Modernizing Legacy RTUs: Forklifting, Retrofitting & Replacing Absolute, GE D20, and ABB 232 Units
Modernizing Legacy RTUs: Forklifting, Retrofitting & Replacing Absolute, GE D20, and ABB 232 Units
Blog Article
In today's fast-evolving utility and industrial environments, legacy Remote Terminal Units (RTUs) like GE D20, ABB 232, and Absolute RTUs are becoming bottlenecks to digital transformation. Whether you're upgrading your SCADA system or improving reliability in field operations, RTU replacement and retrofitting is no longer optional—it’s critical.
At Quadra Electronics, we specialize in RTU modernization, offering comprehensive services including forklifting old RTUs, engineering support for legacy wiring schemes, protocol conversion, and control station interfacing. Here’s how we help you replace obsolete hardware while keeping your operations running seamlessly.
???? Why Replace Legacy RTUs?
Many utilities and infrastructure companies are still operating legacy SCADA RTUs that were deployed decades ago. These units—such as the GE D20 and ABB 232—face several challenges:
Limited or no manufacturer support
Incompatibility with modern SCADA protocols like IEC 60870-5-104 or DNP3
Security vulnerabilities
High risk of downtime during maintenance
We offer a cost-effective RTU replacement strategy that avoids these risks, delivering a vendor-neutral, field-proven, and fully engineered solution.
???? What Is RTU Forklifting and How Does It Work?
Forklifting refers to replacing the entire RTU and its components without redoing the complete control panel or cabinet. This approach saves time and reduces disruption, especially in substations and remote facilities.
Our process includes:
Analysis of the existing RTU wiring scheme
Mapping old I/O points to the new RTU
Retaining terminal layouts for minimal field rewiring
Installing a new RTU with support for IEC104, Modbus, DNP3, or other protocols
⚙️ Protocol Conversion & Control Station Interfacing
Many older RTUs use outdated or proprietary protocols. Our engineering team performs protocol conversion to bridge your legacy devices with your modern SCADA control system.
We support:
Modbus to IEC104
DNP3 to IEC 60870-5-101/104
Serial to Ethernet tunneling
Full SCADA control station interfacing
Whether you're working with a substation, a water treatment plant, or a remote solar farm, our data engineering team ensures smooth transition and continuity.
????️ Engineering Expertise in Wiring & Data Mapping
Replacing an RTU isn’t just plug-and-play—it requires in-depth understanding of your control system architecture and panel wiring schemes.
We provide:
Reverse engineering of legacy RTU panel drawings
Full I/O mapping from old to new
Custom-built migration plans
Testing and validation with SCADA control centers
???? RTUs We Commonly Replace
We have experience in replacing and retrofitting various RTUs, including:
GE D20 RTU
ABB 232 RTU
Absolute RTUs and proprietary models
Other legacy vendor platforms
Each replacement includes data engineering, wiring adaptation, SCADA interfacing, and commissioning.
✅ Why Choose Quadra Electronics?
Vendor-neutral solutions — no lock-in
Over 30 years of SCADA experience
Minimal downtime during RTU upgrades
Custom protocol adapters and SCADA bridges
Proven track record in substation, ABB 232 RTU retrofit utility, and renewable projects
???? Ready to Upgrade Your Legacy RTUs?
Don't wait for your aging RTUs to fail. Get ahead of obsolescence with a tailored RTU modernization plan. We’ll help you forklift, retrofit, or fully replace your GE D20, ABB 232, or Absolute RTUs—without disrupting your operations.
???? Contact us today at [email protected] for a free consultation.
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