Month: May 2025

​Safety Notice

Applicable products: Suitable for ACS800-01/U1 and ACS800-02/U2 products.

Warning and Caution

Warning: Remind of situations that may cause serious injury or death and/or damage to equipment, such as dangerous voltage, electrostatic discharge, etc.

Attention: Remind users of special situations or events, or introduce relevant information on the topic, such as dangerous high voltage at motor cable terminals.

Installation and maintenance work

Only qualified electrical engineers are allowed to install and maintain transmission units.

It is prohibited to install or repair transmission units, motor cables or motors with electricity. After cutting off the input power, wait for at least 5 minutes until the intermediate circuit capacitor is discharged, and use a multimeter to measure and confirm the discharge before operation.

Do not operate control cables when the transmission unit or external control circuit is energized.

All insulation tests must be conducted with the cable disconnected, and ensure the correct phase sequence when reconnecting the cable.

grounding

Proper grounding is necessary to ensure the safety of personnel, reduce electromagnetic radiation and interference. The cross-sectional area of the grounding wire must meet safety regulations, and multiple equipment grounding terminals cannot be connected in series.

In scenarios that comply with European CE standards, cable entrances should maintain a 360 degree high-frequency grounding, and the cable shielding layer should be connected to the protective grounding wire (PE).

Do not install frequency converters with EMC filters in floating or high ground resistance power systems.

Mechanical Installation

The transmission unit is heavy and should not be carried by a single person. When carrying, do not let the front panel bear the weight and rely on lifting the back for transportation.

Ensure that drilling debris does not enter the transmission unit during installation, ensure sufficient cooling space, and do not fix the transmission unit by riveting or welding.

operate

Before debugging the transmission unit, ensure that the motor and driven equipment are suitable for operation within the speed range provided by the transmission unit.

Do not activate the automatic fault reset function of standard applications in situations where danger may occur.

Do not use the main power circuit breaker to control the start and stop of the motor. Instead, use control commands from the control panel keys or transmission unit I/O board.

Permanent magnet motor

When ACS800 is used to drive permanent magnet motors, only scalar control mode can be used.

When the permanent magnet motor is running, do not operate the transmission unit, as its operation transfers electrical energy back to the intermediate circuit. Even if the inverter is not working, the power supply will still charge the transmission system.

During installation and maintenance, use a fuse switch to disconnect the motor from the transmission unit. If possible, lock the motor shaft, connect the motor connection terminals together, and ground them.

Do not operate the permanent magnet motor at speeds higher than the rated speed to avoid overvoltage and capacitor bank rupture.

Product Overview

ACS800-01/U1: A wall mounted transmission unit used to control low-voltage AC asynchronous motors, with different external specifications (R2~R6), protection levels including IP21 (NEMA1) and IP55 (NEMA4, indoor only), etc. The control panel is CDP312R, including printed circuit boards such as main circuit board (RINT), motor control and I/O control board (RMIO), etc. The motor control mode can choose direct torque control (DTC) or scalar control.

ACS800-02/U2: There is relatively little mention in the document, and the external specifications are R7 and R8. Other information can refer to the relevant content of ACS800-01/U1. Some chapters of the two are common, such as safety instructions, electrical installation design, and braking resistors.

Installation

Mechanical Installation

Unpacking and inspection: After unpacking, check for any damage to the appearance, verify if the nameplate of the frequency converter matches the order, and check if the optional modules and equipment are complete.

Preparation before installation: Install vertically, place the radiator against the wall, check if the walls and floors of the installation site meet the requirements, ensure that there is enough space around the transmission unit for cooling air circulation, facilitate maintenance and repair, and pay attention to the space requirements when placing equipment of different protection levels up and down.

Installation method: including wall mounted installation and cabinet installation. Wall mounted installation requires marking the installation hole position with a punching template, fixing screws or bolts, installing the transmission unit and tightening it; Attention should be paid to the horizontal installation distance between the frequency converters when installing inside the cabinet, to prevent the recirculation of cooling air, and to set up air baffles.

Electrical installation design

Motor compatibility check: Ensure that the rated voltage and current of the motor meet the requirements, and avoid the rated voltage of the motor being less than 1/2 of the rated input voltage of the transmission unit or the rated current being less than 1/6 of the rated output current of the transmission unit.

Protecting motor windings and bearings: The output pulse voltage of the transmission unit may affect the motor insulation and bearings. ABB du/dt filters, common mode filters, etc. can be used to reduce the impact. Suitable filters and insulated bearings should be selected according to the motor type and power.

Power supply system connection: A manually operated circuit breaker can be installed between the AC power supply and the transmission unit, which must comply with relevant standards, such as using category AC-23B, etc; The input cable needs to be equipped with a fuse group, and the fuse model should be selected according to local safety regulations, input voltage, and rated current of the transmission unit.

Cable selection and wiring: The main power and motor cables need to be selected according to local regulations to meet the requirements of load current and temperature. The protection ground cables need to consider inductance and impedance limitations; It is best to use shielded cables for control cables, with separate routing for analog and digital signals to avoid long-distance parallel routing. When crossing, the angle should be 90 degrees.

electrical installation

Insulation performance inspection: Check the insulation performance of the motor and motor cables, disconnect the transmission unit from the main power supply, use a 1kV insulation meter to measure the insulation resistance of each relative protective ground, and the resistance value should be greater than 1 megohm.

Power cable wiring: Determine the length of wire stripping according to the external specifications, ground the cable shielding layer, connect the main power cable and motor cable to the corresponding terminals, and fix the junction box cover and front cover.

Control cable wiring: Thread the control cable through the entrance hole and connect it to the relevant detachable terminals on the RMIO board, ensuring a secure connection, grounding the shielding layer, and fixing the control cable and front cover.

Maintenance

Maintenance Cycle

Capacitor update: once a year when stored.

Temperature inspection and cleaning of radiator: Depending on the dust content in the environment, it should be done every 6-12 months.

Cooling fan replacement: Replace every five years, and replace spare fans for IP55 units and some IP21 units every three years.

Maintain content

Cleaning of radiator: Remove the cooling fan, use clean and dry compressed air to blow the radiator from bottom to top, while using a vacuum cleaner to absorb dust at the air outlet, and then install the cooling fan.

Cooling fan inspection: Pay attention to the noise of the fan bearings and the temperature of the radiator. Replace them in a timely manner when signs of damage appear, and use ABB designated spare parts.

Capacitor inspection: Electrolytic capacitors are used in the intermediate circuit, with a service life of about 100000 hours. Damage is often accompanied by the main power fuse melting or fault tripping. If there is suspicion of damage, contact the ABB representative office and use designated spare parts.

LED indication: The LED lights on the RMIO board and control panel installation components can indicate faults and normal power status.

