RTU560E is a component of RTU560 remote terminal unit, suitable for application scenarios of small and medium-sized data point scale, including:
Centralized or distributed system architectures such as local network sites and small distribution substations.
In the field of oil and gas networks: pipeline leak detection and block valve control, pipeline flow measurement, oil well monitoring and control.
OEM applications that require multifunctionality, precise computation, data storage, or custom protocols.
Core Features
Design features: Adopting a compact design, high cost-effectiveness, supporting customer specific configurations, modular structure for easy expansion.
Architecture flexibility: It can adapt to centralized or distributed system architectures and can be configured with up to 27 I/O cards through an expansion bus.
Technical parameters
Hardware composition and specifications
Shell (560HOS80): The dimensions are 366 × 258 × 310 mm (height × width × depth), and the protection level meets EN 60950 and 50178 standards, reaching IP 30.
Central processing unit (560CMU80): equipped with ELAN 400 processor (66 MHz) and 4 MB DRAM (optional 16 MB); Includes 2 RS232 interfaces (baud rate 50-38400), 1 RS485 interface (up to 19200 baud rate), and 2 optional modem slots; Equipped with MMK interface (serial connection with internal web server), optional 10BaseT Ethernet interface.
Multi I/O card (560MIO80): supports 24-60V and 110-220V DC process voltage; Contains 16 binary inputs (input current 1-3 mA), 2 counter inputs (up to 8 kHz), 8 binary outputs, and 4 analog inputs.
Fiber coupler (560FOC80): Input voltage 5-24V, emission wavelength 850 nm, input optical power range -24.0 to -10.0 dBm, maximum transmission rate 1 MBit.
Power supply: 560PSU80 (DC/DC) supports 24-60 V DC or 110-220 V DC input; 560PSU81 (AC/DC) supports 110-230 V AC input.
Environmental adaptation: The working temperature range is -20 to+70 º C.
Communication and Function
Communication capability: Provides up to 3 communication ports, supporting protocols such as IEC 60870-5-101/102/103/104, Modbus, SPA, DNP3.0, RP570/71, etc; Optional Ethernet interface, supports modems (analog dial-up, V.23, GSM, etc.).
Core function: Supports PLC 61131 standard and has data archiving function; Flow calculation for turbine flow measurement (including AGA 8 density calculation, can support other standards upon request); Support optional slave/master protocols (such as IEC870-5-101).
The Advant Master S100 I/O system is an important component of ABB Advant Master automation systems. As a distributed process I/O system, it aims to provide efficient and reliable signal acquisition and control functions for industrial process control. The system adopts a modular design with flexible scalability, which can adapt to industrial application scenarios of different scales and provide precise I/O support for process control.
System composition and structure
Core components
I/O module: covering various types such as digital input, digital output, analog input, and analog output, it can meet the acquisition and control needs of different signals. The module design is compact, using standardized interfaces for easy installation and replacement.
Communication interface: Connect with higher-level control systems (such as Advant Master controllers) through specific communication modules to ensure real-time data transmission and interaction.
Power module: provides stable power supply for the entire I/O system, and some models support redundant configuration to improve system reliability.
Rack/Rail: Used for installing various modules, providing mechanical support and electrical connections. The rack design complies with industry standards, facilitating system integration and expansion.
Structural features: The system adopts a distributed structure, which can install I/O modules near process equipment according to on-site requirements, reducing signal transmission distance, minimizing interference, and improving the accuracy of signal acquisition. Meanwhile, the modular design makes the system configuration and expansion more flexible, and users can increase or decrease the number of modules according to their actual needs.
Main functions and features
Signal processing capability: capable of processing various types of industrial signals, including analog signals such as DC current, DC voltage, AC current, AC voltage, as well as digital signals such as switch values, with high measurement accuracy and response speed, ensuring precise monitoring and control of process parameters.
Reliability guarantee:
Some key components support redundant configuration, such as power modules, communication modules, etc. When the main component fails, the redundant components can automatically switch to ensure the continuous operation of the system.
The module has self diagnostic function, which can monitor its own operating status in real time. When a fault occurs, it can promptly issue an alarm signal, making it easy for maintenance personnel to quickly locate and troubleshoot.
Compatibility and Integration: It has good compatibility with other components of the Advant Master automation system and can be seamlessly integrated into the entire control system, achieving data sharing and collaborative control. At the same time, it supports multiple industrial communication protocols for easy interconnection with devices and systems from other brands.
Environmental adaptability: able to work stably in harsh industrial environments, with certain resistance to vibration, impact, and electromagnetic interference, and adaptable to a wide range of temperature and humidity.
Application scenarios
The Advant Master S100 I/O system is widely used in industrial fields such as power, chemical, petroleum, metallurgy, and water treatment, providing reliable I/O solutions for various industrial process controls. For example, it is used in power plants to monitor and control the operating parameters of boilers, turbines, and other equipment. In chemical production, it is used to collect signals such as temperature, pressure, and flow of reaction vessels and achieve control of valves, pumps, and other equipment.
Summary
The Advant Master S100 I/O system, with its modular design, flexible scalability, high reliability, and good compatibility, has become an indispensable and important component of industrial process control. It can meet the signal acquisition and control needs of different industrial fields and provide strong support for industrial automation production.
