to the Web Server User's Guide.
Connect a protocol analyzer utility running in Master mode, or a master station to the RTU.

The LEDs RxD and TxD indicate message traffic on the connected transmission line. In case of an
open transmission connection, the LED RxD will be permanent ON.

Compare the telegram content received and displayed to the RTU configuration. Check all
status telegrams for proper fault detection.
As a minimum, test the first and last input board of each data type.
The utility connected to the transmission line channel is used for analyzing inputs and simulation
of outputs.
The "1 out of n" test with each of the boards 23BA23, 540CID01 or 520CSD01 requires a
resistor (simulating the resistance value of the connected interposing relays or a test relay) to be
connected to the selected channel output connectors of the binary output board (e. g. 23BA20,
520BOD01).

24 1KGT151095 V003 1
RTU500 Series Documentation RTU500 Series Function Description

6 RTU500 Series Documentation

6.1 RTU500 Series Function Description

The Function Description consists of several parts:

Document identity Part name Explanation

1KGT151095 Part 1: Overview Overview of the RTU500 series and
system architecture
1KGT151096 Part 2: Rack mounted solu- Description of the RTU500 series rack
tions solutions
1KGT151097 Part 3: DIN rail solutions Description of the RTU500 series DIN
rail solutions
1KGT151098 Part 4: Hardware modules Overview of the RTU500 series rack
and DIN rail modules
1KGT151099 Part 5: SCADA functions Description of the RTU500 series
SCADA functions
1KGT151100 Part 6: RTU500 functions Description of the RTU500 series func-
tions
1KGT151101 Part 7: Archive functions Description of the RTU500 series
Archive functions
1KGT151102 Part 8: Integrated HMI Description of the RTU500 series Inte-
grated HMI interface
1KGT151103 Part 9: Interfaces and Net- Description of the RTU500 series Inter-
works face and Network functions
Table 4: Parts of the Function Description

Part 1: Overview contains information about:

– Applications and features of the RTU500 series
– Applicable safety and installation instructions
– Structure and contents of the RTU500 series documentation

Part 2 of the Function Description describes the application and features of the rack-mounted
RTU560 product line of the RTU500 series.

Part 2: Rack Solutions contains information about:

• RTU560 Racks
• Communication units
• Power supply units
• Bus connection units
• Configuration examples

Part 3 of the Function Description describes the application and features of the DIN rail-mounted
system of the RTU500 series.

Part 3: DIN Rail Solutions contains information about:

• Scalable housing
• Base modules
• Power supply units
• Interface adaptor units

1KGT151095 V003 1 25
RTU500 Series Function Description RTU500 Series Documentation

• Configuration examples

Part 4 of the Function Description describes additional hardware modules not included in Part 2 and
3 of the Function Description.

Part 4: Hardware Modules contains information about:

• Input and output modules
• Communication modules
• Comparison of I/O modules

Part 5 of the Function Description describes the basic SCADA functions (Supervisory, Control and
Data Acquisition).

Part 5: SCADA Functions contains information about:

• SCADA functions in monitoring direction
– Indication processing
– Measurement processing
– Pulse counter processing

• SCADA functions in command direction

– Pulsed command output
– Persistent commands

Additional functionality of the RTU500 series is described in Part 6 of the Function Description.

Part 6: RTU Functions contains information about:

• System redundancy
• Host Communication Interfaces (HCI)
• Subdevice Communication Interfaces (SCI)
• Substation automation systems with IEC 61850
• Interfaces and networks
• Programmable Logic Controller (PLC)
• Start up, configuration, time management
• Status and diagnostic information
• System data interface

Archives are stored on the flash card of the communication units. The functionality is described in
Part 7 of the Function Description.

Part 7: Archive Functions contains information about:

• Local Print and Process Archive function
• Disturbance Data File Archive
• Transmission and storage of meter data

The integrated Human Machine Interface (HMI) is a local graphical interface to the RTU500 series.
The interface is described in Part 8 of the Function Description.

Part 8: Integrated Human Machine Interface (HMI) contains information about:

• Organization of the HMI
• Configuration
• HMI Editor
• Component library
• Component views
• Support of additional languages

26 1KGT151095 V003 1
RTU500 Series Documentation Hardware Data Sheets

• HMI runtime system

• Limitations of the HMI

The different interfaces of the CMU modules and the networking facilities of the interfaces are
described in part 9: of the function description.

Part 9: Interfaces and Networks contains information about:

• Interfaces of the CMU modules
• Network functionality of the RTU500 series

The following document types are used in addition to the Function Description. They provide
detailed information on the hardware/software components of the RTU500 series:
• Hardware Data Sheets
• Connections and Settings
• Protocol Manuals for Host Communication Interfaces
• Protocol Manuals for Subdevice Communication Interfaces
• User's Guides

6.2 Hardware Data Sheets

• Environmental Data Sheet RTU500 series, 1KGT 150 400
• Hardware Data Sheets

Hardware Data Sheets are available for all hardware modules listed in Parts 2, 3 and 4 of the
Function Description.

