ABB has launched a remote I/O module upgrade kit for the Symphony Harmony/INFI 90 process control system, which includes a new low-cost IMRIO22 module aimed at providing continuous lifecycle support for the system and addressing various issues with existing systems.
Solve the problem
Components are outdated and new parts are no longer available.
The cost of replacing parts is high.
The ability to repair parts has decreased.
The electrical remote communication chain is affected by noise and lightning strikes.
Difficult to troubleshoot remote I/O issues.
Slow link speed and time-consuming I/O point updates.
Controller configuration requires the use of multiple segment control blocks for special “adjustments”.
IMRIO02 has firmware compatibility issues with some I/O modules.
Be extra cautious when replacing system components.
Advantages of the plan
Reliability improvement: Updated technology has been adopted to enhance fiber optic communication.
Spare parts availability: Provide new replacement parts.
Easy to replace: Compatible with existing remote I/O settings, with the same rack size, can use existing fiber optic cables, IMRIO22 replaces IMRIO02 in remote cabinets.
Reduce cabinet space occupation: IMRIO02 in the local cabinet is no longer needed, and its functions are integrated into BRC300/400, replacing the existing MFP or MFC controllers in the local cabinet with BRC.
Control performance improvement: increased memory capacity, faster execution and communication speed.
Improved communication link and remote I/O update speed.
Hardware/firmware compatibility improvement: better compatibility between remote I/O processors and remote I/O modules.
Easy firmware upgrade: The IMRIO22 module has flash memory.
Redundancy enhancement: Faster fault detection/switching speed from primary IMRIO22 to backup IMRIO22.
Error checking and diagnostic improvement: facilitates troubleshooting.
Redundant HNET remote communication channel.
Minimum System Requirements
The BRC300/400 controller requires a Process Bus Adapter (PBA), which needs to be added if it is not present.
Composer engineering tool version 5.0 or higher.
Fiber optic cable (62.5/125 micron multimode) for remote links.
Restrictive conditions
Only supports fiber optic point-to-point communication links.
The electrical link (dual axis or coaxial cable) must be replaced with optical fiber.
Serial or Daisy Chain multi-point links are not supported, and multi-point connections for multiple remote cabinets (up to 6) now require a star configuration from the local cabinet.
HNET’s process bus adapter cable: 2, 2 PMKHRMPBA1T004
HNET Bus Terminators: 4, 4 PHAMSCTER30000
Redundant cables for bridge controller: 0, 1 PMKHRMBRC3000A
Note: The multi-point remote I/O architecture will require inter column connection cables to daisy chain additional terminal units in the local cabinet.
System/application compatibility
The remote I/O function is compatible with all other existing functions of the Harmony BRC300/400 or higher version controller, including but not limited to:
Supports multiple remote I/O links.
Supports mixed I/O types, such as IOR/S800, Harmony rack I/O, and Harmony module I/O.
Existing fiber optic remote link cables can be reused.
ABB REM610C55HCNN02 belongs to the REM610 series motor protection relay, which is widely used in the industrial field. It is specially designed for the protection of medium and large asynchronous motors, which can effectively ensure the safe and stable operation of motors. It can also be used for the protection of equipment such as feeding cables and power transformers
Core functions
Protection function
Thermal overload protection: detects short-term and long-term overload, calculates thermal stress based on the square value of the motor’s thermal capacity and load current, and can set parameters such as safe stalling time, weighting coefficient, time constant multiplier, etc.
Start monitoring: It can be based on thermal stress calculation or timed overcurrent protection to prevent damage to the motor during the starting process due to overload or short circuit faults.
Short circuit protection: detects overcurrent caused by phase to phase, winding to winding, and phase to ground short circuits, with instantaneous or timed characteristics.
Undercurrent protection: detects faults such as load loss, suitable for applications where undercurrent is considered a fault.
Ground fault protection: detects phase to ground current, has timing characteristics, and can be set to instantaneous action.
Unbalance protection: Based on negative sequence current detection of phase imbalance, it prevents rotor overheating.
Phase sequence protection: detects motor reverse rotation caused by phase sequence errors.
Accumulated startup time counter: prevents motor overheating caused by too frequent startup attempts.
Circuit breaker fault protection: detects the situation where the circuit breaker should have acted but did not.
Temperature protection (optional): Detect the temperature of motor bearings and windings through RTD sensors or thermistors.
Measurement function: It can measure various parameters such as phase current, zero sequence current, negative sequence current, thermal level, start-up time, cumulative start-up time, restart suppression time, motor running time, etc.
Control function: Supports local and remote control of switchgear, including opening and closing operations of circuit breakers and isolating switches, with interlocking function to prevent misoperation.\
Data recording and event recording
Disturbance recorder: It can record data from 4 analog channels and up to 8 user selectable digital channels. The sampling frequency varies according to the rated frequency, the recording length can be adjusted, and there are various triggering methods.
Event recording: Up to 100 event codes and timestamps can be recorded, including events such as startup and tripping during the protection phase.
Communication function: Equipped with front optical communication port (infrared) and optional rear communication module, supporting communication protocols such as SPA bus, IEC 60870-5-103, Modbus (RTU and ASCII), etc.
Technical Parameter
Power supply: Supports multiple AC and DC auxiliary voltages, with different power consumption in static and operating states, and a maximum ripple of 12% of the DC value.
Input
Current input: rated frequency 50/60Hz, rated current 1A or 5A, with certain thermal and dynamic current tolerance capabilities.
Digital input: Supports multiple voltage levels, activation threshold and operating range vary depending on the model, with low current and power consumption.
Output
Signal output: Rated voltage 250V AC/DC, with certain continuous carrying capacity, short-term carrying capacity, and breaking capacity.
Power output: Parameters are similar to signal output and are suitable for controlling devices such as circuit breakers.
Environmental conditions: The recommended continuous operating temperature range is -10…+55 ° C, the extreme temperature range (short-term) is -40…+70 ° C, the storage and transportation temperature range is -40…+85 ° C, and the humidity is less than 95% RH.
Electromagnetic compatibility: Passed multiple electromagnetic compatibility tests, including 1MHz pulse interference, electrostatic discharge, radio frequency interference, etc.
Configuration and parameter settings
Setting group: Provides two optional setting groups that can be switched through HMI or serial communication, including parameters such as safety stall time, weighting coefficient, startup values and operation time for various protection stages.
Switch group: including SGF, SGB, SGR, SGL and other switch groups, used to configure the functions of relays, digital inputs, signal routing of output contacts, and LED indications.
Parameterization: External parameterization can be performed through HMI or using Relay Setting Tool, with set values within a specified range and some parameters requiring password protection.
Installation steps
1、 Preparation before installation
Environmental inspection: Ensure that the installation location meets environmental requirements, with a working temperature range of -10…+55 ° C, relative humidity<95% (no condensation), and avoid harsh environments such as severe vibration, dust, corrosive gases, etc.
Preparation of Tools and Materials: Prepare suitable tools such as screwdrivers, wire strippers, and crimping tools, as well as wires that meet specifications (selected according to terminal requirements, such as terminal X2.1 for 0.5… 6.0mm ² wires, X3.1 and X4.1 for 0.2… 2.5mm ² wires), wiring terminals, and other materials.
Equipment inspection: Open the box and check if the appearance of the relay is intact, verify if the model (REM610C55HCNN02) and accessories are complete, including installation brackets, instructions, etc.