Technical data

IEC level: lists the rated capacity, external specifications, air flow rate, heat loss, and other data of different models of ACS800-01 under 50Hz and 60Hz grid power supply.

Capacity reduction

Temperature induced capacity reduction: When the ambient temperature is between+40 ° C and 50 ° C, for every 1 ° C increase, the rated output current decreases by 1%. The rated current Icont.max is not allowed to be applied in environments exceeding 40 ° C.

Capacity reduction caused by altitude: When the altitude is between 1000-4000m, the rated current decreases by 1% for every 100m increase. If it exceeds 2000m, consult the local ABB dealer or office.

Main power cable fuse: provides cable specifications, fuse models, parameters, etc. corresponding to different models of ACS800-01.

Cable entry hole: information such as terminal size, cable diameter, and tightening torque for different external specifications.

Size, weight, and noise: The size, weight, and noise data of each external specification under different protection levels.

Motor wiring: parameters such as voltage, frequency, current, power limit, and recommended maximum motor cable length.

Efficiency and cooling: The efficiency is approximately 98% of the rated power, and the cooling method is an internal fan with a flow direction from the bottom to the top.

Protection level and environmental conditions: Protection levels include IP21 and IP55, as well as operating conditions such as environmental temperature, relative humidity, and pollution level.

Materials and applicable standards: Information on materials such as transmission unit casing and packaging boxes, following international standards such as EN50178, EN60204-1, etc.

Braking resistor

Configuration and selection: Transmission units with external specifications of R2 and R3 include built-in brake choppers, R4 and larger brake choppers are optional (model+D150), and resistors are additional components; When selecting the transmission unit/chopper/resistor, it is necessary to calculate the braking power to ensure that the resistor resistance and heat loss capacity meet the requirements.

Installation and wiring: All resistors must be installed outside the transmission unit module, with flame-retardant materials nearby. They should be connected using cables of the same model as the input cables of the transmission unit, with a maximum allowable length of 10m. The shielding layer should be properly grounded.

Protection and debugging: It is recommended to configure the main circuit contactor for external specifications R2~R5, and whether R6, R7, and R8 are needed depends on the selection situation; A thermal switch should be installed inside the braking resistor and connected to the digital input port as an external fault interlock signal; Activate the brake chopper function during debugging, turn off the overvoltage control function, and check the resistance value setting.

Brand background

As a globally renowned giant enterprise in the fields of power and rail transportation, ALSTOM has a profound technical foundation and rich industry experience. Since its establishment, we have been committed to providing advanced technological solutions and high-quality products to global customers. In the field of industrial automation control, ALSTOM has established an excellent brand image through continuous innovation and research and development investment. Its products are widely used in various complex industrial scenarios and are known for their reliability and high performance. The ALSTOM LE109A-1 Controller Module is a typical product in the field of industrial control modules.

Core functions

Logical control: capable of executing complex logical operations, processing input signals according to preset control logic, and outputting corresponding control instructions to achieve precise control of industrial equipment. For example, in the automatic production line, according to the input signals of different sensors, control the start and stop of motors, the opening and closing of valves and other equipment actions.

Data collection and processing: It can collect real-time data from various on-site sensors, such as analog data such as temperature, pressure, flow rate, as well as digital data such as equipment status. After preprocessing operations such as filtering and converting the collected data, it is stored in internal memory for subsequent analysis and decision-making.

Communication function: Through the built-in communication interface, data exchange is carried out with the upper computer, other controllers, and on-site intelligent devices. On the one hand, uploading equipment operation data and status information to the upper computer for real-time monitoring by operators; On the other hand, it receives control instructions issued by the upper computer to achieve remote control functions.

Event recording and alarm: With event recording function, it can record key events during equipment operation, such as equipment start stop time, fault occurrence time and type, etc. When an abnormal situation is detected, an alarm signal can be triggered in a timely manner to notify the operator through indicator lights, buzzers, or communication networks, so as to quickly respond and handle the fault.

Working principle

The operation of ALSTOM LE109A-1 Controller Module is based on microprocessor technology. When external sensor signals are input to the input interface of the module, they first pass through the signal conditioning circuit to convert signals of different types and amplitudes into standard signals suitable for microprocessor processing. The microprocessor performs logical operations, data processing, and other operations on input signals according to pre written and stored control programs in internal memory. The calculation results are converted into control signals that can drive external actuators (such as relays, contactors, etc.) through the output interface circuit, thereby achieving control of industrial equipment. Throughout the entire work process, the communication module is responsible for exchanging data with external devices, sending out internal operational data, and receiving control instructions from external devices. At the same time, the event recording and alarm module monitors the real-time operation status of the system. Once any abnormalities are detected, relevant event information is immediately recorded and an alarm signal is issued.

Key advantages

High reliability: Using industrial grade electronic components and advanced manufacturing processes, rigorous quality testing and reliability testing ensure long-term stable operation in harsh industrial environments. For example, in environments such as high temperature, high humidity, and strong electromagnetic interference, normal working performance can still be maintained, reducing equipment downtime and improving production efficiency.

Powerful processing capability: equipped with high-performance microprocessors and large capacity memory, capable of quickly processing complex control logic and large amounts of data. When facing high-speed automated production lines or large-scale industrial control systems, being able to respond promptly and accurately execute control tasks ensures the efficient operation of the system.

Flexible Scalability: Provides rich input/output interfaces and communication interfaces, making it convenient for users to expand the system according to their actual needs. It can easily connect more sensors, actuators, and other intelligent devices to upgrade and optimize system functions, meeting the constantly changing needs of different industrial application scenarios.

Easy to maintain: The module has self diagnostic function, which can monitor its own working status in real time, quickly locate the fault point after discovering the fault, and facilitate quick repair by maintenance personnel. At the same time, adopting modular design, each functional module is relatively independent, and can be easily replaced in case of failure, reducing maintenance costs and time.

precautions

Installation environment: It should be installed in a dry, well ventilated, non corrosive gas and strong electromagnetic interference environment, avoiding direct sunlight. The installation location should be far away from heat sources and water sources to ensure the normal working temperature and humidity conditions of the module.

Electrical connection: When making electrical connections, be sure to disconnect the power supply and strictly follow the wiring diagram for correct wiring. Pay attention to distinguishing between input and output interfaces to avoid module damage or equipment failure caused by incorrect wiring. After the wiring is completed, it is necessary to carefully check the firmness of the wiring to prevent problems such as loose connections and poor contact.

Software programming: When writing and downloading control programs, the programming software and tools provided by ALSTOM should be used, and relevant programming specifications should be followed. Ensure the correctness and stability of the program, and avoid device malfunctions or system failures caused by program errors. At the same time, regularly backup the program to prevent data loss.

Daily maintenance: Regularly clean the module to prevent dust accumulation from affecting heat dissipation and electrical performance. Check the working status indicator lights of the module and observe for any abnormal flashing or extinguishing. Regularly conduct functional testing on modules to ensure that all functions are functioning properly. If any abnormalities are found, the machine should be stopped for inspection and maintenance in a timely manner.

