RTU500 series

RTU500 series Remote Terminal Unit

Function Description Release 12
Part 1: Overview
RTU500 series Remote Terminal Unit Revision

Revision
Document identity: 1KGT 150 940 V000 1
Revision: Date: Changes:
0 07/2016 Initial version

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Revision RTU500 series Remote Terminal Unit

1KGT 150 940 V000 1 - ABB AG

RTU500 series Remote Terminal Unit Contents

Contents
1 Introduction.................................................................................................................... 1-1

2 RTU500 series application and features.........................................................................2-1

2.1 Overview............................................................................................................. 2-1
2.2 Application.......................................................................................................... 2-1
2.3 Features.............................................................................................................. 2-3
2.4 System design.................................................................................................... 2-4
2.5 System concept..................................................................................................2-4

3 System overview............................................................................................................ 3-1

3.1 Cyber security.....................................................................................................3-1
3.2 Telecontrol functions........................................................................................... 3-1
3.3 External communication......................................................................................3-2
3.4 PLC development system...................................................................................3-3
3.5 System redundancy............................................................................................ 3-3
3.6 Status and diagnostic information.......................................................................3-3
3.7 Local Print and Local Archive............................................................................. 3-4
3.8 Integrated Human Machine Interface (HMI)......................................................... 3-4

4 Safety instructions.......................................................................................................... 4-1

4.1 Introduction......................................................................................................... 4-1
4.2 Safety indication symbols................................................................................... 4-1
4.3 Applicable standards and directives for installation and operation....................... 4-2
4.4 Qualified personnel............................................................................................. 4-3
4.5 Intended use.......................................................................................................4-3
4.6 Warnings and Cautions.......................................................................................4-3

5 Installation instructions................................................................................................... 5-1

5.1 Transport, unpacking, identification and storage.................................................5-1
5.2 Documents and instructions............................................................................... 5-1
5.3 Cubicle installation.............................................................................................. 5-1
5.4 Electrical installation............................................................................................ 5-2
5.4.1 Cable grounding................................................................................ 5-2
5.4.2 Cable routing..................................................................................... 5-2
5.5 Function test....................................................................................................... 5-3
5.5.1 Tools and devices.............................................................................. 5-3
5.5.2 Connection of supply voltage.............................................................5-3
5.5.3 Function test...................................................................................... 5-3

6 RTU500 series documentation....................................................................................... 6-1

6.1 RTU500 series Function Description................................................................... 6-1
6.2 Hardware Data Sheets........................................................................................6-3
6.3 Connections and Settings...................................................................................6-3
6.4 Host Communication Interfaces.......................................................................... 6-3

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Contents RTU500 series Remote Terminal Unit

6.5 Subdevice Communication Interfaces................................................................. 6-4

6.6 User's Guides..................................................................................................... 6-4
6.7 Security documents............................................................................................ 6-4

7 Glossary......................................................................................................................... 7-1

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RTU500 series Remote Terminal Unit 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 function-
alities 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

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Introduction RTU500 series Remote Terminal Unit

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RTU500 series Remote Terminal Unit 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 con-
trol requests an ongoing penetration of the network down to the lowest levels. The increasing re-
quirements concerning the availability of energy and their distribution and transportation leads to in-
creasing demands on control systems. Improved and new communication possibilities with a high-
er 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

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

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RTU500 series application and features RTU500 series Remote Terminal Unit
Application

Network Control Center Wireless communication Remote Maintenance Workplace

Process Voltage Fault passage

Measurements Regulation Control indication

Multimeter

Figure 3: 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 infor-
mation 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 config-
urations that match the particular application and data point profiles of a station. Configuration op-
tions 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

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RTU500 series Remote Terminal Unit RTU500 series application and features
Features

communication line. This user-friendly telecontrol approach helps reducing travel expenses and in-
creases operator flexibility, e.g. by using configuration extensions or modifications to existing con-
figurations.

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 inter-
face 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 net-
work 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 inter-
face.

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, hy-
dro power plants, station interlocking for electrical substations, etc.
• Archival of process and station events in a sequence of event lists in the flash memory, acces-
sible via intranet or equivalent independent network
• Archival of Integrated Totals (ITI) and Analog Measured Values (AMI) in the flash memory, ac-
cessible 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 proto-
cols, such as IEC 60870-5-104 or IEC 61850
• Marshaling and filtering of process events to connected NCCs, decoupling transaction se-
quences 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 protec-
tion against unexpected attacks

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RTU500 series application and features RTU500 series Remote Terminal Unit
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 redundan-
cy concept
• RTU540 product line: DIN rail RTU in metal 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 So-
lutions. The features of the RTU540 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 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 4: 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
depends on the requirements of a particular station or router RTU. Single CMU solutions are also
available in the DIN rail RTU product lines.