2、 Mechanical installation
Choose installation method: Select the installation method according to actual needs, supporting semi embedded installation, wall mounted installation, 19 “rack installation, etc. Corresponding installation kits can be used (such as semi embedded installation kit 1MRS050696, 19” rack installation kit 1MRS050695, etc.).
Fixed equipment:
If it is a rack installation, place the relay smoothly into the corresponding position of the 19 “rack, fix it on the rack with screws, and ensure that the installation is firm and not loose.
If it is wall mounted or embedded installation, use expansion screws or fixing screws to fix the installation bracket to the wall or cabinet according to the size of the installation hole, and then fix the relay to the bracket.
3、Electrical connection
（1） Power connection
Find the power terminal at the back of the relay (X4.1-1 is “+”, X4.1-2 is “-“).
According to the rated auxiliary voltage indicated on the relay (this model is 100-240V AC/110-250V DC), connect the corresponding power supply wires to ensure correct positive and negative polarity.
The stripping length of the wire is moderate (about 5-8mm), and after inserting the terminal, tighten the screw to ensure good contact without looseness or virtual connection.
（2） Current input connection
Phase current connection: Connect the secondary side of the current transformer (CT) to the phase current input terminal. The specific terminal definitions are as follows:
X2.1-1/2: Connect L1 phase current
X2.1-3/4: Connect L2 phase current
X2.1-5/6: Connect L3 phase current
Grounding fault current connection: According to the CT type (which has a grounding fault current input of 5A), connect the grounding fault current circuit to terminals X2.1-7/8.
Ensure correct polarity of CT wiring to avoid phase errors affecting protection function.
（3） Digital input connection
The digital input terminals are located at X4.1 and X3.1 (when RTD module is optional), as follows:
X4.1-23/24: Connect DI1
X4.1-21/22: Connect DI2
If equipped with RTD modules, X3.1-1/2, X3.1-3/4, and X3.1-5/6 are respectively connected to DI3, DI4, and DI5
According to the rated voltage of the digital input (this model is 110/125/220/250V DC), connect the external control signal wire, pay attention to wire insulation, and avoid short circuits.
（4） Output contact connection
Power output (PO) and signal output (SO):
PO1（X4.1-16）、PO2（X4.1-14）、PO3（X4.1-12/13） For power output, used to control devices such as circuit breakers, connected to external circuits according to control requirements.
SO1（X4.1-9/10/11）、SO2（X4.1-6/7/8） For signal output, used for alarm or status indication, connected to indicator lights, alarms, etc.
IRF contacts: X4.1-3 (common terminal), X4.1-4 (closed when faulty), X4.1-5 (closed when normal), connected to the fault alarm circuit.
TU810V1 is a 16 channel 50V compact module terminal unit (MTU) designed by ABB for the S800 I/O series. It is a passive device mainly used to connect field wiring to I/O modules, and also includes some Module Bus components. Its function includes allocating Modulus Bus to the I/O module and the next MTU, and generating the correct address for the I/O module by shifting the output position signal to the next MTU.
Core Features and Advantages
Adopting a single wire connection to achieve compact installation of I/O modules.
Supports up to 16 on-site signals and process power connections.
Can be connected to Modulus Bus and I/O modules.
Equipped with mechanical key control devices to prevent incorrect insertion of I/O modules.
Equipped with DIN rail locking device for grounding, supporting DIN rail installation.
Basic parameters
Product Code: 3BSE013230R1
Type: Compact
Connection method: Terminal block
Number of channels: 16
Voltage: 50V
Installation direction: Both directions are available
Installation temperature: Horizontal installation at 55 ° C (131 ° F), vertical installation at 40 ° C (104 ° F)
Compatible with I/O modules: AI810, AI815 and other models (such as AI, AO, DI, DO, DP series related modules)
Process connection: 2 × 2 process power supply, 5 × 2 process power supply (0V)
I/O redundancy type: single redundancy
Environment and Certification
Compliant with CE mark, electrical safety follows standards such as EN 61010-1, UL 61010-1, etc.
Dangerous Place Certification: C1 Div 2 cULus, C1 Zone 2 cULus, ATEX Zone 2.
Ship certification: ABS, BV, DNV-GL, LR.
Working temperature: 0 to+55 ° C (+32 to+131 ° F), certified temperature range:+5 to+55 ° C; Storage temperature: -40 to+70 ° C (-40 to+158 ° F).
Compliant with RoHS (EN 50581:2012) and WEEE (Directive/2012/19/EU) standards.
Size and weight
Width: 64mm (2.52 inches) including connector, 58.5mm (2.3 inches) from edge to edge after installation.
Depth: 64mm (2.52 inches) including terminals.
Height: 170mm (6.7 inches) including lock buckle.
Weight: 0.17kg (0.37 pounds).
Application area
Industrial Automation: Used for industrial production lines, automation equipment, etc., it is an important component of industrial automation systems that can achieve automated control of industrial processes, such as CNC machinery, electronic manufacturing, automotive manufacturing, and other industries.
Process control: Suitable for process control in industries such as chemical, metallurgical, food, petroleum and natural gas, it can control various parameters such as temperature, pressure, flow rate in industrial processes, and achieve precise measurement and control of process variables.
Discrete control: can be applied to discrete manufacturing industries, such as mechanical manufacturing, plastic machinery, etc., to control and manage discrete production processes.
Motion Control and Robotics: Plays a role in robot control, controlling the motion and operation of robots; It is also applicable to motion control scenarios, providing control support for related devices.
Electricity and Energy: Used in energy related fields such as electricity, water conservancy, water treatment/environmental protection, for data collection, equipment control, and system monitoring to ensure the stable operation of the energy system.
Other fields: It can also be used in industries such as building materials, paper printing, textile printing and dyeing, tobacco, as well as HVAC control and lighting control in building automation; It is also applicable to distributed control systems and SCADA systems, achieving centralized control of multiple devices and monitoring and management of processes.
REF 541, REF 543, and REF 545 feeder terminals are equipment developed by ABB for the protection, control, measurement, and monitoring of medium voltage power grids, and are part of ABB’s substation automation system. They can adapt to different types of switchgear (such as single bus, double bus, and duplex systems) as well as multiple network types (such as neutral insulation networks, resonant grounding networks, and partial grounding networks), and can also be applied to the protection and control of medium-sized three-phase asynchronous motors and parallel capacitor banks for reactive power compensation. The main difference between these three devices lies in the number of digital inputs and outputs.
Core functions
Protection function
It includes multiple types of protection, such as non directional and directional overcurrent and ground fault protection, residual voltage protection, overvoltage and undervoltage protection, thermal overload protection, circuit breaker fault protection, and automatic reclosing.
The protection function based on current measurement can use Roche coils or traditional current transformers, while the protection function based on voltage measurement can use voltage dividers or voltage transformers.
control function
Support local and remote control of switchgear, status indication of switchgear, and interlocking at interval and station levels.
Measurement function
Capable of measuring phase current, phase to phase and relative ground voltage, residual current and voltage, frequency, power factor, active and reactive power, and electrical energy.
The standard configuration includes pulse counter inputs, with varying quantities depending on the model (7 for REF 541 and 10 for REF 545).
Status monitoring function
Including circuit breaker status monitoring, trip circuit monitoring, and internal self-monitoring of feeder terminals.
Other functions
Such as synchronous inspection, frequency protection, capacitor bank protection and control, current and voltage harmonic measurement, etc.
Equipped with RTD/analog modules for temperature measurement, current/voltage measurement, and mA output.