The ABB S500 series heavy-duty circuit breaker is a protective switchgear designed to meet the increasing demand for short-circuit current in low-voltage power grids, with high safety, reliability, and breaking capacity. Its core function is to protect circuits, motors, equipment, and systems from the effects of overload and short-circuit currents through thermal and/or electromagnetic trip functions. It is widely used in various fields such as railways, commercial buildings, offshore platforms, ships, process industries, and rail trams.
Core Features
High performance parameters:
High rated breaking capacity, up to 30/50 kA.
High rated working voltage, AC 400/690 VAC, DC 750 VDC.
Equipped with current and energy limiting breaking capabilities, the breaking time is extremely short, ensuring system safety.
Functional advantages:
Excellent selectivity ensures that only the faulty part is disconnected in the event of a malfunction, while maintaining the operation of other parts of the system.
The switch and contact position indication are reliable and convenient for status monitoring.
Provide multiple special application versions to meet the needs of different scenarios.
Compact in size (compliant with DIN standards), with a wide range of accessories including undervoltage release, shunt release, auxiliary contacts, and signal contacts.
Main product types and applications
Circuit protection series:
S500-B: Suitable for equipment with no or only minimal surge current (such as boilers, electric heaters, etc.).
S500-C: Standard type, suitable for devices with surge current (such as inductive devices, sockets, etc.).
S500-D: Suitable for devices with extremely high surge currents (such as transformers, capacitor banks, etc.), and can also be used as protection for upstream circuit breakers.
Motor protection series:
S500-K: Used to protect single-phase and three-phase motors, can be installed in a fuse free motor control center, with adjustable rated current.
S500-KM: It only has electromagnetic trip function and needs to be combined with independent overload protection to provide short circuit protection for the motor.
S503X-AG0084: Alternative to S500-KM, with high breaking capacity (50 kA at 400 VAC), suitable for high short-circuit current scenarios.
DC Circuit Protection Series (S500UC-B/K):
Suitable for DC applications such as railway systems, electroplating, and DC networks. Single pole can switch to 250 VDC, and multi pole series can switch to 750 VDC+20%.
It is divided into fixed rated current (B characteristic) and adjustable rated current (K characteristic) versions.
Residual current protection series:
F500-C/D: It has both circuit protection and residual current tripping functions, and can protect against direct contact, dangerous residual current, etc.
F500-K: Equipped with motor protection features and residual current trip function, suitable for motor systems.
DDA series: can be installed by users on S500 circuit breakers, suitable for sine AC residual current and pulse residual current scenarios in DC circuits.
Short delay/selective residual current protection: F500K… 0.03 G (short delay type) and F500S… 0.3 S (selective type), respectively used to avoid false tripping and ensure selectivity with downstream equipment.
Technical parameters and characteristics
Electrical parameters:
The rated current range is wide, covering 0.1 A to 63 A (some models have higher ratings).
The rated breaking capacity varies depending on the model and application scenario, and can reach up to 50 kA.
The working frequency covers 50/60 Hz, and can support 16 ²/∝ Hz and 400 Hz under special requirements.
Environment and Installation:
Allowable ambient temperature -25 ° C…+55 ° C, storage temperature -25 ° C…+70 ° C.
Protection level IP20, flexible installation method, can be installed at any angle, supports up and down incoming lines.
Long mechanical lifespan, with a switch frequency of over 20000 times.
Selective and Backup Protection
Selectivity: By properly coordinating the upper and lower circuit breakers, ensure that only the faulty part is disconnected during a short circuit. The document provides selective coordination parameters with upstream circuit breakers, backup fuses, and downstream miniature circuit breakers.
Backup protection: When the short-circuit current at the installation point exceeds the breaking capacity of the circuit breaker, it is necessary to configure according to the rated current limit of the upstream circuit breaker. The document provides specific backup protection parameters and cable length requirements.
Accessories and Installation
Accessories: including factory pre installed accessories (such as switching neutral wire NA, separating neutral wire N, release, residual current signal contacts, etc.) and user installable accessories (such as auxiliary contacts, signal contacts, locking devices, rotary drives, etc.).
Installation: 35 mm standard rail clip shall be used for installation, and the safety spacing requirements shall be followed. When cleaning, use a vacuum cleaner or wet rag (soap lotion), and avoid using compressed air or high-pressure cleaner.
Standards and Certification
Compliant with multiple international standards such as IEC 60947-2, UL 1077, CSA, etc., certified by CE, cULus, FM, etc., ensuring product quality and compliance.
S800 I/O is a comprehensive distributed modular process I/O system that can communicate with higher-level controllers and PLCs through industry standard fieldbus. Its advantages lie in:
Wide compatibility: compatible with various process controllers and PLCs from ABB and other brands.
Cost effectiveness: Supports on-site installation, located close to sensors and actuators, reducing wiring costs.
High availability: With features such as “hot swappable” modules, online reconfiguration, and redundancy options, it helps maintain production operations and ensure revenue.
