Substation Protocol Gateway

The problem

Private substations must report to the utility over IEC 104 or IEC 61850, but the installed meters and relays only speak Modbus, and a full substation automation upgrade is out of budget.

Solution overview

MILESGO gateways collect data from protection relays and bay controllers, electricity meters, transformer temperature and tap monitors, run/stop and fault dry contacts over Modbus RTU / Modbus TCP / DL/T 645, and deliver it to the utility SCADA (IEC 104 / IEC 61850), SCADA as IEC 60870-5-104 / IEC 61850 / OPC UA. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

protection relays and bay controllers
electricity meters
transformer temperature and tap monitors
run/stop and fault dry contacts

Protocol path

Modbus RTU / Modbus TCP / DL/T 645 → IEC 60870-5-104 / IEC 61850 / OPC UA

Implementation checklist for the project manager

Obtain SCL/ICD files or the IEC 104 point list from the utility early, and agree which signals are monitored and which are controlled.
Configure NTP so trends, alarms and meter readings carry consistent timestamps.
Commission in read-only mode first; enable write / control points only after the client approves each one.
Keep OT networks segregated and use VPN for remote access instead of opening ports to the internet.
Build and simulate the configuration off site (FAT) before installation to shorten time on site.
Confirm the authority’s reporting requirements and data formats at the start of the project.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: protection relays and bay controllers, electricity meters, transformer temperature and tap monitors, run/stop and fault dry contacts, connected over Modbus RTU / Modbus TCP / DL/T 645. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: the utility SCADA (IEC 104 / IEC 61850), SCADA, which receives the data as IEC 60870-5-104 / IEC 61850 / OPC UA. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: protection relays and bay controllers, electricity meters, transformer temperature and tap monitors, run/stop and fault dry contacts
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: the utility SCADA (IEC 104 / IEC 61850), SCADA (IEC 60870-5-104 / IEC 61850 / OPC UA)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Alarm noise reduction and root-cause groupingRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

New equipment integrated by configuration, not custom driver development
Open interfaces (BACnet, Modbus, OPC UA, MQTT, HTTP) avoid lock-in to one vendor
Timestamped records for compliance and reporting
Monitoring added without changing existing control programs

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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