Data recording and communication
Transient disturbance recorder: capable of recording 16 current or voltage waveforms and 16 logical digital signals, with a sampling frequency of 2kHz at rated frequency 50Hz and 2.4kHz at 60Hz. The recording can be uploaded and converted to COMTRADE format.
Communication: Provides two communication interfaces, one for local communication with PC and the other for remote communication through substation communication system, supporting SPA and LON serial communication protocols.
Software and hardware configuration
Hardware
Analog channels: Depending on whether sensors are included, there are 9 (no sensors) or 10 (with sensors) analog channels, as well as virtual channels for calculating neutral current and residual voltage.
Digital input: voltage controlled and optically isolated, partially programmable as a pulse counter, with a pulse counting frequency of up to 100Hz, and two global parameters for suppressing digital input oscillations.
Digital output: divided into high-speed power output (HSPO), power output (PO), and signal output (SO).
Display panel: equipped with a fixed display screen or external display module, the display panel includes multiple buttons and indicator lights for operating and indicating device status.
Software
It can be configured through the CAP 505 relay product engineering tool, including basic terminals, protection and logic function blocks, control and measurement functions, etc.
Support the use of relay configuration tools to program PLC functions (such as interlocking and alarm logic), using functional block diagram language.
Technical Parameter
Environmental conditions: The specified working temperature range is -10…+55 ° C, the transportation and storage temperature range is -40…+70 ° C, the front protection level of the shell is IP 54, and the back connection terminal is IP 20.
Power supply: There are two basic versions of power modules, PS1 and PS2, and the input voltage and operating range vary depending on the model.
Input and output parameters: including voltage, current range, and accuracy of digital input and output, analog input and output, etc..
Application scenarios
Suitable for various application scenarios of medium voltage power grids, such as different types of switchgear and networks, as well as protection, control, and monitoring of medium-sized three-phase asynchronous motors, parallel capacitor banks, etc. Specific application examples include utility incoming lines, feeders, measuring cabinets, ring/mesh network cable feeders, etc.
Major function
Protection function: With multiple types of protection, it can comprehensively ensure the safety of the power system. In terms of current protection, overcurrent directional protection has 8 thresholds with freely programmable tripping characteristics, ground fault directional protection has 2 thresholds, and ground fault directional fan-shaped protection has 10 thresholds, which can accurately detect and respond to abnormal current situations. Voltage protection can monitor and protect the system voltage, preventing damage to equipment caused by overvoltage or undervoltage. It also covers differential protection, power direction protection, distance protection, etc., which can be used to protect multiple system components and provide reliable protection solutions for different types of faults. In addition, functions such as automatic reclosing, frequency monitoring, synchronization detection, and fault recording have further enhanced the stability and reliability of the system.
Control function: Supports multiple operating state switches, including running, testing, setting state switches, as well as local and remote state switches, making it convenient for operators to flexibly control equipment according to actual needs. Equipped with closing, opening and emergency opening functions, ensuring effective control of the equipment in different situations. Various interlocking functions are set up in the software, and the interlocking functions implemented through software settings can effectively prevent misoperation and ensure the safety of equipment and personnel.
Measurement function: It can accurately measure various electrical parameters, including three-phase current, zero sequence current, maximum demand for three-phase current, three-phase/line voltage, zero sequence voltage, active/reactive power, active/reactive electricity degree, power factor, frequency, etc. The measured values can be displayed on the LCD screen as numbers and LED bar charts, visually presenting the system’s operating status and providing accurate data reference for operators.
Communication function: Supports multiple communication protocols such as RS485, Modbus, IEC 61850, DNP3.0, etc., and can exchange data with different devices and systems. Adopting fiber optic connection, it has the characteristics of simple wiring, strong anti-interference ability, and high reliability, which can achieve real-time information processing and perfect system management, facilitate networking, and meet communication needs in different scenarios.
Monitoring and diagnostic functions: capable of effectively monitoring primary equipment, such as monitoring spring charging time (when applicable) and trip coils, to promptly identify potential equipment issues. Equipped with a self diagnostic program that can continuously check the status of hardware and software modules. The binary input and output module is equipped with watchdog contacts, which are triggered in the event of a fault or power outage. The analog input channel can be selected for monitoring, detecting disconnection from the instrument transformer or sensor connection, and triggering an alarm.
Power quality function: It can monitor and analyze the power quality of the power system, provide data support for optimizing power quality, and ensure that the power system provides high-quality power for various equipment.
PLC function: Standardize the wiring of switchgear, simplify production management, reduce the types of spare parts, and facilitate on-site management and operation maintenance. Through flexible software development, engineering design can be simplified, design cycles can be shortened, on-site debugging efficiency can be improved, and it is easy to change the function of the switchgear or adapt to different load properties in the future.
The ABB UNITOL 1000 series is a compact, high-performance automatic voltage regulator (AVR), consisting of three models: UNITOL 1005, 1010, and 1020, designed specifically for low-power range applications, setting a new benchmark in the industry with functionality, reliability, and connectivity. This series adopts separate communication and control processors, equipped with non-volatile flash storage for event and data logs, supports Ethernet time synchronization and event timestamps, and is suitable for various industrial scenarios.
Product model and core parameters
UNITROL 1005:5A continuous, 10A peak, for low-end excitation applications, shares software source code and simulation model with 1010/1020, supports USB, Ethernet, no HMI, analog I/O is 2 inputs, digital I/O is 8 inputs+4 outputs
UNITROL 1010:10A continuous, 20A peak, compact device with limited functionality, same mechanical size and interface as 1020, supports Ethernet RS485（Modbus RTU/VDC）、USB， Analog I/O consists of 3 inputs and 2 outputs, while digital I/O consists of 4 inputs and 8 inputs/outputs
UNITROL 1020:20A continuous, 38A peak, high performance, with a local human-machine interface, comprehensive functions, interface identical to 1010, I/O configuration identical to 1010, and an intuitive local control panel added
Main functions and features
Control mode: Supports automatic voltage regulator (AVR), excitation current regulator (FCR), power factor regulator (PF), reactive power regulator (VAR), etc., and can achieve disturbance free switching between various modes.
Limiter and protection: including excitation current limiter (minimum/maximum), PQ minimum limiter, motor current limiter, V/Hz limiter, motor voltage limiter, etc., to ensure the safe and stable operation of synchronous motors; It has functions such as soft start, voltage matching, and rotating diode monitoring.
Software Function Package: Provides four versions: ECO, LIGHT, BASIC, and FULL, ranging from basic functions to advanced features such as synchronization, event recording, data recording, and real-time clock. The FULL version can also add a Power System Stabilizer (PSS) option, which complies with the IEEE 421.5-2005 standard.
Communication capability: Supports protocols such as Modbus RTU, Modbus TCP, CAN, etc., equipped with Ethernet and USB ports for easy connection to debugging tools and remote access.
Environmental adaptability: Designed for wide temperature environments and harsh industrial conditions, it can be directly installed on machines and has high EMC immunity.
Debugging and maintenance tools
CMT 1000 is a debugging and maintenance tool for this series, which connects devices via USB or Ethernet. Its functions include:
Set parameters and adjust PID to ensure stable operation;
Comprehensive monitoring system to assist in identifying and locating issues during on-site debugging;
Provide functions such as a main window (displaying access modes and device information), a settings adjustment window (viewing control modes, alarms, etc.), and an oscilloscope (recording and analyzing signals).
application area
Widely used in land-based power plants (based on diesel engines, gas/steam turbines, water turbines), ships (electric propulsion and auxiliary power supply), traction (diesel electric locomotives), wind energy (based on directly connected synchronous motors), synchronous motors, and variable speed applications.