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RTU500 series Remote Terminal Unit RTU500 series application and features
System concept

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 con-
version: into or from the RTU's internal representation.

This approach requires each protocol module to maintain its own process database for signal pro-
cessing, 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)

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RTU500 series application and features RTU500 series Remote Terminal Unit
System concept

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RTU500 series Remote Terminal Unit 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 stan-
dards:
– NERC /CIP
North American Electric Reliability Corporation – Critical Infrastructure Protection
– IEC 62351
Power systems management and associated information exchange – Data and communica-
tions 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 Account Management (UAM), integrated in the web server
– 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
– IEEE 802.1X Port-based Network Access Control

3.2 Telecontrol functions

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

Binary input modules:

• 23BE23
• 560BIR01
• 23BE40
• 23BE50
• 520BID01

Analog input modules:

• 23AE23
• 520AID01
• 520PTD01 (PT100 interface)

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System overview RTU500 series Remote Terminal Unit
External communication

Multiple I/O modules:

– 540CID01 (binary input, binary output, analog input and command output supervision)

Multimeter modules:
• 560CVD03
• 560CVD11 (with fault current detection FCD)

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

Binary output modules:

• 23BA20
• 23BA23 (command output supervision)
• 23BA40
• 520BOD01
• 520CSD01 (command output with command output supervision)

Analog output modules:

• 23AA21
• 520AOD01

Multiple I/O modules:

– 540CID01 (binary input, binary output, analog input and command output supervision)

Telecontrol functions are described in RTU500 series function description - part 5: SCADA functions
(1KGT 150 944).

3.3 External communication

The RTU500 series allows communication with up to 16 different host systems by using the com-
munication 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.

The subdevice communication interface is used for communication between the RTU and subordi-
nated 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 pro-
tocol-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 (1KGT 150 945)

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RTU500 series Remote Terminal Unit System overview
PLC development system

3.4 PLC development system

This chapter describes the PLC function, the RTUtil500 series runtime system for control applica-
tions. It has been designed according to IEC 61131-3 and is engineered with the programming and
debugging system MULTIPROG wt.

The PLC function is a licensed software package that generally enables the CMU to run PLC ap-
plications and to communicate with MULTIPROG wt 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 RTUtil500 series. This provides maximum processor power for each of the activities.

The PLC development system is described in Part 6 of the Function Description.

3.5 System redundancy

Retaining accessibility to stations in energy transmission and distribution networks is a key require-
ment.

The RTU560 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 boards for any com-
munication lines and functions that are critical to the operation of the station. In the event of an
error, the RTU560 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.

System redundancy is described in Parts 2 and 6 of the Function Description.

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.

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System overview RTU500 series Remote Terminal Unit
Local Print and Local Archive

Status and diagnostic functions are described in RTU500 series function description - part 6:
RTU500 functions (1KGT 150 945).

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 sys-
tem 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 cate-
gories:
– 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 (1KGT 150 946).

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 RTUtil500 configuration files.

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

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RTU500 series Remote Terminal Unit System overview
Integrated Human Machine Interface (HMI)

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
(1KGT 150 947).

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System overview RTU500 series Remote Terminal Unit
Integrated Human Machine Interface (HMI)

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RTU500 series Remote Terminal Unit Safety instructions
Introduction

4 Safety instructions

4.1 Introduction
Read the following chapter before mounting and commissioning an RTU 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 the RTU. 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 observedThis symbol is
used to indicate restrictions, prerequisites, and other information that is important for configuring
the RTU.

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

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 connection and settings docu-
ments)

Table 2: Safety indication symbols on RTU500 series modules

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Safety instructions RTU500 series Remote Terminal Unit
Applicable standards and directives for installation and operation

4.3 Applicable standards and directives for installation and

operation
The devices of the ABB RTU500 series are produced in compliance with the relevant regulations
and standards.

According to IEC 60664-1 (DIN VDE 0110) 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 61131 Part 2

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

Standard Explanation

DIN VDE 0100 Erection of power installations with nominal voltages up to 1 000 V

DIN VDE 0106 Protection against electrical shock

Part 100: Actuating members positioned close to parts liable to shock

EN 60204 Safety of machinery; Electrical equipment of machines

Part 1: General requirements

EN 50178 Electronic equipment for use in electrical power installations and their assembly
into electrical power installations

DIN VDE 0800 Telecommunications

Table 3: Standards

If the "Pollution degree 2" classification according to DIN VDE 0110 cannot be guaranteed or if
further protection against direct contact is required, mount the devices into suitable cubicles.