Model and core parameters of analog input module
The S800 I/O series includes six analog input modules: AI810, AI815, AI820, AI825, AI830/AI830A, and AI835/AI835A. The core parameters are compared as follows:
Input type: Single ended unipolar (current/voltage)/Single ended unipolar (current/voltage)/Differential bipolar (current/voltage)/Independent galvanic isolation (current/voltage)/3-wire RTD and resistance potentiometer/thermocouple (B, C, E, etc.) and linear range
Measurement range: 0 (4)… 20mA, 0 (2)… 10V, etc./0… 20mA, 0… 5V, etc./-20…+20mA, -10…+10V, etc./-20…+20mA, -10…+10V, etc. See Table 1 (covering multiple RTD temperature ranges)/See Table 2 (covering multiple thermocouple temperature ranges)
Accuracy: Maximum 0.1%/Maximum 0.1%/Maximum 0.1%/Maximum 0.1%/See Table 1 (varies by sensor type) Maximum 0.1%
Working temperature range: 0~55 ° C (storage -25~70 ° C)/0~55 ° C (storage -25~70 ° C)/0~55 ° C (storage -25~70 ° C)/0~55 ° C (storage -25~70 ° C)/0~55 ° C (storage -25~70 ° C)/0~55 ° C (storage -25~70 ° C)
Dimensions (width x depth x height): 45mm x 97mm x 119mm (including connector 106mm deep)
/45mm x 97mm x 119mm (including connector 106mm depth)/45mm x 97mm x 119mm (including connector 106mm depth)/45mm x 97mm x 119mm (including connector 106mm depth)/45mm x 97mm x 119mm (including connector 106mm depth)/45mm x 97mm x 119mm (including connector 106mm depth)
All modules support status indication for module errors, warnings, and channel errors, with some modules providing additional information through the PROFIBUS-DPV1 service.
The monitoring content includes internal power supply, checksum, watchdog, memory errors, etc. External errors such as open circuit, abnormal process power supply, etc.
Electrical characteristics:
Isolation: Most modules are group isolated (RIV=50V), and AI825 is group isolated (RIV=250V) to ensure electrical safety.
Common mode rejection ratio (CMRR): AI820 reaches 80dB, AI825, AI830/AI830A, AI835/AI835A reach 120dB, with strong anti-interference ability.
Overvoltage protection: Some modules support overvoltage protection, such as AI825 which supports 30V protection when voltage and overvoltage current are input.
Environment and Certification:
Compliant with multiple international standards such as IEC 61140, with CE mark, cULus, FM, CSA certification, etc., suitable for various industrial environments.
Resistant to corrosive atmosphere (ISA-S71.04 G2 level), suitable for environments with 5% to 95% non condensing humidity.
Application and compatibility
Terminal unit: Each module is adapted to different terminal units (such as TU810, TU812, etc.), with specific models listed in the “Module termination units” column of the table.
Communication: Supports communication with PROFIBUS through interfaces such as CI801 and CI840, with parameter bytes and update cycles varying depending on the module.
ABB’s Triguard 2 TMR safety product originated from August Systems, founded in 1978. The company was the world’s first to develop triple modular redundancy (TMR) processing technology for real-time fault-tolerant control. After being acquired by ABB in 1997, it combined TMR technology with ABB’s mature dual redundancy safety system to establish the ABB Safety business unit, dedicated to providing a wide range of safety solutions for the industry.
The Triguard SC300E product can be provided as an engineering system for ABB, as well as an integrated product for third-party system integrators and original equipment manufacturers (OEMs), enabling its technology to serve a wide range of customers and application scenarios. Many well-known companies around the world, such as BP/AMOCO, Exxon/Mobile, Saudi Aramco, etc., have adopted it.
Core Features and Advantages of Triguard SC300E
1. High availability and reliability
Achieved extremely high TMR availability (99.999%) by maximizing mean time to failure (MTTF) and shortening mean time to repair (MTTR).
Adopting modern low-power integration technology makes TMR architecture cost-effective in an increasing number of high integrity applications.
Having fault tolerance capability, the system design can continue to operate correctly in the presence of major component failures and tolerate multiple non concurrent failures.
2. Safety and operational characteristics
Fault safe operation: The fault modes of the processor, input/output circuit, control program, and watchdog timer circuit are all managed to ensure that the circuit defaults to the predetermined safe state.
Fast response speed: Adopting advanced processor technology while maintaining the stability of the original core software, providing an unparalleled scanning time resolution of 10ms, which is beneficial for event sequence recording (SoE) and high-speed advanced control applications.
Usability: Running as a single set of hardware and software, three processors and triple I/O circuits are transparent to users, reducing operation and maintenance difficulty, low lifecycle cost, and supporting online maintenance.
3. Architecture and hardware design
TMR architecture: A fully triple system architecture is adopted from input module to output module, with each system containing one or more identical chassis that accommodate power supply, processor, I/O, and communication modules.
Chassis types: including Main Chassis, Extension Chassis, Remote Master Chassis, and Remote Chassis, all provide 10 I/O module slots and redundant power supplies, can connect up to 15 chassis, and support up to 9500 I/O.
Processor: Each system contains three asynchronous parallel running processors, connected to I/O and communication modules through a triple bus system on the chassis backplane, with battery backed static RAM, EPROM, real-time clock, etc.
I/O module: The input/output module design is universal, achieving component rationalization and distributed processing. All modules have “key control” to prevent incorrect installation, support hot repair, and can be repaired without affecting system operation.