Working principle
Signal acquisition: Real time acquisition of key parameters such as three-phase voltage, current, and grid voltage of the motor through measuring terminals, as a basis for adjustment.
Deviation calculation: Compare the actual voltage of the collected motor with the set target voltage to calculate the deviation value.
Control regulation: Based on the deviation value, the built-in control algorithm (such as PID regulation) is used to generate excitation current regulation commands, and the current size of the excitation system is adjusted through the IGBT power output stage.
Dynamic response: Quickly respond to changes in the power grid or load, adjust the magnetic field strength of the motor by changing the excitation current, and then correct the motor terminal voltage to stabilize it within the set range.
Protection and Limitation: Equipped with multiple limiters (such as excitation current, V/Hz limit, etc.), it automatically intervenes when parameters exceed the safe range to prevent motor overload or damage, ensuring the safe operation of the system.
Digital input: With 16 digital input channels, it can quickly and accurately collect various switch signals on site, such as the start stop status of equipment, limit switch signals, etc., providing real-time and accurate equipment operation status information for the control system.
Analog Input: Equipped with 4 analog input channels, it can convert continuously changing analog signals from sensors, such as temperature, pressure, flow rate, and other physical quantities, into digital signals that can be recognized by the control system. It also has high resolution and low noise characteristics to ensure the accuracy of signal acquisition.
Digital output: Equipped with 12 relay outputs, it can directly drive external loads and control various actuators such as contactors, solenoid valves, etc. Its output contacts have high load capacity and electrical isolation performance, ensuring stable and reliable execution of control instructions.
Analog output: Four analog output channels are used to output continuously changing analog signals, which can accurately control devices such as regulating valves and frequency converters, and achieve precise adjustment of parameters such as flow rate and speed in industrial processes.
Communication capability
Ethernet interface: Supports Ethernet communication protocol, has high-speed data transmission capability, can quickly exchange data with upper computer, other intelligent devices or control systems, facilitates remote monitoring, data sharing and system integration, and meets the needs of equipment interconnection and intercommunication in the Industry 4.0 era.
Serial communication (RS232, RS485): Equipped with both RS232 and RS485 serial communication interfaces, it is compatible with various traditional devices and sensors. It plays an important role in scenarios where communication speed is not high but communication distance and anti-interference ability are required, providing convenience for different types of industrial equipment to access the system.
Power characteristics: Powered by a 24V DC power supply, this power supply specification is widely used in the industrial field and has the characteristics of high stability, easy access, and maintenance. The module is equipped with an efficient power management circuit that can effectively suppress the impact of power fluctuations on the system, ensuring stable operation in complex industrial power environments.
Memory and processing performance
Memory configuration: With 128 kB of RAM for real-time storage and processing of data, it can quickly respond to various data read and write operations during system operation; 512 kB Flash is used to store programs and important data, which will not be lost even after the system loses power, ensuring that the system can quickly recover to normal operation after restarting.
Processing capability: Built in high-performance processor with powerful computing and logic processing capabilities, capable of quickly processing large amounts of input data, executing complex control algorithms, and outputting control instructions in a timely manner, meeting the requirements for real-time and high-precision control in industrial automation production processes.
Environmental adaptability
Working temperature range: It can work stably within the temperature range of -20 ° C to 55 ° C. Whether in cold northern industrial environments or hot southern production workshops, it can ensure the normal operation of the system and adapt to temperature conditions in different regions and industrial scenarios.
Protection level: reaching a certain protection level standard, such as good dust and splash resistance, can effectively resist the erosion of pollutants such as dust and water droplets in industrial environments, ensure the normal operation of electronic components inside the module, and extend the service life of equipment.
Core Features and Advantages
Ultra short cycle time: capable of achieving control cycles as low as 100 μ s, and even handling extremely fast tasks as low as 25ns, while also considering second level tasks for long-term transient operation, meeting control tasks with different speed requirements.
Powerful processing capability: Combining the floating-point computing performance of the CPU with the flexibility and high-speed capability of FPGA, it can efficiently handle complex control algorithms such as model predictive control.
Convenient programming tool: supports multiple programming methods, including using ABB’s Control Builder (supporting IEC61131-3 language) for system engineering design, and utilizing MATLAB ®/ Simulink ® Develop products and controls (automatically generate and download code), and use VHDL to handle extremely fast processes, easily bridging the gap from simulation to implementation.
Comprehensive integration: It can be fully integrated into ABB’s System 800xA automation system, achieving seamless integration with the factory control system and ensuring transparent data exchange and control throughout the factory.
Innovative FPGA Applications: Capable of flexibly utilizing FPGA to integrate protocols and application functions into devices without increasing additional processor load.
Optical communication technology: using optical communication to improve communication speed and electromagnetic interference resistance, and achieving potential free connection, eliminating the need for isolated transmitters.
Industrial grade hardware: The hardware has no moving parts, possesses industrial grade reliability, has a long lifecycle, is easy to upgrade, and can adapt to harsh environments.
Modular structure: It can be flexibly adjusted according to the application scale, suitable for large industrial factories, propulsion systems, and small compact products. At the same time, the software provides pre configured packages to adapt to different processing performance and I/O speed requirements.
Software and hardware architecture
Hardware architecture: divided into three performance levels, corresponding to different cycle times, perfectly matched with the three-level software structure. We provide fast I/O systems and slow I/O systems. Fast I/O is connected through fiber optic links, with a data throughput of less than 100 μ s, while slow I/O uses modules from ABB S800 system.
Software architecture: divided into three levels, Level 1 is used for systems engineering to handle slow tasks (with a cycle as low as 1ms); Level 2 is used for product and control development, handling fast tasks (with a cycle time as low as 100 μ s); Level 3 is used for communication and extremely fast logic processing, handling extremely fast tasks (as low as 25ns).
Application scenarios
Traction field: capable of working in a wide temperature range of -40 to+70 ° C and vibration environment that meets traction standards, suitable for compact applications with limited space.
In the field of power generation: In the excitation system, with modular architecture and redundant subsystems, reliability is improved. When the main controller fails, the hot standby second controller can take over the work.
Industrial process: In rolling mills, thickness control solutions developed based on MIMO control concepts can reduce thickness deviation by up to 50% and improve product quality.
Development and Engineering Advantages
Adopting a model-based design process using MathWorks ® The tool is a single development platform that integrates system simulation, code generation, download, and debugging, reducing time consumption and errors in traditional development processes, shortening development cycles, lowering development and engineering costs, accelerating product launch time, saving manpower and resources in engineering and software development, and improving asset return on investment.
Connectivity and Scalability
Rich communication protocols: Supports multiple native and additional communication protocols, such as Profibus Master DPV1, Modbus RTU, MMS, Profinet I/O, etc., to ensure connectivity with various devices and systems.
Flexible I/O configuration: Fast and slow I/O can be configured according to project requirements. Fast I/O is connected through fiber optic links and has advantages such as high speed, electromagnetic interference resistance, and potential free connection; Slow I/O can add modules to ABB S800 system.
**Scalability * *: Hardware can be expanded from compact configurations to large modular systems, and software provides pre configured packages to adapt to different processing performance and I/O speed requirements, meeting various application scales.