Application scenarios

Industrial automation production line: widely used in various automated production lines such as automobile manufacturing, electronic equipment manufacturing, food and beverage processing, etc. Responsible for logical control and data collection of various equipment on the production line, such as robots, conveyors, processing equipment, etc., to ensure efficient and stable operation of the production line, improve production efficiency and product quality.

Power system: Used in power plants, substations, and other electrical facilities to monitor and control the operational status of electrical equipment. For example, the start stop control, parameter monitoring, and fault alarm of equipment such as generators, transformers, and circuit breakers ensure the safe and reliable power supply of the power system.

Intelligent building: In the intelligent building control system, it is used to achieve automated control of lighting, air conditioning, elevators, water supply and drainage equipment inside the building. By collecting various sensor data such as indoor temperature, humidity, and light intensity, the device’s operating status is automatically adjusted according to preset control strategies, achieving energy conservation, consumption reduction, and improving the intelligent management level of buildings.

Transportation: In the field of rail transit, it can be used for the operation control and monitoring system of trains such as subways and light rails. Accurately control the traction, braking, door control and other functions of the train, while collecting real-time train operation data to ensure the safe and on-time operation of the train. Used in transportation hubs such as ports and airports to control the operation of cargo loading and unloading equipment, transport vehicles, etc., and improve transportation efficiency and management level.

Overview

ALSTOM’s UT150-1 is a device with significant application value in the industrial field. From the model perspective, UT150-1 has clear markings, making it easy to identify and configure in various industrial systems.

In terms of application, UT150-1 is mainly used in DCS/PLC industrial control systems. In these systems, it plays a crucial role in facilitating the stable operation of the entire industrial control process. In order to ensure performance, the device adopts a series of advanced measures, such as digital filtering and power frequency shaping sampling. This technology can effectively eliminate periodic interference, ensure the accuracy of data acquisition, avoid signal deviation caused by interference, and thus ensure the stable operation of the control system. At the same time, UT150-1 also uses measures such as timed calibration of reference point potentials to prevent potential drift. Potential drift may affect the normal working state of equipment, and this measure can adjust the potential in a timely manner to maintain stable operation of the equipment.

NOTE

To install the controller, select a location where:

1. No-one may accidentally touch the terminals;

2. Mechanical vibrations are minimal;

3. Corrosive gas is minimal;

4. The temperature can be maintained at about 23°C with minimal fluctuation;

5. There is no direct heat radiation;

6. There are no resulting magnetic disturbances;

7. The terminal board (reference junction compen sation element, etc.) is protected from wind;

8. There is no splashing of water; and

9. There are no flammable materials

Never place the controller directly on flammable items.

If the controller has to be installed close to flammable items or equipment, be sure to enclose the controller in shielding panels positioned at least 150mm away from each side.

These panels should be made of either 1.43mm thick metal plated steel plates or 1.6mm thick uncoated steel plates.

Mount the controller at an angle within 30° from horizontal with the screen facing upward. Do not mount it facing downward.

CAUTION

1) Before you start wiring, turn off the power source and use a tester to check that the controller and cables are not receiving any power in order to prevent electric shock.

2) For safety, be sure to install a circuit breaker switch (of 5A and 100V AC or 220V AC, and that

conforms to IEC60947) near the instrument so as to be operated easily, and clearly indicate that the

device is used to de-energize the instrument.

3) Wiring should be carried out by personnel with appropriate electrical knowledge and experience

IMPORTANT

1) Use a single-phase power source. If the source has a lot of noise, use an isolation transformer for the primary side and a line filter (we recommend TDK’s ZAC2205-00U product) for the secondary side.

When this noise-prevention measure is taken, keep the primary and secondary power cables well apart.

Since the controller has no fuse, be sure to install a circuit breaker switch (of 5A and 100V AC or 220V AC, and that conforms to IEC standards) and clearly indicate that the device is used to de-energize the controller.

2) For thermocouple input, use shielded compensating lead wires. For RTD input, use shielded wires which have low resistance and no resistance difference between the 3 wires. See the table given later for the specifications of the cables and terminals and the recommended products.

3) The control output relay cannot be replaced even though it has a limited service life (100,000 relay

contacts for the resistance load).  Thus, an auxiliary relay should be used so that the load can be turned on and off.

4) When using an inductive load (L) such as an auxiliary relay and solenoid valve, be sure to insert a CR filter (for AC) or diode (for DC) in parallel as a spark-rejecting surge suppressor to prevent malfunctions or damage to the relay.

5) When there is the possibility of being struck by external lightening surge, use the arrester to protect the instrument.

NOTE

• Always fix a terminal cover bracket to the UT150 controller before wiring if an optional anti-electric

shock terminal cover (part number: L4000FB) is used.

• Two types of optional anti-electric-shock terminal covers (part numbers T9115YE and T9115YD) are

available for the UT152 and UT155 controllers, respectively.

Field and purpose

As a globally renowned enterprise in the fields of rail transit, electricity, etc., Alstom’s UT150-1 control board is commonly used in the control systems of rail transit vehicles, such as subways, light rails, trains, etc., to achieve various control functions of the vehicles, ensuring the safe operation and efficient performance of the trains. For example, it may be responsible for controlling important functions such as traction, braking, speed regulation, and door opening and closing of the train.

Working principle

Signal processing and transmission: The control board receives signals from various sensors and operating devices of the train, such as speed sensors, position sensors, driver operation handles, etc., processes and analyzes these signals, and then sends control signals to the corresponding actuators according to preset logic and algorithms to achieve precise control of the train’s operating status.

Communication and network connection: Through specific communication protocols and network interfaces, the UT150-1 control board interacts and communicates with other systems and devices on the train, such as the central control system, traction system, braking system, etc., to share information and work together to ensure the coordinated operation of the overall train system.

FEATURES

High reliability: Adopting redundant design, fault-tolerant technology, and highly reliable electronic components to ensure stable operation in complex operating environments, reduce the probability of failures, and ensure the safety and reliability of train operation.

High real-time requirements: Real time response is required for train control, which can react to various signals and events in a very short time to achieve precise control of train operation and meet the safety and efficiency requirements of train operation.

Strong anti-interference ability: With good electromagnetic compatibility, it can work normally in the complex electromagnetic environment on the train, without being affected by electromagnetic interference from other devices, and without causing interference to other devices.

Maintenance

Regular inspection: It is necessary to regularly inspect the UT150-1 control board, including visual inspection, connection component inspection, circuit board status inspection, etc., to discover possible physical damage, looseness, corrosion and other issues.

Cleaning and dust removal: Keep the control board clean, regularly remove dust and debris, and prevent dust accumulation from affecting heat dissipation and circuit performance.