Digital input module: There are 32 channel isolated (24Vdc/120Vdc/120Vac TMR), 64 channel isolated (24Vdc Simplex) and other types.
Digital output module: including 32 channels (24Vdc TMR), 16 channels (120Vdc/120Vac TMR), etc., equipped with line monitoring circuit, six element voting circuit, etc.
Analog input/output module: The analog input module supports 0-5VDC, 0-10VDC, etc. The analog output module is a 4-channel 12 bit resolution 4-20mA TMR.
Pulse Input Analog Output Module (PIANO): 8 channels, including 4 pulse inputs and 4 analog outputs.
Communication module: Four channel serial communication module, supporting RS232/423, with a speed of 19.2 kbits/sec, directly communicates with three processors, and data is transmitted after 2oo3 voting. It can also be connected to standard communication networks such as Ethernet/TCP/IP through gateway products.
4. Software and Programming
Operating System: The Real Time Task Monitor (RTTS) is installed in three processors and has undergone over 10 million hours of runtime validation. It controls offline/startup and online continuous diagnostic and voting functions, providing a single application programming environment.
Supporting software:
TriBuild ™： Windows compatible configuration and application programming software, supporting online/offline configuration, programming, documentation, and testing, using ladder logic, functional block programming, and structured networking methods.
TriCommand ™ Server: Based on Wonderware InTouch ™ The display and control system workstation provides real-time system control and monitoring functions.
TriLog ™： A simple PC based alarm/event recorder that can monitor up to four Triguard SC300E systems.
Standard compliance and global support
1. Compliance with international standards
ABB’s quality system complies with international standards and is certified by BS EN ISO 9001 1994.
The product meets multiple international standards and guidelines, such as TUV Rheinland certification (for safety related applications, suitable for Safety Integrity Level 3 (SIL 3)/IEC61508), EU CE marking, UL/C industrial control equipment standards, Russian GOST standards, etc.
2. Global Support Services
The global business and engineering center provides comprehensive services, including product technical support, installation supervision, debugging, and on-site acceptance testing.
Provide consulting and application engineering services, such as reliability and availability assessment, fault tree analysis, lifecycle cost analysis, etc.
We have spare parts inventory, provide maintenance services, training courses (for OEMs/integrators, engineers, technicians, etc.), and support remote diagnosis and problem solving.
4、 Product specification summary
Size and weight: Installed in a 19 inch rack, different components have varying weights, such as the main chassis (containing two power supplies and three processors) weighing approximately 16.8kg.
Environmental specifications: Operating temperature 0-60 ° C, storage temperature (with battery) -30 ° C to+75 ° C, relative humidity 5-95% (non condensing), with anti vibration, shock, and electrostatic discharge capabilities.
Power module: Supports 24Vdc and 120/240VAC inputs, with corresponding voltage range, power, and output characteristics.
System 800xA for Harmony/INFI 90 Systems aims to reduce the lifecycle costs and risks of automation systems through a system evolution strategy, while extending the investment return cycle of Harmony systems. The core idea is to improve operational efficiency, extend the lifespan of existing systems, and provide users with a clear and convenient evolution path through the release of new hardware and software.
Core advantages of evolving towards System 800xA
By evolving to System 800xA, the scope of automation can be expanded, including:
Personalized user workspace: With the help of Process Portal personalized workspace, optimize information and interface layout based on the preferences and needs of maintenance, engineering, management, and operations personnel, and shorten decision-making and action time.
Wide range of control functions: Added AC 800M control and I/O modules to meet all factory automation needs, suitable for various control and safety applications. Easy integration with the Harmony system is achieved through HPG800 point-to-point communication and the INFI90 function code library of AC 800M.
Equipment management: The equipment management function reduces the cost of on-site equipment during the design, implementation, and operation phases, thereby lowering lifecycle costs.
Asset optimization: By optimizing the repair workflow and early detection of asset performance issues, it significantly improves process uptime and reduces maintenance costs.
Batch management: Improve batch consistency, quality, traceability, and shorten cycle time, fully integrated with the Harmony system, and can reuse existing Harmony batch configurations.
Information management: Enhance the visibility of integrated information to facilitate efficient decision-making.
Automation Sentinel Software Management Plan
This plan provides extended support and value-added services for existing ABB system software investments, while establishing a flexible and economical evolution path that allows users to upgrade to the latest software versions at their own pace, providing the best overall ROI for past, present, and future ABB software investments.
Overview of System Architecture
The system adopts client/server network (TCP/IP) and control network (TCP/IP) architectures, and the main components include:
800xA Process Portal workspace (for operators, engineers, and maintenance personnel)
System Server
Control layer equipment (such as BRC, NIS/NPM, HPG, AC 800M HI (SIL3), AC 800M, etc.)
Communication networks (such as INFINET, Controlway, H-Net, XBUS, etc.)
Symphony Plus is a new generation of factory wide automation system developed by ABB for the power and water industries, aimed at maximizing factory efficiency and reliability through automation, integration, and optimization of the entire factory, providing a simple, scalable, seamless, and secure solution. Its core features include:
Simplicity: Easy to adapt to various factory configurations and application scenarios.
Scalability: The unique system architecture supports flexible and scalable configurations, covering everything from small serverless systems to large multi system and multi server architectures.