If devices of the ABB 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.

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RTU500 series Remote Terminal Unit 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 qual-
ified personnel with knowledge of the following information.

• Dealing with dangerous voltages

Application of the relevant specifications, standards, and regulations, in particular of the applica-
ble 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.

ABB 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 chan-
nels) is in secure OFF state before connecting or withdrawing the terminals.

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Safety instructions RTU500 series Remote Terminal Unit
Warnings and Cautions

ADVICE

Protect the device from dampness, dirt and damage during transport, storage and operation.

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 cubicle 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.

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RTU500 series Remote Terminal Unit Installation instructions
Transport, unpacking, identification and storage

5 Installation instructions

5.1 Transport, unpacking, identification and storage

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

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

5.2 Documents and instructions

The assembly drawing shows the location of the racks, the connection units and other units in the
cubicle 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 Cubicle installation

1. If the electronics cubicle to be installed will have direct physical contact with another cubicle
containing electronics equipment only, you can omit the side panels between cubicles. How-
ever, in order to protect the electronics from interference, the side panels between electronics
cubicles and relay cubicles must remain in place.
2. If the cubicle is not welded to a steel deck or similar, fasten the electronics cubicle to the floor
using floor screws.
3. Use a duct for incoming and outgoing cables.
4. Connect the cubicle to protective earth and test earth protection before welding it to a steel
deck or similar surfaces.
5. If the cubicle needs to be installed with its rear against a wall, provide a minimum clear space
of 1 m in front of the cubicle to leave a passage while the cubicle door is open.
6. When installing cubicles with a hinged frame, provide sufficient clear space to the left of the
row of cubicles to allow the doors and frames of the cubicles to be opened entirely.
7. Provide a clear space of 0.5 m above the cubicle to ensure ventilation in the cubicle.

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Installation instructions RTU500 series Remote Terminal Unit
Electrical installation

8. If the equipment to be installed is distributed across multiple cubicles, make sure interference
is limited to a minimum. Connect the cubicles at ten or more positions evenly spread across
the entire area of contact. Use the supplied screws and washers to ensure electrical contact.
9. Verify that the cubicles are properly connected to protective earth to ensure normal function
and safety of the operating personnel.
10. 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.
11. If the equipment to be installed is distributed across multiple cubicles, connect the horizon-
tal earthing bars from enclosure to enclosure and connect the cubicles 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:

1. Ensure that the main switch in the cubicle is in the OFF position.
2. Open all input and output circuits to ensure that no circuits in the cubicle are live when volt-
age 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, open all input and output circuits to ensure that no
circuits in the cubicle are live when voltage is applied to other plant sections.

5.4.1 Cable grounding

1. Connect the shield of all process and signal cables leaving or entering the cubicle to protec-
tive earth to ensure the required EMC/EMI protection.
2. Connect the cable shield to the earthing of the cubicle. Use a position close to the cubicle en-
try for that connection.
3. Install appropriate earthing bars close to protective earthing conductors.
4. When connecting the cable shields to the earthing bar, ensure a sufficient contact area.

5.4.2 Cable routing

1. Use cable shields for cables transmitting process signals.
2. Connect the cable shields to the earthing bar of the cubicle at a location allowing the shortest
possible conductor (max. 10 cm).
3. Route signal cables as far as possible from other cables to make sure interference is limited to
a minimum.
4. 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.
5. Ensure that the protective earthing lines follow the signal cables in the cable ducts.

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RTU500 series Remote Terminal Unit Installation instructions
Function test

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 utility program RTUtil500 and Microsoft® Windows® Internet Explorer
• 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

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

5.5.3 Function test

1. Connect the PC running Microsoft® Windows® Internet Explorer to the remote terminal as
described in the Web Server User’s Guide.
2. Ensure that the configuration to be tested is already installed. If the configuration is not in-
stalled, use Internet Explorer to upload the required configuration files as distributed by data
engineering of the PC running RTUtil500 to the RTU. For more information on uploading con-
figuration files, refer to the Web Server User's Guide.
3. 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.

1. Ensure that no red ST LED remains ON. For LED display status definitions, refer to Part 6 of
the Function Description.
2. Microsoft® Internet Explorer® can be used to ensure correct operation for process I/O sig-
nals. For more information, refer to the Web Server User's Guide.
3. 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.