Software updates and upgrades: With the development of technology and changes in train operation requirements, it is necessary to timely update and upgrade the software of the control board to fix vulnerabilities, optimize performance, add new features, etc.

Basic configuration preparation

Clarify application scenarios and requirements

Determine the protected objects: lines, transformers, motors, etc. Different objects require corresponding protection functions to be enabled (such as motors requiring startup monitoring and thermal overload protection).

System grounding method: neutral point directly grounded, grounded through arc suppression coil, or ungrounded system, affecting the configuration of grounding fault protection (such as high resistance grounding requiring REF1A function to be enabled).

Short circuit current calculation: Calculate the maximum/minimum short-circuit current based on the system impedance, which is used to set the overcurrent protection threshold.

Hardware configuration verification

Confirm model and version: Check if the hardware version (Basic/Medium/High/Sensor) matches the requirements, such as the need to configure an additional adapter for IEC 61850 communication.

I/O interface allocation: Reasonably plan digital inputs (DI) for status acquisition (such as circuit breaker position), digital outputs (DO) for tripping/alarm, and reserve backup interfaces.

Power compatibility: Ensure that the power supply voltage (DC 18-265V/AC 85-240V) is consistent with the site to avoid misoperation caused by undervoltage.

Key points for setting protection functions

Current protection parameter setting

Overcurrent protection (3I>):

Action current: Set according to the normal load current, usually 1.2-1.5 times the rated current.

Time characteristics: Choose definite time (DT) or inverse time (IDMT) according to system selectivity requirements, and the inverse time curve can be selected according to IEC or ANSI standards.

Differential protection (if any):

Balance coefficient: automatically calculated based on transformer ratio and wiring group to ensure zero differential current during normal operation.

Braking coefficient: usually set to 0.3-0.5 to prevent misoperation in case of faults outside the area.

Voltage and frequency protection

Overvoltage/undervoltage protection (3U>, 3U<<):

Action value: Overvoltage is generally 1.1-1.3 times the rated voltage, and undervoltage is 0.7-0.9 times the rated voltage.

Delay: Set according to the allowed voltage fluctuation time of the system, such as the need for motor restart.

Frequency protection (f1/f2):

Action value: Under frequency is generally 47-49Hz, over frequency is 51-52Hz.

Special function: Enable df/dt change rate detection to suppress system oscillation triggering errors.

Earth fault protection

Neutral point grounding method:

Direct grounding system: adopting zero sequence current protection (Io>), the operating current is set to avoid the maximum unbalanced current.

Non directly grounded system: adopting zero sequence voltage protection (Uo>) or directional zero sequence current protection (67N).

High resistance grounding fault: Enable REF1A function to detect high resistance grounding by comparing the sum of neutral point current and three-phase current.

Special function configuration

Automatic reclosing (O ->I):

Overlap frequency: generally 1-3 times, permanent faults require locking of overlap.

Dead time: adjustable from 0.2-300s seconds, which should be greater than the detachment time of the fault point (usually 0.5-1 seconds).

Circuit Breaker Failure Protection (CBFP):

Starting condition: After the tripping command is issued, there is no feedback change in the position of the circuit breaker.

Action delay: 100-1000ms, which should be greater than the inherent opening time of the circuit breaker.

Communication and System Integration

Protocol selection and parameter configuration

Communication protocol:

Traditional system: Choose Modbus RTU/ASCII or DNP 3.0, configure baud rate (9600-115200bps), parity check.

IEC 61850 system: Define GOOSE dataset (such as trip commands, alarm information) and SMV subscription relationship through SPA-ZC 400 adapter configuration.

IP address management:

Manually assign static IP addresses to ensure no conflicts with other devices in the network.

The subnet mask and gateway settings must be consistent with the upper computer, and support ping testing to verify connectivity.

Time synchronization configuration

IEEE 1588 v2：

Mode selection: PTP transparent clock or boundary clock, with the main clock priority (Priority 1/2) set to high.

Synchronization accuracy: Ensure ≤± 1 µ s to meet the requirements of distributed protection collaboration.

NTP synchronization: As a backup solution, configure the NTP server address with a synchronization period of 1-60s.

Data Mapping and Monitoring Point Configuration

Telemetry data: Map measured values such as current, voltage, and power to corresponding data points, and set an update cycle (such as 1 second).

Remote signaling data: configure status variables such as circuit breaker position and protection action signals, and define SOE resolution (≥ 1ms).

Remote control point: Set circuit breaker opening and closing control permissions, password verification is required to prevent misoperation.

Engineering implementation and verification

Parameter import and backup

Configuration file management:

Use ABB’s CAP 505 tool to import pre configured files to avoid manual input errors.

Back up the current configuration (in. prf format) and restore it to its initial state before upgrading firmware or modifying parameters.

Version control: Record the configuration version and modification time, and establish a change approval process.

Functional testing and validation

Static testing:

Simulate overcurrent/overvoltage signals to verify the accuracy of protection action values and delay (error ≤± 5%).

Test GOOSE communication and check the transmission time of trip command (≤ 3ms).

Dynamic testing:

Circuit breaker opening and closing test, record action time and synchronicity.

During system debugging, verify the selective coordination with adjacent devices (such as the timing of upper and lower level protection actions).

Safety precautions

Prevent accidental tripping:

Enable ‘Test Bit’ during debugging to avoid actual tripping.

Before disconnecting the trip circuit, confirm that the protective outlet pressure plate has exited.

Anti interference measures:

Communication cables and high-voltage cables are laid separately, using shielded cables and reliably grounded.

Set hardware filtering parameters (such as RC filter time constant) to suppress high-frequency interference.

​Operation and maintenance

Daily monitoring and inspection

Status monitoring: View operating parameters through HMI or SCADA system, with a focus on:

Circuit breaker wear counter (CB wear 1), reminds maintenance when the threshold is exceeded.

Trip circuit supervision (TCS1) status, promptly troubleshoot in case of abnormalities.

Alarm handling: Set different priority alarms (such as red for emergency tripping and yellow for warning) and establish a response process.

Regular maintenance and upgrades

Firmware upgrade: Upgrade online through CAP 505 tool, backup configuration and confirm compatibility before upgrading.

Hardware inspection: Check the internal module connections, battery level (if equipped), and clean the heat dissipation holes every 1-2 years.

Fault handling

Wave recording analysis: Retrieve fault wave recording data (MEDREC16), analyze fault types, phases, and development processes.

Communication diagnosis: locate communication faults through built-in counters (such as Modbus communication error counting).

summarize

The configuration of REX 521 needs to follow the entire process of “requirement analysis → parameter tuning → communication integration → testing and verification → operation and maintenance optimization”, with a focus on matching protection functions with system characteristics, compatibility of communication protocols, and implementation of security measures. Through rigorous configuration and verification, the reliable operation of relays in the power system can be ensured, effectively protecting equipment and personnel safety.