ABB GFD233 3BHE02294R0102 is a widely used redundant system control module, which is a key component of ABB’s rich product line. It is designed for scenarios with extremely high requirements for system stability and reliability in complex industrial environments. It plays a core role in distributed control systems (DCS) and programmable logic controller (PLC) systems, and can accurately and efficiently achieve automated control of various industrial processes.
Technical specifications
Communication interface: This module supports multiple mainstream communication protocols, such as Profibus DP, Profinet, and Modbus TCP. This enables it to easily achieve seamless communication with devices of different brands and models, greatly improving the convenience and flexibility of system integration. Whether it is data collection from on-site devices or instruction transmission with the upper computer, they can be stably and efficiently completed through these communication interfaces.
I/O channels: With up to 32 I/O channels, it can meet the needs of large-scale data input and output. Through these channels, the module can receive real-time signals from field devices such as sensors and switches, and accurately send processed control instructions to the executing mechanism, ensuring precise control of the industrial production process.
Power supply: Powered by a 24V DC power supply, this common DC power supply specification not only has high stability and reliability, but is also easy to obtain and maintain. A stable power input provides a solid guarantee for the continuous and stable operation of the module, ensuring reliable operation even in industrial environments with minimal power fluctuations.
Installation method: Supports DIN rail installation, which is a standardized industrial installation method with the characteristics of convenient installation, firm and reliable. In the industrial control cabinet, the module can be fixed on the DIN rail through simple card mounting operation, which is convenient for later maintenance, replacement, and system expansion.
Protection level: reaching IP67 protection level, which means that the module has excellent dust and water resistance capabilities. Even in harsh industrial environments such as dusty mines and damp chemical workshops, it can effectively resist the invasion of dust and water, ensure the normal operation of modules, and reduce the probability of failures caused by environmental factors.
Application Fields
Chemical industry: In the process of chemical production, there are numerous complex chemical reactions and process flows involved, which require extremely high stability and reliability of control systems. The ABB GFD233 module can be used to precisely control key parameters such as reaction temperature, pressure, and flow rate, ensuring the safe and stable operation of chemical production processes, and avoiding production accidents and product quality issues caused by control errors.
Petroleum industry: This module is widely used throughout the entire industry chain from oil extraction to refining and chemical product production. At oil extraction sites, it can be used to control the operation of drilling equipment and oil extraction equipment; In refineries and chemical plants, automation control of various production equipment can be achieved, such as temperature, liquid level, and flow control of distillation towers, reaction vessels, and other equipment, to ensure efficient and safe production in the petroleum industry.
Electronics industry: The electronic manufacturing process requires strict precision and stability of production equipment. This module can be used for the control of automated production lines, achieving precise control over process links such as electronic component placement, soldering, and testing, and improving the production quality and efficiency of electronic products.
Power industry: In power plants, whether it is thermal power generation, hydropower generation, or wind power generation, ABB GFD233 modules can play an important role. It can be used for controlling the excitation system of generators to ensure stable output of electrical energy; It can also be used for substation automation control in power systems to achieve real-time monitoring and control of power equipment, ensuring the safe and stable operation of the power system.
Product advantages
Modular design: Adopting advanced modular design concepts, users can flexibly configure modules according to actual needs, facilitating system expansion and customization. When the production scale expands or the process flow changes, only the corresponding modules need to be added or replaced to meet the new control requirements, without the need for large-scale transformation of the entire control system, greatly reducing the cost and difficulty of system upgrade and maintenance.
High performance processing capability: With powerful processing capabilities, it can quickly respond to and process various complex control instructions. In the process of industrial automation production, facing the task of collecting, analyzing, and processing a large amount of real-time data, this module can quickly make decisions and execute corresponding control actions to ensure the efficient and stable operation of the production process, effectively improving production efficiency and product quality.
High stability and reliability: After rigorous quality testing and reliability testing, it can still maintain stable and reliable operation in harsh industrial environments. Whether it is extreme environmental conditions such as high temperature, low temperature, high humidity, strong electromagnetic interference, or long-term continuous operation, this module can consistently maintain high performance, provide reliable control guarantees for industrial production, reduce production downtime caused by equipment failures, and lower production losses for enterprises.
Self diagnostic function: Built in advanced self diagnostic system, capable of real-time monitoring of module operation status. Once a hidden fault is discovered, the system will immediately issue an alarm and provide detailed fault information to prompt users of the location and cause of the fault, helping them quickly locate and solve the problem, greatly improving the efficiency of equipment maintenance and reducing equipment maintenance costs.
Remote monitoring and maintenance: Supports remote monitoring and maintenance functions. Users can remotely connect to the module through the network to obtain real-time operation data and status information of the module, and perform remote debugging, parameter setting, and fault diagnosis of the module. This feature not only facilitates user management and maintenance of equipment, but also effectively reduces the workload and travel costs of on-site maintenance personnel, especially suitable for widely distributed industrial production systems.
The DMC-40×0 series is a Galil high-performance independent controller that supports up to 8-axis control, with high-speed communication, non-volatile program memory, faster encoder speed, and improved EMI reduction wiring.
Provides two communication channels, RS-232 (2-channel, maximum 115K baud rate) and 10BaseT Ethernet, supporting high-speed servo control with up to 22 million encoder counts per second and stepper motor control with 6 million steps per second, with a sampling rate as low as 31.25 µ sec/axis.
Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays, and firmware, which can be upgraded on-site.
Supported motor types
Standard servo motor with ± 10V command signal
Brushless servo motor with sinusoidal commutation
Stepper motor with step and direction signals
Other actuators (such as hydraulic devices, please contact Galil for more information)
Overview of External Amplifier
Current mode amplifier: accepts analog command signals within the ± 10V range, and the amplifier gain should be set to+10V command to generate the maximum required current.
Speed mode amplifier: The 10V command signal should cause the motor to operate at the maximum required speed.
Stepper motor amplifier: accepts step and direction signals.
Overview of Galil amplifiers and drivers
A1- AMP-430×0 (- D3040, – D3020): Multi axis brushed/brushless amplifier, capable of processing 500 watts of continuous power per axis, accepting 18-80VDC DC power supply voltage.
A2-AMP-43140 (- D3140): Contains four linear drivers for operating small brushed servo motors, requiring ± 12-30 DC voltage input, with an output power of 20W per amplifier and a total power of 60W.
A3-SDM-44040 (- D4040): Stepper driver module capable of driving up to four bipolar two-phase stepper motors, with selectable currents of 0.5, 0.75, 1.0, and 1.4 amperes per phase, and selectable step resolutions of full step, half step, 1/4, and 1/16.
A4- SDM-44140 (- D4140): Microstep module, driving four bipolar two-phase stepper motors with 1/64 microstep resolution (SDM-44140 drives two), with selectable current of 0.5, 1.0, 2.0, and 3.0 amperes per axis.
Beginner’s Guide
Layout and Size
Introduced the layout and size information of DMC-4040 and DMC-4080.
power connection
The power connector information for controllers without Galil amplifiers or when ordering ISCNTL power options, as well as the power connector information for controllers with Galil integrated amplifiers.
Required components
Including DMC-40×0 motion controller, motor amplifier (integrated when using Galil amplifier and driver), power supply for amplifier and controller, brushed or brushless servo motor or stepper motor with optical encoder, cable connected to DMC-40×0 integrated ICM, PC (RS232 or Ethernet for DMC-40×0), GalilTools or GalilTools Lite software package.
Installation steps
Determine the overall motor configuration, install jumpers on DMC-40×0, install communication software, connect 20-80VDC power supply to the controller, establish communication with Galil software, determine the axis for sine commutation, connect to amplifiers and encoders, connect standard servo motors/sine commutation motors/stepper motors, and adjust the servo system.