1. Compare the telegram content received and displayed to the RTU configuration. Check all
status telegrams for proper fault detection.
2. As a minimum, test the first and last input board of each data type.

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Installation instructions RTU500 series Remote Terminal Unit
Function test

3. The utility connected to the transmission line channel is used for analyzing inputs and simula-
tion of outputs.
4. 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).

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RTU500 series Remote Terminal Unit 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

1KGT 150 940 Part 1: Overview Overview of the RTU500 series and system ar-
chitecture

1KGT 150 941 Part 2: Rack mounted solutions Description of the RTU500 series rack solutions

1KGT 150 942 Part 3: DIN rail solutions Description of the RTU500 series DIN rail solu-
tions

1KGT 150 943 Part 4: Hardware modules Overview of the RTU500 series rack and DIN rail
modules

1KGT 150 944 Part 5: SCADA functions Description of the RTU500 series SCADA func-
tions

1KGT 150 945 Part 6: RTU500 functions Description of the RTU500 series functions

1KGT 150 946 Part 7: Archive functions Description of the RTU500 series Archive func-
tions

1KGT 150 947 Part 8: Integrated HMI Description of the RTU500 series Integrated
HMI interface

1KGT 150 948 Part 9: Interfaces and Networks Description of the RTU500 series Interface 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

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RTU500 series documentation RTU500 series Remote Terminal Unit
RTU500 series Function Description

– Interface adaptor units

– 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

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RTU500 series Remote Terminal Unit RTU500 series documentation
Hardware Data Sheets

• Support of additional languages

• HMI runtime system
• Limitations of the HMI

The different interfaces of the CMU modules and the networking facilities of the interfaces are de-
scribed 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 de-
tailed 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 com-
munication 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

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RTU500 series documentation RTU500 series Remote Terminal Unit
Subdevice Communication Interfaces

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 (1KGT 150 939).

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 (1KGT 150 939).

6.6 User's Guides

The following User's Guides are available:
– User Manual RTU500 series Web Server (1KGT 150 924)
– User Manual Integrated HMI (1KGT 150 563)
– User Manual RTUtil500 (1KGT 150 801)
– User Manual Migration Guideline Release 12 (1KGT 150 926)
– User Manual Security Deployment Guide Release 12 (1KGT 150 925)

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 In-
ternet, additional configurations are required to increase protection and privacy for the RTU500 se-
ries Ethernet communication. These features are described in the User Manual Security Deployment
Guide Release 12 (1KGT 150 925).

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RTU500 series Remote Terminal Unit Glossary

7 Glossary
AMI Analog Measured value Input

CF Compact Flash

CMU Communication and Data Processing Unit

HCI Human Maschine Interface (here Integrated HMI function of the RTU500 series)

IED Intelligent Electronic Device

ITI Integrated Totals Input

NCC Network Control Center

PLC Programmable Logic Control

PPP Point to Point Protocol

RTU Remote Terminal Unit

SCADA Supervision, Control and Data Acquisition

SCI Sub-Device Communication Interface

SEV System Event

USB Universal Serial Bus

VPN Virtual Private Network

ABB AG - 1KGT 150 940 V000 1 | 7-1

  RTU500 series Remote Terminal Unit

2 | 1KGT 150 940 V000 1 - ABB AG

RTU500 series Remote Terminal Unit  

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 ABB 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. ABB AG 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.

ABB AG shall be under no warranty whatsoever whether express or implied and assumes no re-
sponsibility for the information contained in this document or for any errors that may appear in this
document. ABB AG's liability under or in connection with this Brochure or the files included within
the Brochure, irrespective of the legal ground towards any person or entity, to which the Brochure
has been made available, in view of any damages including costs or losses shall be excluded. In
particular ABB AG shall in no event be liable for any indirect, consequential or special damages,
such as – but not limited to – loss of profit, loss of production, loss of revenue, loss of data, loss
of use, loss of earnings, cost of capital or cost connected with an interruption of business or oper-
ation, third party claims. The exclusion of liability shall not apply in the case of intention or gross
negligence. The present declaration shall be governed by and construed in accordance with the
laws of Switzerland under exclusion of its conflict of laws rules and of the Vienna Convention on the
International Sale of Goods (CISG).

ABB AG reserves all rights in particular copyrights and other intellectual property rights. Any repro-
duction, disclosure to third parties or utilization of its contents - in whole or in part - is not permitted
without the prior written consent of ABB AG.

© Copyright ABB 2016

All rights reserved

ABB AG - 1KGT 150 940 V000 1 | 3