Product positioning and hardware configuration

REX 521 is a multifunctional protective relay that supports multiple hardware versions (Basic/Medium/High/Sensor) and standard configurations (such as B01/B02/M01/H01, etc.), suitable for different voltage levels and protection requirements.

Hardware differences:

Basic: Basic type, supports basic overcurrent and ground fault protection, with fewer digital inputs/outputs.

Medium: Enhanced, extended digital input/output, supports directional protection and automatic reclosing.

High/Sensor: A high-end model that integrates advanced functions such as sensor interfaces, voltage/frequency protection, and motor start monitoring.

Key components:

Built in current/voltage transformer interface, supporting 1A/5A current and 100V voltage input.

Provide digital input/output, communication ports (RS-232/RS-485), and optional fiber optic modules, supporting protocols such as Modbus and DNP 3.0.

Core functions and protective features

1. Protection function

Overcurrent protection:

Supports three-phase overcurrent (3I>, 3I>>, 3I>>>) and ground fault (Io>, Io>>, Io>>>), including directional (67N) and non directional configurations, supporting definite time (DT) and inverse time (IDMT) characteristics.

Built in harmonic suppression and excitation inrush current detection (3I2f>) to avoid misoperation.

Voltage and frequency protection:

Overvoltage/undervoltage protection (3U>, 3U<<), residual voltage protection (Uo>), frequency anomaly protection (f1/f2), supporting voltage imbalance and phase sequence protection (U1U2<>_1).

Motor and transformer protection:

Motor start-up monitoring (Is2t n<), thermal overload protection (3Ithdev>), phase sequence reversal protection (3I()), fuse fault detection (FUSEF).

Automatic reclosing (O ->I):

Supports up to 5 reclosures, can be triggered by protection start or trip signals, and has dead time and discrimination time settings.

2. Measurement and monitoring

Electrical quantity measurement:

Real time measurement of three-phase current/voltage, power, frequency, and energy, supporting true RMS and fundamental wave analysis.

The disturbance recorder (DREC) can capture fault waveforms and supports manual or triggered recording.

Status monitoring:

Circuit breaker wear monitoring (CB wear1), trip circuit supervision (TCS1), power input supervision (MCS 3I/3U).

Power quality monitoring (PQ 3Inf/PQ 3Unf), supporting harmonic analysis and THD/TDD calculations.

3. Communication and Control

Protocol support:

Standard SPA, Modbus RTU/ASCII, DNP 3.0, optional IEC 61850 adapter (requires expansion module).

​Remote control:

Support local/remote switching (I<->O POS), circuit breaker opening and closing control (I<->O CB1), and integrated interlocking logic.

3、 Standard configuration and application scenarios

1. Basic Configuration (Basic: B01/B02)

Function: Non directional overcurrent/ground fault protection, thermal overload protection, B02 supports automatic reclosing.

Application: Single busbar system for outgoing or incoming line protection, suitable for resistance grounding or solid grounded networks.

2. Intermediate configuration (Medium: M01/M02)

Function: Add directional grounding fault protection (67N), phase sequence protection, M02 supports reclosing and angle control (BACTRL).

Application: Compensate for grounding or isolated networks, requiring selective protection for outgoing scenarios.

RET 541/543/545 Transformer Terminal is a multifunctional protection and control device launched by ABB, mainly used for the protection, control, measurement, and monitoring of double winding power transformers and generator transformer units. Its working principle is based on four core links: data acquisition, logic processing, communication interaction, and execution control, combined with the characteristics of the power system to achieve precise protection and automation management. The following is a detailed analysis of the working principle:

Data acquisition and signal processing

Analog quantity acquisition

Real time collection of electrical quantities such as three-phase current (I ₁, I ₂, I ∝), neutral current (I ₀), phase voltage (U ₁, U ₂, U ∝), and zero sequence voltage (U ₀) through built-in current/voltage transformers (CT/PT) or external sensors.

The analog signal is converted into a digital quantity by an analog-to-digital converter (ADC) with an accuracy of ± 1%. It supports fundamental and harmonic analysis (such as 2nd harmonic braking to prevent excitation inrush current misoperation).

Digital quantity and status acquisition

Connect the position signals (DI) of circuit breakers, isolating switches, tap changers, as well as status signals such as gas pressure and spring energy storage.

Monitor the number of switch actions through a pulse counter, and collect non electrical quantities such as oil temperature and winding temperature through an RTD module (optional).

Protection logic processing

Real time analysis of collected data based on predefined protection algorithms and user configurations, triggering corresponding protection actions:

Current differential protection (87T)

Compare the current vectors on both sides of the transformer and distinguish internal and external faults through ratio braking characteristics.

Built in 2nd harmonic blocking and waveform recognition technology to avoid false tripping caused by CT saturation or excitation inrush current.

Overcurrent and ground fault protection

Three stage overcurrent protection: low setting value (NOC3Low), high setting value (NOC3High), transient period (NOC3Inst), supporting definite time (DT) and inverse time (IDMT) characteristics.

Zero sequence current protection (NEF1): detects grounding faults, supports high impedance principle (REF1A) and stable numerical principle (REF4A), and is compatible with different grounding systems.

Abnormal working condition protection

Overvoltage/undervoltage protection (OV3/UV3): Monitor the deviation of three-phase voltage from the rated value, trigger an alarm or trip.

Negative sequence current protection (NPS3): detects unbalanced loads or phase failure faults to prevent motor overheating.

Overexcitation protection (OE1): Monitor transformer core saturation through U/f ratio to avoid insulation damage.

Control and automation functions

Switchgear control

Control the opening and closing of the circuit breaker through the power output contact (PO), supporting local button operation or remote communication commands.

Tap changer automatic adjustment (COLTC): automatically adjusts the tap position according to voltage deviation, supports Master Follower mode (parallel transformer cooperative control), negative reactance principle or minimum circulating current control.

Interlocking and Logic Control

Implement interval interlocking through Boolean logic function blocks (such as AND/OR/timer) to prevent misoperation (such as the operation sequence of circuit breakers and isolating switches).

Support dynamic display of switch status, measured values, and alarm information on MIMIC interface, which can be interacted through HMI or remote SCADA system.

Status monitoring and maintenance

Circuit breaker status monitoring: Record the number of actions, travel time, degree of electrical wear (CMBWEAR1/2), and provide predictive maintenance reminders.

Trip Circuit Supervision (TCS): detects the integrity of the trip circuit through constant current injection to avoid the risk of refusal to operate.

Communication and System Integration

Multi protocol communication stack

Serial interface: Supports SPA, LON, Modbus RTU/ASCII, DNP 3.0, and is compatible with traditional SCADA systems.