Seamless: It enables seamless integration of on-site equipment, process and turbine automation systems, electrical and SCADA systems, as well as business and maintenance systems.
Secure: Provides a secure and reliable control environment, with built-in security features to prevent unauthorized access to the control system.
Evolutionary: Supports system evolution without being eliminated.
SD Series Series Features
The SD Series is the latest member of the Symphony Plus family, a set of environmentally friendly control and I/O product combinations with the following advantages:
Fully Scalable: Suitable for the entire control field, providing factory wide automation regardless of application type, scale, or physical location.
Energy conservation and environmental protection: characterized by high energy efficiency.
Design advantage: Adopting a compact lead-free design, optimizing the footprint.
Strong adaptability: capable of operating within extreme operating ranges.
Technological maturity: Based on on-site validated technology.
Integration capability: Supports the integration of equipment and electrical systems.
Application area
Power industry: In the power industry, this series can provide support for power plants of various scales. From real-time monitoring and control of power generation equipment to automated management of power production processes, Symphony Plus SD Series can play an important role. For example, by precise control and monitoring of equipment such as generators and transformers, the stability and reliability of power supply can be ensured, and efficient operation of power production can be achieved.
Water industry: When applied to the water industry, it can achieve rational allocation of water resources and automated control of the treatment process. Whether it is monitoring and regulating water quality and pressure in urban water supply systems, or precise control of sewage purification processes in sewage treatment plants, it can improve water resource utilization efficiency and ensure stable operation of the water system with its advanced control and I/O functions.
Oil and gas industry: In the oil and gas industry, Symphony Plus SD Series helps achieve automation in oil and gas extraction, transportation, and processing processes. By connecting various intelligent on-site devices, real-time monitoring and control of parameters such as pressure and flow during the production process can be achieved, improving production safety and efficiency, reducing energy waste and environmental pollution.
Pharmaceutical industry: The pharmaceutical industry has extremely high requirements for precise control and quality monitoring of the production process. The Symphony Plus SD Series can meet these needs by strictly controlling key parameters such as temperature, humidity, and flow rate on pharmaceutical production lines, ensuring the stability and consistency of drug quality, while improving production efficiency through equipment integration and automated processes.
Pulp and paper industry: This series can achieve full process automation control from raw material processing to finished paper production in the pulp and paper industry. By precise control of production equipment, such as speed and pressure regulation of paper machines, as well as monitoring and adjusting various parameters during the production process, paper quality can be improved and production costs can be reduced.
ABB Ability ™ Symphony ® Plus S+Engineering is an integrated engineering tool designed for Symphony Plus control systems, aimed at addressing the automation component management needs brought about by the development of new technologies in the process industry. It provides a unified platform, integrates various automation processes, achieves unified data management, reduces repetitive operations, improves engineering efficiency, and is suitable for engineering design, configuration, debugging, and maintenance in all aspects from control system components to network architecture, advanced applications, etc.
This tool takes into account the current situation of intensified industry competition, shortened project delivery cycles, and dispersed engineering tasks. By optimizing workflows, supporting multi-user access, and allowing flexible modifications during the start-up and commissioning phases, it helps EPC contractors and end-users shorten project design cycles, commissioning start-up times, and reduce operation and maintenance costs.
Core Features
Fundamentals of Efficient Engineering Platform
Client/Server Technology: Supports multi-user operation in a network environment, with a configuration server that can simultaneously accept up to 10 client connections, enabling shared access to system configuration information and real-time factory data, ensuring a single source of data, reducing duplicate entries, simplifying database management, and automating configuration tasks. Supports import and export of multiple commonly used file formats.
Engineering and operation separation: Strictly distinguish between engineering and operating environments, support flexible offline engineering workflows, and during the debugging phase, multi-user and remote access capabilities are crucial for on-time delivery. Debugging can be carried out from loop level to controller basic functions.
Tool integration and automation: seamlessly integrate various tools, with powerful workflow automation and batch import/export functions, to improve engineering efficiency; Integrated version control and version comparison facilitate progress tracking and shorten debugging time; Support native language display and ensure data consistency throughout the project lifecycle through intelligent batch interfaces.
Compatibility and Reusability: Supports the reuse of control systems such as Symphony and INFI 90 OPEN from previous generations. Based on ABB’s experience in the power and water industries, we provide proven solutions to optimize factory design.
Intuitive engineering interface and management functions
User Management: Configure user information for Windows domains or workgroups, including subdomains or organizational units, through an intuitive interface. Create user profiles and roles, project access permissions, and support copying user and role lists from existing projects to achieve fine-grained authorization management and ensure system security.
Project Management: Integrated project management functions allow authorized users to create system, control, equipment, and electrical engineering projects with just one click, perform user allocation, project backup and recovery, database maintenance, and project upgrades.
Multi user engineering: supports multiple users to access engineering tasks simultaneously. Users can reserve the entire application or part of the content for exclusive use, enabling multiple people to collaborate simultaneously without interfering with each other. Various engineering tasks can be processed in parallel.
Audit Tracking: Provides complete audit tracking functionality, tracks and archives user operations and system configuration changes to a central database, and can also be archived in system history records to meet industry compliance requirements.