Hardware connection
Optical isolation input
Including limit switch input, origin switch input, abort input, ELO (electronic lock) input, reset input, and unconfirmed digital input, their functions, wiring, and electrical specifications are introduced.
TTL input
The auxiliary encoder input can be used for general purposes, with one auxiliary encoder per axis, containing two inputs, and can accept TTL level signals, etc.
High power optical isolation output
Introduced its electrical specifications and wiring methods, the outputs 9-16 of the 5-8 axis controller are located on the I/O (E-H) D-Sub connector.
analog input
There are eight analog inputs configured in the range of -10V to 10V, and different ranges and modes can be set through the AQ command. The electrical specifications are introduced.
TTL output
Including output comparison, error output, etc.
Expansion I/O of DMC-40×0 Controller
Provides 32 extended TTL I/O points that can be configured as inputs or outputs in 8-bit increments, and introduces their electrical specifications.
Amplifier interface
Introduced its electrical specifications and overview, as well as the ICM-42000 and ICM-42100 amplifier enable circuits, and the ICM-42200 amplifier enable circuit.
Software tools and communication
RS232 and RS422 ports
Introduced RS-232 and RS-422 configurations, including pin descriptions, configuration methods, baud rate selection, and handshake.
Ethernet configuration
Supports two industry standard protocols, TCP/IP and UDP/IP, and introduces addressing methods including MAC address, IP address, and UDP or TCP port number.
communication protocol
Introduced communication methods with multiple devices and multicast functionality.
Third party software usage
Supports tools such as DHCP, ARP, BOOT-P, and Ping for establishing Ethernet connections, and can communicate with hosts through any application that can send TCP/IP or UDP/IP packets, such as Telnet.
Modbus
An RS-485 protocol is introduced, including its function code, communication level, and examples.
data record
The status information block can be provided through QR commands, which introduces the mapping of data records and the interpretation of bit fields.
GalilTools (Windows and Linux)
It is a software toolset provided by Galil for the current Galil controller, which includes multiple tools and can run on both Windows and Linux platforms.
Create custom software interface
Provide programming tools such as GalilTools communication library, ActiveX Toolkit,. NET API, and DMCWin to facilitate users in developing their own custom software interfaces.
Command Fundamentals
introduce
Provide over 100 commands for specifying motion and machine parameters, which can be sent via ASCII or binary.
ASCII command syntax
The instruction consists of two uppercase letters followed by applicable arguments, terminated with a semicolon or carriage return, and introduces the syntax for specifying axis data and requesting actions.
Binary Command Syntax (Advanced)
The binary communication mode is about 20% faster than ASCII commands. The binary format can only send commands from a PC and cannot be embedded in applications. This article introduces the binary command format and tables.
Controller’s response to data
Return ‘:’ for valid commands and ‘?’ for invalid commands, error codes can be requested through the TC1 command.
Inquire about the controller
There is a set of commands that directly query the controller and return the required data, introducing the query commands and operands.
Sports programming
overview
Provides multiple motion modes, such as independent positioning and jogging, coordinated motion, electronic cam motion, and electronic gear transmission, and introduces application examples applicable to different modes.
Independent axis positioning
Each axis moves independently and follows its own contour. Relevant commands and operands, as well as examples, are introduced.
Independent Jogging
The ability to change speed, direction, and acceleration during motion is introduced, along with relevant commands and operands, as well as examples.
Position Tracking
This article introduces the characteristics and examples of a target that allows absolute position movement to be changed during motion.
Linear interpolation mode
Multi axis motion coordination, maintaining specified vector velocity, acceleration, and deceleration along a specified path, introducing relevant commands and operands, as well as examples.
Vector mode: Linear and circular interpolation motion
Allow the specification of long 2-D paths consisting of linear and circular arc segments, introduce relevant commands and operands, and provide examples.
Electronic gear transmission
Up to 8 axes can be connected to certain main axis electronic gears, and relevant commands and examples are introduced, including bevel gear transmission.
Electronic cam
A motion control mode that supports periodic synchronization of multiple motion axes, introducing relevant commands and examples.
PVT mode
Allowing the definition of arbitrary motion contours for all 8 axes through position, velocity, and time, relevant commands and examples are introduced.
Multi axis coordinated motion
Many applications require multiple axes to move in a coordinated manner, while also requiring smooth motion. An example was introduced.
contour mode
Allowing the specification of curves at any position for 1 to 8 axes, introduces relevant commands and examples, including recording and playback functions.
Stepper motor operation
Introduced the relevant commands for operating stepper motors, smoothing functions, methods for using encoders, and the Stepper Position Maintenance Mode (SPM).
Double loop (auxiliary encoder)
Except for the shaft configured for stepper motor operation and the shaft used for circular comparison, each shaft provides a second encoder interface, and its purpose and related commands are introduced.
**Backlash compensation**
Two methods of using auxiliary encoders for backlight compensation were introduced: continuous dual loop and sampling dual loop.
Motion Smoothing
Smooth motion and reduced mechanical vibration of the system can be achieved through IT and KS commands.
zeroing
The Find Edge (FE) and Home (HM) commands can be used to zero the motor to the mechanical reference point, and the steps and related commands for zeroing are introduced.
High speed position capture (latch function)
The position of the main encoder or auxiliary encoder can be captured within 25 microseconds of external low input signals (or index pulses), and its usage steps and examples are introduced.
Quick update rate mode
It can run at a much faster servo update rate than the default per millisecond, and introduces the update rates and related limitations of different models of controllers.
Application Programming
overview
Provide a powerful programming language that allows users to customize controllers for specific applications. The program can be downloaded to DMC-40×0 memory, freeing up the host for other tasks.
Using DMC-40×0 editor to input program
The GalilTools package or the line editor provided by DMC-40×0 can be used to input and modify programs, and the editing mode commands are introduced.
Program Format
Composed of DMC instructions, action instructions are combined with program flow instructions to form a complete program, introducing the use of tags and special tags.
Comment
You can use the NO command or apostrophe (‘) to add comments to the program.
Executing Programs – Multitasking
Up to 8 independent programs (threads) can run simultaneously, and instructions for starting and stopping threads are introduced.
debugger
Provide commands and operands that help debug applications, such as trace commands, error code commands, stop code commands, etc.
Program flow command
Including event triggers and conditional jumps, the program flow can be changed based on the occurrence of events.
Mathematics and Function Expressions
Provides a variety of mathematical operators and functions that can be used for data manipulation.
variable
Provides 510 variables that can be used to store mutable parameters, and introduces the definition and assignment of programmable variables.
array
Used for storing and collecting numerical data, this article introduces the definition, assignment, upload and download of arrays, as well as automatic data capture functions.
Data input (numerical and string)
The IN command can be used to prompt the user to enter numerical or string data, introducing the operator data input mode and the use of communication interruption.
Data output (numerical and string)
MG commands can be used to output numerical and string data, introducing message sending, port specification, and formatting.
Hardware I/O
Introduced the usage methods of digital output, digital input, auxiliary encoder input, input interrupt function, analog input, and extended I/O.
Example application
Examples include line cutters, X-Y worktable controllers, speed control through joysticks, position control through joysticks, and backlight compensation through sampling dual loops.