IEC 61850 Integration: Connected to the IEC 61850 network through SPA-ZC 400 adapter, supporting GOOSE fast message (transmission delay<3ms) and SMV sampling value sharing, achieving substation level automation.

Data Interaction and Remote Management

Communicate with the station control layer through MMS protocol, upload measurement values, event records (SOE), and fault waveform data (MEDREC16).

Support IEEE 1588 v2 time synchronization to ensure data timestamp accuracy of ≤ 1 µ s across the entire network, meeting the requirements of distributed protection collaboration.

Workflow and Typical Scenarios

Normal operating mode

Continuously collect electrical quantities and status signals, display data in real-time through HMI or communication interface, and report measurement values to SCADA at set intervals (such as 1 second).

The tap changer automatically adjusts according to the voltage setting value to maintain stable secondary voltage.

Fault response mode

When an internal fault is detected (such as differential current exceeding the set value), immediately trigger a trip command (≤ 45ms) and send a fault signal to adjacent devices through GOOSE.

Record the fault waveform (MEDREC16), including data from multiple cycles before and after the fault, for fault analysis.

Maintenance and Configuration Mode

Download protection settings remotely through CAP 505 tool, modify logic function blocks, or adjust parameters locally through HMI.

Utilize self diagnostic functions to detect hardware faults (such as RAM/ROM verification, power supply abnormalities), and alert maintenance personnel through LED indicator lights and alarm outputs.

​Core technological advantages

Flexibility and Scalability: Adapt to different voltage levels and protection requirements through functional block programming (IEC 61131-3) and modular hardware (such as RTD modules).

Reliability: Industrial grade design (IP54 protection, -10 ° C~55 ° C operating temperature), EMC and vibration testing, suitable for harsh environments.

Standardization and interoperability: Supports IEC 61850 and multiple industrial protocols, compatible with third-party devices, and reduces system integration costs.

RET 541/543/545 achieves intelligent protection and control of power transformers through the above principles. Its core value lies in accurate fault identification, fast control response, and full lifecycle state management, making it a key component of modern intelligent substations.

Product positioning and functional overview

RET 541/543/545 is a multifunctional terminal designed specifically for dual winding transformers and generator transformer units in distribution networks, supporting harsh industrial, marine, and offshore applications. The core functions include:

Protection functions: three-phase current differential protection, overcurrent protection, ground fault protection, overvoltage/undervoltage protection, overheating protection, etc.

Control functions: local/remote switch control, interlocking logic, automatic control of tap changer (supporting multiple modes such as Master Follower).

Measurement and monitoring: three-phase current/voltage, power, frequency, energy measurement, circuit breaker status monitoring, self diagnostic function.

Communication capability: Supports protocols such as SPA, LON, IEC 60870-5-103, Modbus RTU/ASCII, DNP 3.0, etc., and can be connected to Profibus DP or IEC 61850 systems through adapters.

Core functional characteristics

Protection function

Current differential protection: with stable and instantaneous stages, supporting harmonic suppression and waveform recognition, suitable for CT saturation scenarios, supporting automatic matching of transformation ratios and vector groups.

Ground fault protection: supports high impedance principle and stable numerical principle, suitable for different grounding systems.

Backup protection: multi-stage overcurrent, negative sequence current, overexcitation, frequency anomaly protection, etc., meeting IEEE and IEC standards.

Control and Monitoring

Tap changer control: supports automatic voltage regulation of single or parallel transformers, with control modes such as Master Follower and negative impedance.

Status monitoring: monitoring of circuit breaker wear, gas pressure, and tripping circuit, supporting regular maintenance reminders.

Communication and Interface

Provide 3 serial communication ports (RS-232/RS-485), support fiber optic interface modules (RER 103/123/133), and adapt to different communication protocols and network topologies.

Support IEC 61850 standard (via SPA-ZC 400 adapter) to achieve substation automation system integration.

Hardware and Design

Model difference:

RET 541: Basic type, suitable for simple protection scenarios, with 15 digital inputs and low power output.

RET 543: Enhanced, with 25 digital inputs, supporting more power outputs and analog modules (RTD/analog modules).

RET 545: High end type, with 34 digital inputs and the highest power output, suitable for complex systems.

Hardware configuration:

Supports multiple current/voltage inputs (1A/5A, 100V, etc.), with built-in isolation transformers and analog-to-digital converters.

Optional fixed or external graphical display module (HMI), supporting multilingual interface and remote configuration.

The power module supports wide voltage input (DC 18-265V/AC 85-240V) and has undervoltage and overheating alarms.

Environmental adaptability:

Working temperature -10 ° C~+55 ° C, protection level IP54 (front side), tested for vibration, impact, and electromagnetic compatibility.

Application scenarios and engineering configurations

Typical applications:

Industrial substations, distribution networks, ship power systems, and generator transformer unit protection.

Support multiple transformer wiring methods such as Yd, Dyn, YNyn, etc., suitable for high resistance/low resistance grounding systems.

Engineering tools:

CAP 505: A graphical configuration tool based on IEC 61131-3, supporting functional block programming and MIMIC interface design.

Relay Mimic Editor: Used to configure HMI display and alarm logic.

Protocol Mapping Tool: Configure DNP 3.0 and Modbus interface parameters.

Configuration process:

Define protection logic, measurement points, and communication parameters through CAP 505.

Use IET600 or IEC 61850 Configuration tool to configure GOOSE/SMV communication (with IEC 61850 adapter RET 545).

Download the configuration to the device and verify its functionality through HMI or remote system.

Technical parameters and selection

Measurement accuracy: Current/voltage measurement error ≤ ± 1%, frequency accuracy ± 0.01Hz.

Trip time: The instantaneous action of differential protection is ≤ 45ms, and overcurrent protection can be set with timed or inverse time characteristics.

Ordering information:

The model suffix distinguishes the functional level (C=control type, B=basic type, M=multifunctional type).

Please specify the power type, number of digital I/O, communication protocol module, and display language.

Summary

The RET 541/543/545 series provides reliable automation solutions for power systems through highly integrated protection and control functions, flexible communication protocol support, and adaptability to harsh environments. Its modular design and standardized interfaces facilitate system integration and expansion, making it suitable for multi-level requirements ranging from simple power distribution to complex industrial scenarios. It is a key component of ABB’s substation automation product line.

The IEC 61850 standard is the core communication standard for intelligent substations and power system automation. Its main advantages are reflected in interoperability, layered architecture, real-time performance, reliability, engineering efficiency, and future scalability, significantly improving the intelligence level and operation efficiency of power systems. The following is a specific analysis of advantages:

Equipment interoperability and standardization

Unified Data Model and Communication Protocol

IEC 61850 adopts object-oriented modeling methods (such as logical nodes LN and data objects DO) to abstract functions such as protection, measurement, and control into standardized data models, breaking down the private protocol barriers of traditional devices. For example, protection relays and measurement devices from different manufacturers can exchange data through a unified GOOSE/SMV protocol, achieving “plug and play” functionality.