Intuitive Navigation: With the help of a graphical user interface, context menu, navigation window, and help function, intuitive navigation is achieved. It supports navigation from tags to relevant control logic documents in the engineering environment, seamlessly crossing navigation with the S+Operations human-machine interface, making it easy to quickly associate relevant information and third-party documents.
System topology and operation engineering
System topology engineering: Through the system topology builder, users can drag and drop visual construction control projects, support logical and detailed network development, automatically generate charts through wizards, automatically configure communication ports, share topology information to S+Operations, generate document reports, etc. It also supports multiple virtual factory network interfaces and multiple historical server configurations.
Operation Engineering: Integrating S+Operations human-machine interface for operation engineering configuration, achieving seamless data exchange with other components, supporting remote deployment configuration, providing parallel deployment, incremental deployment, and differential viewing functions, and efficiently controlling the deployment process; Suitable for traditional DCS and SCADA applications, supporting multiple common protocol configurations.
Multi system support: Multiple S+Operations human-machine interface systems can be configured from a single engineering node or project, facilitating centralized development, maintenance, and deployment of independent systems such as online production and offline testing.
Human Machine Interface Upgrade Support: Provides a seamless path for factories upgrading from the old Symphony human-machine interface platform to S+Operations, allowing for direct reuse of existing console databases and graphics, reducing upgrade workload and training requirements.
Integrated Control Engineering and Tools
Control engineering function: supports the development and maintenance of Symphony Plus control system configuration, including HR series, SD series, and SDe series controllers; Intuitively interact with system configuration information through the Explorer application, supporting the association of various documents; The data browser supports editing label data in Excel view and saving it to the configuration server. It also supports database filtering, batch import and export, and complex query replacement; Automation Architect visualizes control strategies, supports saving as macro reuse, and creates advanced control strategies through drag and drop function blocks.
Control Logic Templates (CLTs): Allow users to define and maintain reusable standard control policy templates as blueprints for control policy structures, support object exchange management, and enable quick definition of control logic documents. Template updates can retain instance specific configurations and spread to all associated instances.
Configurable Function Codes (CFCs): Engineers can use standard function codes to create specific control logic and save it as a package, which can be reused as standard function codes in control logic design. They support custom shape, input-output, parameter, and label mapping, and can choose to hide or display control strategy content.
Library management: The engineering library contains various components and functional blocks, etc. Reusable components are displayed through the object exchange window. Users can use preset function codes and symbols, or customize and save them to a separate folder. It supports copy and paste functions, making it easy to share objects between different projects, saving time and reducing errors.
Controller automatic conversion: Provides conversion tools that support upgrading from Symphony Harmony Rack controllers to the latest SDe series controllers, automatically updating and modifying the communication logic of affected controllers, preserving the original application logic without manual modification.
Batch engineering and equipment integration
Batch engineering: supports configuring signal lists, controlling hardware, I/O allocation, etc. through importing process points or I/O spreadsheets, supports processing multiple revised versions of signals and I/O lists, and avoids duplicate imports; Improve reengineering efficiency through a data editor based on custom queries, supporting entity filtering.
PROFIBUS/HART device integration: supports the use of PROFIBUS and HART protocols to configure, debug, and maintain intelligent field and electrical equipment. Data within the device can be accessed by controller function blocks and used for real-time control strategies; By using Field Device Tool (FDT) and Device Type Manager (DTM) technology to graphically configure and manage devices, it supports standard protocol configuration and can be integrated with Field Information Manager (FIM) to extend device management functionality.
Other protocols and device integration: Supports bidirectional real-time communication between SD and HR series controllers and Modbus TCP devices. Modbus points can be used to control application algorithms or human-machine interface interactions, providing gateway software for simplified configuration and other operations; Support communication between SD series controllers and devices using IEC 60870-5-104 and DNP 3.0 protocols, providing integrated configuration functions and templates; Support the control and monitoring of intelligent electronic devices through the IEC 61850 (Edition 2) protocol, interface configuration and maintenance from S+Engineering, and support horizontal and vertical communication.
Soft controller: Integrated with a soft controller suitable for SD and SDe controllers, it allows the execution of compiled functional code application logic on any S+Engineering node, facilitating testing and pre tuning of control applications before implementation, reducing the start-up and debugging costs of new projects, upgrades, or expansion projects.
Batch and sequential control function
Batch Data Manager (BDM): a tool that includes creating, editing, managing, and downloading batch, sequential, and user-defined feature code configurations. It supports the use of natural syntax control statements to create batch programs and download them to Batch Sequence (BSEQ) feature codes; Create unit programs and main formulas through graphical means, and download the complete formulas to the controller. New formulas can be marked as pending approval status, and relevant events are recorded in the log to ensure system integrity.
User defined Function Codes (UDFs): Support the use of natural syntax control statements to create and compile UDF programs, download them to specific function codes, and integrate them into control strategies without the need for recipes or operator input. The controller automatically executes upon startup, making it suitable for creating unique process function codes or sequential control applications for continuous execution.
Dynamic debugger: facilitates troubleshooting of Batch 90 and UDF programs, allows observation of process data, normal operation of pumps, valves, and control loops, single step execution of programs, setting breakpoints, and online editing of recipe parameters.