Hardware Data Sheets contain information about:

• Application
• Characteristics
• Technical data of the modules

6.3 Connections and Settings

Connections and Settings documents are available for all hardware modules described in Parts 2, 3
and 4 of the Function Description.

These documents describe:

• Operation
• Signaling
• External connections
• Jumpers and switches

6.4 Host Communication Interfaces

Host Communication Interface documents describe the communication protocols used for
communication between the following devices:
• The RTU of the RTU500 series and a Network Control Center (NCC)
• A subordinate RTU of the RTU500 series (IEDs) and a communication node

1KGT151095 V003 1 27
Subdevice Communication Interfaces RTU500 Series Documentation

Some of the communication protocols are limited to special versions of the CMU or to selected
communication ports. These limitations and restrictions are described in the document RTU500
series Interfaces and Protocols Release 13 (1KGT151104).

6.5 Subdevice Communication Interfaces

Subdevice Communication Interface documents describe the communication protocols used for
communication between an RTU500 series node and a subordinated device (IED).

Some of the communication protocols are limited to special versions of the CMU or to selected
communication ports. These limitations and restrictions are described in the document RTU500
series Interfaces and Protocols Release 13 (1KGT151104).

6.6 User's Guides

The following User's Guides are available:
• User Manual RTU500 series Web Server Release 13 (1KGT151108)
• User Manual Integrated HMI (1KGT 150 563)
• User Manual RTUtil500 Release 13 (1KGT151107)
• User Manual Migration Guideline Release 13 (1KGT151105)
• User Manual Security Deployment Guide Release 13 (1KGT151106)

6.7 Security Documents

As a communication gateway, the RTU500 series links a control system to a directly connected
process or to subordinate devices. For wide area networks in particular, with connection to the
Internet, additional configurations are required to increase protection and privacy for the RTU500
series Ethernet communication. These features are described in User Manual Security Deployment
Guide Release 13 (1KGT151106).

28 1KGT151095 V003 1
Glossary

7 Glossary
AC Alternating Current

CMU Communication and Data Processing Unit

DC Direct Current

HMI Human Maschine Interface (here Integrated HMI function of the

RTU500 series)

HTTPS Hypertext Transfer Protocol Secure

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

LED Light Emitting Diode

NCC Network Control Center

PC Personal Computer

PLC Programmable Logic Control

RTU Remote Terminal Unit

SCADA Supervision, Control and Data Acquisition

SD Secure Digital Memory Card

TCP/IP Transmission Control Protocol / Internet Protocol

USB Universal Serial Bus

1KGT151095 V003 1 29
 Glossary

30 1KGT151095 V003 1
1KGT151095 V003 1 31
 Note:

The specifications, data, design or other information contained in this document (the “Brochure”)
- together: the “Information” - shall only be for information purposes and shall in no respect be
binding. The Brochure does not claim to be exhaustive. Technical data in the Information are only
approximate figures. We reserve the right at any time to make technical changes or modify the
contents of this document without prior notice. The user shall be solely responsible for the use of
any application example or information described within this document. The described examples
and solutions are examples only and do not represent any comprehensive or complete solution.
The user shall determine at its sole discretion, or as the case may be, customize, program or add
value to the Hitachi ABB Power Grids products including software by creating solutions for the
end customer and to assess whether and to what extent the products are suitable and need to be
adjusted or customized.

This product is designed to be connected to and to communicate information and data via a network
interface. It is the users sole responsibility to provide and continuously ensure a secure connection
between the product and users or end customers network or any other network (as the case may
be). The user shall establish and maintain any appropriate measures (such as but not limited to the
installation of firewalls, application of authentication measures, encryption of data, installation of
anti-virus programs, etc) to protect the product, the network, its system and the interface against
any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of
data or information. Hitachi ABB Power Grids is not liable for any damages and/or losses related
to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of
data or information.

Hitachi ABB Power Grids shall be under no warranty whatsoever whether express or implied and
assumes no responsibility for the information contained in this document or for any errors that
may appear in this document. Hitachi ABB Power Grids's liability under or in connection with this
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Hitachi ABB Power Grids reserves all rights in particular copyrights and other intellectual property
rights. Any reproduction, disclosure to third parties or utilization of its contents - in whole or in part -
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ABB is a registered trademark of ABB Asea Brown Boveri Ltd.

Manufactured by/for a Hitachi Power Grids company.

© 2021 Hitachi Power Grids.

All rights reserved.

32 1KGT151095 V003 1
1KGT151095 V003 1 33
Visit us

Hitachi Power Grids Germany AG

P.O. Box 10 03 51
68128 Mannheim, Germany

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1KGT151095 V003 1