Eliminate vendor lock-in

Based on open standard communication interfaces such as MMS and TCP/IP, users can flexibly choose devices from different vendors to build systems, reducing dependence on a single supplier and improving the flexibility and cost-effectiveness of system integration.

Hierarchical distributed architecture

Clear three-tier architecture

Station control layer (SCADA system): Data monitoring and management are achieved through MMS protocol.

Interval layer (protective measurement and control device): Fast tripping command transmission is achieved through GOOSE, and sampling value sharing is achieved through SMV.

Process layer (intelligent terminal, merging unit): Based on IEEE 1588 time synchronization, real-time acquisition and execution of switch and analog quantities are achieved.

Function distribution optimization

Support distributed function configuration, such as anti misoperation locking, backup automatic switching, etc., which can be distributed across different devices at different intervals, and work together through high-speed communication to reduce the complexity of centralized systems.

High speed real-time communication capability

GOOSE Fast Message Mechanism

By adopting multicast communication and event triggering mechanism, the transmission delay can be as low as milliseconds, meeting the requirement of rapid tripping between protection devices (such as differential protection).

Support Heartbeat mechanism and ConfRev configuration version verification to ensure real-time monitoring and data consistency of communication links.

SMV sampling value transmission

Supports the IEC 61850-9-2 LE protocol to transmit current/voltage sampling values at a fixed sampling rate (such as 4000 points/second), replacing traditional cable analog transmission, reducing hardware wiring and improving accuracy.

Combining IEEE 1588 v2 time synchronization, microsecond level synchronization of sampling values across the entire network is achieved, supporting distributed protection and synchronous phasor measurement.

High reliability and redundant design

Network redundancy topology

Support HSR (High Availability Seamless Redundant Ring Network) and PRP (Parallel Redundancy Protocol), which can automatically switch when a single link or device fails, ensuring communication continuity.

The switch supports VLAN partitioning and traffic priority setting (such as GOOSE/SMV priority transmission) to avoid network congestion affecting critical services.

Fault diagnosis and self-healing

Built in communication diagnostic counters (such as GSELPRT1, MMSLPRT1), real-time monitoring of message sending and receiving status, configuration conflicts (such as IP address duplication), and time synchronization errors.

Support “Test Bit” to verify configuration changes without affecting actual operation, reducing debugging risks.

Engineering efficiency and maintenance convenience

Model driven engineering tools

Use SCL (Substation Configuration Language) to uniformly describe the system structure, equipment parameters, and communication connections, and use tools such as PCM600 and IET600 to achieve graphical configuration and batch parameter distribution, reducing manual configuration errors.

Support version management and comparison of configuration files (such as SCD file difference analysis), facilitating engineering changes and version traceability.

Remote operation and diagnosis

Based on web servers and MMS protocol, device parameters, fault recording, and real-time data can be remotely accessed through a browser, reducing on-site maintenance workload.

Support remote firmware upgrade and batch configuration synchronization to shorten the system upgrade cycle.

Support smart grid and future expansion

Facing digital transformation

Support IEC 61850-7-420 extensions (such as new energy access, energy storage system modeling) to meet the integration requirements of distributed energy (DER) and microgrids.

Compatible with the Internet of Things (IoT) and big data analysis, device data is connected to the cloud platform through standardized interfaces, supporting intelligent operation and predictive maintenance.

Protocol scalability

The modular design can flexibly expand new logic nodes (such as electric vehicle charging interface LN) and communication services to meet the future technological evolution (such as 5G, edge computing).

Reduce full lifecycle costs

Reduce hardware investment

Replace traditional secondary cables (such as trip circuits and analog circuits) with network communication to reduce cable procurement, laying, and maintenance costs.

A unified communication platform reduces the use of interface conversion devices (such as protocol converters) and simplifies system architecture.

Improve operational efficiency

Shorten fault location time through standardized fault reporting and event recording (such as SOE sequential event recording).

Support “plug and play” device replacement, new devices can automatically load configuration files, reducing power outage time.

summarize

The IEC 61850 standard solves the protocol barriers and operational challenges of traditional power systems through standardized interoperability, real-time communication, redundant architecture, and efficient engineering tools. It is the foundation of intelligent substations and power IoT. Its advantages are not only reflected in the current integration of automation systems, but also lay the foundation for the digital and intelligent upgrading of future power grids, becoming the mainstream communication standard in the global power industry.

​Overview of IEC 61850 Standard

standard framework

IEC 61850 is an international standard for substation communication and systems, which defines an object-oriented data model and communication services, supports device interoperability, and is divided into multiple parts (such as data model, communication protocol, configuration language, etc.). It supports Edition 1 and Edition 2 versions, which have differences in data model and functionality. It is recommended to unify the versions in the project.

communications architecture

Vertical communication: Based on MMS (Manufacturing Message Specification) and TCP/IP, used for communication between controllers and upper level systems such as SCADA.

Horizontal communication: GOOSE (General Object Oriented Substation Events) and SMV (Sampling Values) are used to achieve fast data exchange between devices, supporting IEEE 1588 v2 time synchronization.

Tools and Configuration Process

PCM600 tool

Used for the full lifecycle management of protective relays, supporting engineering design, configuration, debugging, and monitoring.

Adapting different models of devices through ‘Connectivity Packages’ requires communication configuration using the IEC 61850 Configuration tool.

IET600 tool

Focused on IEC 61850 system level configuration, supports importing/exporting SCD files, and achieves centralized management of communication parameters such as GOOSE and SMV.

Collaborate with PCM600 to exchange configuration data through SCL files and support third-party device integration.

configuration process

Device definition: Create a project and add devices in PCM600, export SCD files to IET600.

Communication configuration: Configure GOOSE publish/subscribe, SMV transmission parameters, IEEE 1588 time synchronization, etc. in IET600.

Function mapping: Use the Signal Matrix tool to map GOOSE/SMV data to protection function blocks, completing application logic connections.

Verification and Download: Export the configuration to PCM600, write it to the device, and verify the communication status.

Core communication function configuration

GOOSE Communication

Data Model: Based on the Data Set and GOOSE Control Block (GoCB), supporting the transmission of state and analog variables, with a response time of less than 3ms.

Configuration points:

Unique multicast address and APP ID to avoid VLAN configuration conflicts.

Define data entries and subscription relationships through PCM600’s IEC 61850 Configuration tool or IET600.

Diagnostic counters (such as FrRxCnt, RxTmOutCnt) are used to monitor communication status.

SMV (Sampling Value) Communication

Support IEC 61850-9-2 LE protocol, transmit current/voltage sampling values, with a sampling rate of 4000 points/second (50Hz system).

Time synchronization: relying on IEEE 1588 v2 PTP protocol, supporting HSR/PRP redundant topology, ensuring microsecond level synchronization accuracy.