Hardware and software protection
overview
Providing multiple hardware and software functions to check for error conditions and disable motors in case of errors helps protect various system components from damage.
hardware protection
Including output protection lines (such as amplifier enable, error output) and input protection lines (such as universal stop, selective stop, ELO, forward limit switch, reverse limit switch).
software protection
Provides programmable error limits that can set limit values for position errors, introduces programmable position limits, Off On Error functionality, automatic error programs, and limit switch programs.
Troubleshooting
overview
Potential issues are classified into three categories: installation, stability and compensation, and operation. Various symptoms, diagnoses, causes, and remedial measures are introduced.
Operational theory
overview
Discussing the operation of a motion control system, a typical motion control system consists of multiple elements, and the operation can be divided into three levels: closed-loop, motion contour, and motion programming.
Closed loop system operation
Qualitatively and quantitatively explained the operation of the servo system, including the principle of closed-loop control, the causes of instability, and the role of PID filters.
system modeling
Established mathematical models for various elements of the servo system, such as motor amplifier, encoder DAC、 Digital filters and ZOH.
system analysis
Starting from the block diagram model of system elements, analyze to determine the stability of the system.
System design and compensation
Aiming to close the loop with cross frequency and phase margin, the analysis and design methods are introduced.
appendix
Electrical specifications
Electrical specifications including servo control, stepper control, input/output, and power requirements.
Performance specifications
Including performance parameters such as minimum servo loop update time, position accuracy, and speed accuracy.
Quick update rate mode
Introduced the update rate and disabled features in fast mode.
Ordering options for DMC-40×0
Introduced controller board options, CMB communication board options, ICM interconnect board options, and AMP internal amplifier options.
DMC-40×0 power connector
Introduced the Molex connector models and cable connections used.
Integration Components
Detailed descriptions, electrical specifications, mating connectors, and operation information of integrated components such as A1 to A8 were provided.
The specialized operating guide for ABB AO2040-CU Ex central unit (2G class) serves as a supplement to the main operating manual for the AO2000 series continuous gas analyzer (publication number 42/24-10 EN), containing key information for safe installation, start-up, and operation of the equipment. The “Analyzer Data Sheet” accompanying each device should be used in conjunction with this manual. The symbols “1, 2, 3,…” in the manual indicate safety operation points, and the symbol “●” indicates specific instructions for equipment operation.
Technical Parameter
Compliant with standards: Compliant with DMT 08 ATEX 2018 U 605 standard, explosion-proof mark Ex de IIC T4 Gb, equipment category 2G, suitable for use in Zone 1 and Zone 2 explosion hazardous areas.
Size and weight: The equipment size is not explicitly mentioned, with a weight of approximately 28kg.
Suppress gas related parameters
Gas type: Use air that meets ISO 8573-1 standard level 3 as the suppression gas.
Gas quality requirements: maximum particle size of 40 μ m, maximum oil content of 1mg/m ³, maximum pressure dew point+3 ° C.
Working pressure range: Suppress gas working pressure to 250-500kPa (2.5-5bar).
Power supply parameters
Voltage setting: Before connecting to the power supply, it is necessary to confirm that the equipment voltage setting matches the line voltage. The specific voltage setting value is not explicitly mentioned.
Power protection device: Install suitable protection devices and easy to operate circuit breakers, specific specifications are not explicitly mentioned.
Pressure parameters
Positive pressure inside the system casing: Maintain a positive pressure of approximately 2hPa inside the system casing during operation.
Positive pressure alarm and protection threshold: When the positive pressure is below 0.8hPa or above 15hPa, disconnect the power supply and isolation relay connection circuit inside the system enclosure; When the internal pressure is below 1.2hPa, a status signal is output through passive relay contacts.
Electrical connection parameters
Potential compensation connection: External potential compensation connection or protective wire with a minimum cross-sectional area of 4mm ².
Intrinsic safety signal circuit: The total length of the intrinsic safety signal circuit for the condensate water monitor shall not exceed 75 meters, and a 100k Ω resistor shall be installed next to the sensor.
Cable connector specification: M20 threaded connector is suitable for cable outer diameters of 6-12mm.
Safety operation information
General safety requirements: The equipment must be properly handled, stored, installed, set up, operated, and maintained; Only personnel who are familiar with similar equipment and have relevant qualifications can operate it; It is necessary to comply with the content of this manual, equipment safety information, safety precautions for electrical equipment and gas operation, as well as explosion-proof regulations and standards.
Special safety instructions: Follow all explosion-proof safety measures before operation; Do not operate current carrying components in explosive risk environments except for intrinsically safe circuits; Connect the local potential compensation point first; Ensure that the equipment voltage setting matches the line voltage; Before opening the casing, disconnect all power sources and wait for 10 minutes for the power capacitor to discharge; If the equipment is damaged, unable to operate, or has poor storage and transportation conditions, it should be stopped from use.
Installation guide
Unpacking and installation: The equipment weighs approximately 28kg and requires two people to operate. The installation position should be stable; Can be installed in Zone 1 and Zone 2 explosion hazardous areas, and cannot be installed outdoors.
Suppression gas pipeline connection: Use air that complies with ISO 8573-1 Level 3 as the suppression gas; Install the accompanying compressed air conditioning filter to prevent valve damage caused by gas pipeline contamination.
Electrical connection safety precautions: Do not change the internal wiring of the factory, only modify the wiring between the isolation relay and the system controller and I/O board connectors; First, connect the external potential compensation connection or protective wire, with a minimum conductor cross-sectional area of 4mm ²; Electrical circuits need to be firmly fixed, and shielded wires need to pass through metal connectors; The intrinsic safety signal line is only connected to the blue cable connector, with a minimum distance of 8mm from other lines; the communication interface line needs to be connected through factory pre wired isolation relays; Connect the power line to the pressurized enclosure system control unit, do not directly connect it to the system enclosure port.
Electrical connection details: Clarify the application of different types of connectors (light blue M20, black M20, metal M20); The M20 threaded connector is suitable for cable outer diameters of 6-12mm. Unused connectors need to be sealed with original plugs and tightened.
Electrical equipment composition: including isolation relays, terminal blocks, line filters, pressurized enclosure system control units, isolation amplifiers, etc.
Each device has its specific functions and connection requirements.
Analysis module connection: The system bus and 24VDC cable are components of the pressurized enclosure system, with a length of not less than 1 meter; Connect the system bus cable and 24VDC cable to the central unit according to the steps.
Non intrinsic safety signal line connection: connected to the right side of the isolation relay; The intrinsic safety signal circuit of the condensate monitor is connected through a bright blue cable, with a total length not exceeding 75 meters, and a 100k Ω resistor is installed next to the sensor.
Status signal, potential compensation and power connection: The minimum cross-sectional area of the conductor for potential compensation connection is 4mm ²; Connect the status signal to control unit terminals 21 and 22; Before connecting the power supply, confirm that the voltage settings match, install appropriate protective devices and easy to operate circuit breakers, and connect control unit terminals 15, 17 and PE terminals.
Operation and maintenance
Pre start inspection: Confirm that the installation site conditions, equipment installation firmness, suppression of gas flow, shell integrity, electrical circuit connections, etc. meet the requirements.
Startup steps: Connect the power supply and suppress the gas supply. After the initial purge is completed, switch the solenoid valve to “leakage compensation” and activate the power supply of the equipment inside the system casing; After startup, the “Power”, “Maintenance”, and “Error” LEDs light up, and the screen displays the startup phase and software version, then switches to measurement mode.