Evolution and Compatibility
S+Engineering supports users to retain factory specific intellectual property accumulated over many years, allowing for the reuse of any Symphony Harmony, INFI 90 ™ By configuring the controller (with appropriate modifications), the system can evolve and avoid obsolescence, ensuring user investment in the control system and ensuring continuous adaptation to business needs.
UNITROL ® 5000 is ABB Switzerland UNITOL ® The most powerful product in the series of excitation systems, the microprocessor based voltage regulator adopts the latest technology, and its research and development integrates over 40 years of semiconductor voltage regulator experience and more than 15 years of microprocessor technology application experience.
application area
Suitable for static excitation systems (SES) powered by 50Hz, 60Hz, or 16 ²/∝ Hz, with excitation currents ranging from 1000ADC to over 10000ADC.
An automatic voltage regulation system (AVR) suitable for excitation machines, with special functions and power supply frequencies ranging from 16 ²/∝ Hz to 400Hz.
Core features of the system
Highlights of the regulator
Additional regulator redundancy: Dual channel system equipped with backup current regulator.
Digital input processing: three-phase voltage measurement, three-phase current measurement, and digital processing of input values through signal processors.
Additional features: Implemented solely through software solutions, without the need for additional hardware.
Additional Input/Output: Utilizing ARCnet ® The device can be easily expanded to the required quantity, including both digital and analog types.
Event and error logs: with real-time timestamps, can be remotely queried.
Power section highlights
Power converter redundancy: It can support up to 8 parallel power converters, and its redundancy is completely independent of the regulator configuration.
Intelligent power conversion electronic devices: realize active current balancing between power converters, four quadrant operation (can generate negative excitation current), thyristor current monitoring, fan control and monitoring, fuses, power converter temperature and cooling airflow monitoring, and bridge current display functions.
system communication
Supports the most commonly used protocols for advanced control systems.
A second control panel can be installed in the control room, with a maximum distance of several hundred meters.
The remote diagnosis can be carried out by ABB service office through the Internet using PC software “AVRview”.
System configuration
UNITROL ® The 5000 adopts a modular “building block system” design, with over 80% of the system consisting of system components that have undergone type testing, ensuring higher quality and reducing delivery time.
Structural composition
The power section includes one or more thyristor power converters, excitation circuit breakers on the AC or DC side, excitation flicker circuits, and solid-state demagnetization systems with Crowbar.
High availability design
In addition to voltage regulators (AUTO) and excitation current regulators (MAN), independent current regulators (separate devices with independent power supply, measurement, and gate control circuits) can also be used to improve the availability of the excitation system. Due to the tracking control of all inactive regulators, a smooth switch to the backup regulator channel can be ensured in the event of a failure in the active regulator.
Internal Communication and Power Converter
The internal data exchange of the system is carried out through the serial ARCnet bus, and additional interfaces or control panels can be located and operated within thousands of meters through optical links.
Adopting DCS 500 series compact power converters or UNL 13300 and Verithyr power converters, the type and parallel quantity are determined based on the required excitation current, maximum voltage, and maximum duty cycle required by the customer. It also provides options such as natural or forced cooling, redundant fans, and the ability to maintain a power converter during system operation (with a 5-pole isolator).
Software functions
Standard software functions
Regulator functions: including voltage regulator with PID filter (automatic mode), excitation current regulator with PI filter (manual mode), reactive and/or active current droop compensation, multiple limiters, tracking control, power factor/reactive load control, manual limitation, and optional power system stabilizer (PSS), etc.
Protection and monitoring functions: covering multiple functions such as excitation flashing time, overcurrent protection, volt/hertz protection, demagnetization protection, rotor temperature monitoring, etc., and can be classified at three different action levels (fault display only, switching to the second channel or backup regulator, instantaneous excitation trip).
Control function: All standard excitation sequences and interlocks are based on software, using fixed pre programmed function blocks that users can expand through free programming function blocks.
Data recording: The event recorder (fault log) can record up to 100 events and alarms with real-time timestamps, and the data recorder (data log) can record up to 6 measurement signals in real time.
Processor monitoring: After the power is turned on, the processor starts self checking and also has an internal watchdog function to monitor the correct execution of the program.
Additional software features
Application Function Blocks: In addition to standard software functions, there are various general application function blocks, such as input/output extensions, specific monitoring functions, etc.
Power System Stabilizer (PSS): Provides three types of PSS2A, Adaptive Power System Stabilizer (APSS), and Multi Band Power System Stabilizer (MBPSS) that comply with IEEE standards.
Rotating diode monitoring: It can detect short circuits or open circuits in the rotating rectifier branch of a brushless system over a wide speed range.
Communication and software tools
System communication
Human computer interaction: The service panel SPA is connected to the system through RS485 interface, and the control panel LCP (optional) is connected through ARCnet bus, which can be used for local or remote control.
Advanced control system integration: Communication with advanced control systems is achieved through appropriate bus couplers (connected to DDCS interfaces via optical links), supporting standard protocols such as MODBUS, MODBUS+, Profibus, etc.
Remote diagnosis: With the optional remote diagnosis function, ABB service personnel can access the system through the Internet with the customer’s permission.
Debugging and maintenance software tools
GAD tool: also known as “Graphic Application Designer”, is a PC software tool used for application programming, with functions such as application programming, creating and modifying program documents.