Configuration restriction: The SMV dataset cannot be manually modified and needs to be activated through the SMVSENDER function block. The receiving end processes the data through the TVTR module.

Event Reporting

Based on the report control block (RCB) and dataset, it supports buffered and non buffered report modes.

The triggering conditions include data change, quality change, etc. The report content and target client can be defined through PCM600.

System architecture and redundancy design

network topology

HSR (High Availability Seamless Redundancy): A ring network with nodes supporting dual port redundancy, with a maximum of 30 devices, suitable for high reliability scenarios.

PRP (Parallel Redundancy Protocol): Double star network, devices are connected through LAN A/B dual ports, supporting single node redundancy box (RedBox).

IEEE 1588 v2 Time Synchronization

Following IEEE C37.238-2011 power configuration file, supporting one-step mode and transparent clock.

The priority of the master clock is set through PTP Priority 1/2, with an accuracy of ≤± 1 µ s to ensure synchronization of SMV sampling values.

performance optimization

The switch needs to support VLAN partitioning and SMV traffic filtering to avoid broadcast storms.

The maximum delay of SMV needs to be configured according to the number of network hops, with a typical value of 2-7ms, to ensure real-time protection function.

Engineering Verification and Maintenance

Verification process

Functional testing: Use the Signal Monitoring tool of PCM600 to forcibly send GOOSE signals and verify the status updates of the receiving end.

Time synchronization check: Monitor the synchronization status of IEEE 1588 (such as Sync Accuracy<4 µ s) to ensure consistent clocks across the entire network.

Redundancy testing: Simulate a main clock failure to verify the continuity of backup clock takeover and SMV transmission.

Diagnosis and Maintenance

Logs and counters: View GSELPRT1 (GOOSE diagnosis) and MMSLPRT1 (MMS diagnosis) counters through the device LCD interface or PCM600.

Firmware upgrade: Update device firmware and Connectivity Packages through PCM600’s Update Manager to ensure compatibility.

Safety precautions

Backup project files before configuration to avoid data loss caused by misoperation.

Third party devices must support IEEE 1588 v2 and Power Profile to ensure interoperability.

Terminology and Abbreviations

GOOSE: General object-oriented substation event for fast status transmission.

SMV: Sampling Value, used for transmitting analog data such as current and voltage.

HSR/PRP: High availability seamless redundancy/parallel redundancy protocol to enhance network reliability.

PTP: Precision Time Protocol (IEEE 1588), achieving nanosecond level time synchronization.

SCL/SCD/ICD/CID: IEC 61850 configuration language and file format, used for device description and system integration.

summarize

This guide comprehensively covers the IEC 61850 engineering design of ABB 620 series equipment, providing detailed process and parameter recommendations from standard principles to tool operation, from communication configuration to system verification. It is suitable for the design and implementation of automation systems in smart substations, ensuring efficient interoperability and reliable communication between equipment.

Ethernet standards and component requirements

Communication standards

Adopting 100Mbps Ethernet, supporting TCP/IP protocol, suitable for ALSTOM’s EPIC, FIC and other controllers.

Industrial standard: Switches must comply with EN 50082-2 or EN 61000-6-2 electromagnetic compatibility (EMC) standards, and HMS or Hirschman brands are recommended.

Network components

Switch: Industrial grade switches must be used, and hubs must be disabled (affecting performance).

Cable: Cat 5E FTP twisted pair cable (RJ45 interface) is recommended, with fiber optic mode supporting up to 4000 meters of transmission.

Controller interface: RJ45 10/100M adaptive port, supporting automatic speed negotiation.

Protocol and Ports

Common ports: 80 (HTTP), 502 (Modbus/TCP), 20/21 (FTP), 3250 (PC-MTU configuration).

Disable router: Do not access the router in the network, otherwise PC-MTU and master station functions may fail.

Network setup and IP configuration

software tool

PC-MTU software: used for configuring and monitoring multiple controllers, requiring the controller to have a built-in web server (accessed through a browser).

System requirements: Windows 2000/XP system, IE 6.0+browser, processor ≥ 300MHz, memory ≥ 128MB.

IP address allocation

Manual configuration (DIP switch):

The default IP is 192.168.0. X (X is set through an 8-bit DIP switch, binary to decimal, range 1-255).

Step: Turn off the controller → Set DIP switch → Restart → Configure PC IP (same network segment, such as 192.168.0.100) → Scan the network through PC-MTU.

DHCP automatic allocation: Check the DHCP option and enable DNS (controller names must be unique).

Network verification

The “IP Config” window of PC-MTU identifies controller status by color:

Red: Declared but not connected; Blue: Undeclared but online; White: Normal connection.

Support batch replication configuration: Single controller settings can be quickly synchronized to other devices.

Operation and monitoring functions

PC-MTU main interface

Real time display of controller name, number, status (voltage, pressure, current, etc.), and alarm information.

Double clicking on the controller name will redirect you to a web page for parameter configuration or firmware upgrade.

Alarm and Control

Alarm types: red (trip alarm, controller automatically shuts down), yellow (warning alarm), double-click to view detailed logs.

Remote operation: Reset the alarm and start stop controller (HV button) through interface buttons.

MENU

Advanced: IP configuration, password modification, switching working directory.

View: Save/load layout, lock interface (password required), enable alarm sound prompt.

Key basis for troubleshooting

LED status diagnosis

LED 1 (green): Always on indicates link connectivity, off indicates no connection (check cable or switch port).

LED 2 (red): The flashing frequency corresponds to different faults (such as IP conflict, MAC address error, flash configuration loading failure).

LED 4 (green): Flashing indicates normal data transmission and reception. If it does not light up, it may be a port or protocol failure.

IP address conflict handling

When duplicate IPs are detected through PC-MTU scanning, DIP switches or DHCP parameters need to be reset to ensure uniqueness.

Network component validation

Switch failure: Replace the port or switch and observe if the LED status is restored.

Router existence: Remove routers from the network to avoid interference with PC-MTU and controller communication.

Terminology and Precautions

Modbus/TCP: Industrial communication protocol used for data exchange between controllers and upper computers.

Master: Monitor controllers within a specified range (such as range 5-10, and synchronously shut down controllers within that range when the master is turned off).

Attention: After configuration is completed, save the settings to the controller flash memory and restart to take effect; Prohibit the use of hubs or routers in the network.

summarize

This manual provides a comprehensive guide for the entire process from network design, software installation to troubleshooting. The core is to achieve efficient Ethernet configuration and monitoring through the collaboration of PC-MTU software and controller web interface. Suitable for centralized management of multiple controllers in industrial automation scenarios, especially for communication integration of devices such as electrostatic precipitators (ESP) and filtration systems, emphasizing the value of IP uniqueness, industrial grade component selection, and LED status fault location.