Maintenance bypass operation: When there is no explosive environment, the bypass of the pressurized shell system control unit can be activated, which requires approval from the operations manager; Activate and deactivate the bypass according to the steps, and the bypass must be deactivated during normal operation.
Regular inspection: Conduct routine checks according to the pre startup checklist.
Appendix: Application and Design
Application and Design Overview: Used in conjunction with the AO2060 series analysis module to control and monitor the measurement and control process; The system casing is wall mounted and designed to comply with EN 60079-2 “pressurized casing with leakage compensation”; Can access intrinsic safety and non intrinsic safety signal circuits, and the system controller has no battery backup.
Pressure shell system: using air that complies with ISO 8573-1 Level 3 as the suppression gas, with a particle trap at the outlet; Perform preliminary blowdown set by the factory during startup, and maintain a positive pressure of approximately 2hPa inside the system casing during operation; When the positive pressure is lower than 0.8hPa or higher than 15hPa, disconnect the power supply and isolation relay connection circuit of the equipment inside the system casing, and after the pressure is restored, blow and activate again; When the internal pressure is below 1.2hPa, a status signal is output through passive relay contacts.
Positioning and Function: REF615 is a specialized feeder protection relay designed for feeder protection, measurement, and monitoring in public substations and industrial power systems. It follows the IEC 61850 standard and supports multiple communication protocols. It can serve as the main protection for overhead lines and cable feeders, as well as backup protection.
Adaptation scenario: According to the pre configuration, it is suitable for the protection of overhead lines and cable feeders in isolated neutral points, resistance grounding, compensation, and solid grounding networks. After specific application settings are given, it can be directly put into use.
Standard configuration
Four configuration types: standard configuration A, B, C, D, supporting different combinations of protection functions, such as configuration A and B supporting directional ground fault protection, and configuration C and D supporting non directional ground fault protection.
Functional differences: Different configurations have differences in the stage settings and directionality of protection functions such as overcurrent, ground fault, and negative sequence overcurrent, as well as varying degrees of support for control, monitoring, and measurement functions.
Protection function
Core protection functions: including three-phase non directional overcurrent (low setting, high setting, instantaneous stage), directional and non directional grounding faults (low setting, high setting, instantaneous stage), negative sequence overcurrent, phase discontinuity, thermal overload, circuit breaker fault protection, three-phase surge detection, arc protection, etc.
Arc protection: Equipped with three optical detection channels through optional hardware and software, it is used for arc fault protection of circuit breakers, busbars, and cable rooms in metal enclosed indoor switchgear, quickly tripping to improve personnel safety and limit equipment damage.
Application scenarios
Grounding system adaptation: Directional grounding fault protection is mainly used for isolated or compensated networks, while non directional grounding fault protection is suitable for direct or low impedance grounding networks.
Substation protection application: In substations, different configurations can be used for overcurrent and ground fault protection of incoming and outgoing feeders, and system protection is achieved through the combination and interlocking of protection functions.
Control and Measurement
Control function: Provides circuit breaker control, including basic interlock and extended interlock, supports automatic reclosing of circuit breakers, and interlock schemes can be configured through the signal matrix tool of PCM600.
Measurement function: Continuously measure phase current, symmetrical component of current, residual current, and if directional grounding fault protection is included, measure residual voltage to calculate maximum demand, thermal overload, and phase imbalance values. The measured values can be accessed locally or remotely.
Fault recording and monitoring
Disturbance recorder: With up to 12 analog and 64 binary signal channels, it can set trigger conditions, record waveforms or trends, and store them in non-volatile memory for fault analysis.
Event log: stores 50 timestamp event codes, non-volatile memory retains data in case of loss of auxiliary power supply for analysis before and after faults.
Circuit breaker monitoring: Monitor the spring charging time, SF6 gas pressure, travel time, and inactivity time of the circuit breaker, and provide operational historical data for preventive maintenance scheduling.
Communication and Interface
Communication protocol: Supports IEC 61850 (including GOOSE messages) and Modbus ®， IEC 61850 supports horizontal communication, Modbus supports RTU, ASCII, and TCP modes, and supports SNTP and IRIG-B time synchronization.
Interface types: including 100BASE-TX RJ45, 100BASE-FX LC fiber optic, and RS-485 interfaces to meet different communication needs.
Technical Parameter
Physical characteristics: Width 177mm, height 177mm (4U), depth 155mm, weight 3.5kg, protection level front panel IP54, top IP40, back IP20.
Power supply: There are various types of auxiliary power supplies with a wide voltage range, low power consumption, and the ability to withstand power interruptions.
Input/output: Current input supports multiple rated values, voltage input can be configured, binary input and output contacts can be freely configured, and I/O expansion modules are supported.
Environmental adaptability: Operating temperature -25 ℃~+55 ℃, storage temperature -40 ℃~+85 ℃, adaptable to various environmental conditions, passed EMC, insulation, and mechanical tests.
Display and installation
Display options: Provide small-sized and large-sized LCD displays, with large-sized displays reducing menu scrolling and improving information overview.
Installation method: Supports various installation methods such as flush installation, semi flush installation, wall mounted installation, 19 inch rack installation, etc. It can be installed at a tilt of 25 ° and is equipped with a test switch.
Working principle
Signal acquisition and processing: Collect current and voltage signals in the power system through devices such as phase current transformers, residual current transformers, and voltage transformers. Process the collected analog signals, such as filtering, amplification, etc., convert them into digital signals for analysis and calculation, obtain electrical quantity information such as phase current, current symmetry component, residual current, residual voltage, etc., and provide data support for subsequent protection and measurement functions.
Protection function action logic
Overcurrent protection: Real time monitoring of current signals. When the current exceeds the preset overcurrent protection value, according to the set time curve (timed or inverse time limit), the protection action is triggered after reaching the corresponding time, such as issuing a trip command to cut off the circuit breaker and protect the equipment from overload current damage.
Grounding fault protection: For directional grounding fault protection, the fault direction and current magnitude are calculated using phase current and residual voltage, and action is taken when the fault direction and current exceed the set values; Non directional grounding fault protection is mainly judged based on the magnitude of residual current, and if it exceeds the set value, the protection will be triggered.
Other protections: Negative sequence overcurrent protection monitors negative sequence current and activates when it exceeds the threshold; Phase discontinuity protection detects the relationship between phase currents to determine faults; Thermal overload protection simulates the heating process of equipment, calculates heat accumulation based on current and time, and starts protection when the set temperature is reached; Three phase inrush current detection identifies inrush current by analyzing the proportion of current harmonics, and takes action when it exceeds the set value; Arc protection uses light detection channels to monitor arc light, combined with current to determine faults, and quickly trips when conditions are met.
Control and monitoring mechanism
Circuit breaker control: The opening and closing operation of the circuit breaker is controlled by internal logic and external input signals, with basic interlocking and extended interlocking functions to prevent misoperation and ensure safe and reliable operation.
Monitoring function: Continuously monitor the status of circuit breakers, such as spring charging time, SF6 gas pressure, etc; Monitor the integrity of the trip circuit, detect open circuits and control voltages; Self monitor its own hardware and software, issue alerts in case of malfunctions, and take corresponding measures.
Communication and Interaction: Supports communication protocols such as IEC 61850 and Modbus for data exchange with other devices. Upload the collected electrical quantity data, event records, fault information, etc. to the monitoring system, receive control instructions and configuration parameters issued by the monitoring system, and achieve remote monitoring and configuration. Support time synchronization function to ensure the accuracy of event recording and data collection, facilitating fault analysis and system operation management.
