- Power grids often contain both modern and legacy systems. Newly built utilities and substations may adopt IEC 61850 technology, while existing SCADA or battery management systems may still use Modbus TCP.
- In this application, new IEDs running IEC 61850 needed to be integrated into an existing Modbus TCP-based battery management and SCADA environment. The challenge was to bridge these two communication worlds without replacing the existing system.
Case Studies
Protocol Bridge for Renewable Grid Integration
26 Jun 2026A protocol gateway application that connects modern IEC 61850 IEDs with existing Modbus TCP-based SCADA and battery management systems, simplifying renewable power grid integration.
Overview
ChallengesThe main challenges were
- • New IEDs used IEC 61850
- • Existing SCADA and battery management systems used Modbus TCP
- • Legacy grid equipment had long service life and could not be easily replaced
- • Protocol compatibility was required for system integration
- • Equipment was installed in harsh cabinet environments exposed to heat
- • Secure and reliable data conversion was required
ObjectivesThe system needed to
- • Integrate IEC 61850 IEDs into a Modbus TCP-based system
- • Avoid unnecessary replacement of existing grid infrastructure
- • Simplify protocol conversion and testing
- • Support reliable operation in harsh cabinet environments
- • Enable secure conversion and transmission of data
- • Improve retrofit efficiency for renewable power grid applications
Solution DeliveredThe solution included
- A protocol gateway was used to convert IEC 61850 data into protocols usable by the existing system.
- The gateway allowed the IEC 61850 CID file to be imported, making it easier to retrieve relay settings and configure protocol conversion. Active read and write functions helped users test communication without needing full system connectivity during setup.
- The gateway's rugged design and wide operating temperature range supported long-term operation in sunlit cabinets. Secure boot and encrypted data support helped maintain system integrity during protocol conversion and transmission.
Conclusion
This application is useful for the Power vertical because it shows a very practical grid-modernisation problem: integrating modern IEC 61850 devices with existing Modbus TCP systems. It is a strong story for renewable and battery projects where new equipment must be added without disrupting legacy infrastructure.