CMT tool: a debugging and maintenance tool that can modify application programs, monitor system functions, change parameter values, and also has multiple window functions such as trend display, application display, parameter and signal display.
AVRView remote diagnosis
Additional CAP boards need to be inserted for each voltage regulator channel, which can be connected to a local area network (LAN) or telephone network through Ethernet cables to achieve functions such as operation status display, signal and parameter display, parameter change, etc., making remote diagnosis as convenient as on-site service.
System advantages
Modular structure design, easy to assemble and expand, can quickly meet different needs.
High redundancy design, including regulator redundancy and power converter redundancy, significantly improves the availability and reliability of the system.
Powerful communication capabilities, supporting multiple protocols and remote operation and diagnosis, facilitating system integration and maintenance.
Rich software functions and tools enable precise control, comprehensive monitoring, and efficient debugging and maintenance.
ABB UNITROL ® 6000 excitation system is a benchmark product in the field of power generation, which has set the industry standard in terms of progressiveness technology and operational availability. As a core component of many power generation units, it can help power plant owners and operators achieve reliable operation, stable performance, and fast transient response of assets, fully meeting the requirements of the power grid for power generation equipment.
The system has a wide range of applications, covering various power generation and industrial scenarios:
Generator field: Suitable for generators in steam, gas, nuclear, and hydroelectric power plants, including nuclear emergency diesel generators.
In the field of electric motors, they can be used in places such as steel mills, pulp and paper mills, chemical plants, natural gas production plants, refineries, etc.
System version and features
UNITROL ® The 6000 excitation system is divided into two versions, Medium and X-power, each with its own characteristics for different scale application scenarios.
（1） UNITOL ® 6000 Medium
This is a customizable solution designed specifically for small and medium-sized static excitation systems, setting a benchmark for flexibility, reliability, and connectivity in brushless and critical steam generator sets.
Configuration and selection:
Supports single/dual channel configuration, with additional backup channels available upon request.
Provide a variety of thyristor bridge module options to meet various on-site data and availability requirements.
Typical applications:
Hydroelectric power plants, pumped storage power plants, and combined cycle power plants.
A key steam power plant using brushless excitation, excitation current of 200A, and power supply frequency of 400Hz.
Engineering solution: It has functions such as online power conversion and electric braking.
Main parameters:
DC current range:<1800A.
Converter redundancy: single channel, dual channel, dual channel+backup.
Maximum number of converters: 3.
Converter types: D1, D2, D3, D4, D5.
Power System Stabilizer (PSS): 2B/2C.
Adaptive Power System Stabilizer (APSS): None.
PEC controller version: 2nd generation.
IEC 61850 standard: optional.
Excitation circuit breaker: AC or DC.
（2） UNITOL ® 6000 X-power
This version is designed specifically for large power generation units, setting new benchmarks in flexibility, reliability, and connectivity.
Configuration and selection:
Supports single/dual channel control configuration and can be equipped with backup controllers according to requirements.
Provide a variety of thyristor bridge module options to meet various on-site data and availability requirements.
Typical applications:
Nuclear power plants with excitation current>10000A.
An underground hydroelectric power plant with an excitation current of 4500A and equipped with a redundant air-water heat exchange system.
A gas turbine power plant (MEGATROL package) equipped with a 15MW static frequency converter for turbine start-up and excitation current of 6000A.
The power part is located in a coal-fired power plant with an IP54 protection level container, automatic voltage regulator cabinet spacing>150m, and excitation current of 3500A.
A hydroelectric power plant equipped with two DC excitation circuit breakers (one for DC backup excitation) and an excitation current of 4000A.
Main parameters:
DC current range: 1800A<X<12000A.
Converter redundancy: single channel, dual channel, n-x redundancy.
Maximum number of converters: 8.
Equipped with H-shaped configuration.
Converter types: D5, UNL13300, UNL14300.
Power System Stabilizer (PSS): 2B/2C/4B.
Adaptive Power System Stabilizer (APSS): Yes.
PEC controller version: 3rd generation.
IEC 61850 standard: standard configuration.
Excitation circuit breaker: AC (4000A) or DC.
Control function
UNITROL ® The control function of the 6000 excitation system is comprehensive and powerful, covering multiple aspects such as closed-loop control, protection monitoring, data recording, and power system stability, ensuring the safe and stable operation of the generator.
（1） Closed-loop control
In automatic mode, equipped with a voltage regulator with PID filter.
In manual mode, equipped with an excitation current regulator with PI filter.
Capable of compensating for reactive and/or active current sag.
Multiple limiter circuits are installed to ensure the safe operation of the generator, including maximum and minimum excitation current limits, maximum stator current limit depending on the temperature of the motor cooling medium, P/Q under excitation limit, volt/hertz limit, etc.
The manual restriction function can keep the generator within a safe range even in manual control mode.
Support power factor/reactive load control.
（2） Protection and monitoring functions
The monitoring and protection functions can be freely configured at three action levels: only issuing alarm signals, switching to redundant circuits, and instantaneous excitation tripping to protect assets.
The main functions include overcurrent protection (instantaneous/inverse time limit), volt/hertz protection, demagnetization protection, rotor temperature monitoring, thyristor conduction monitoring, actual value monitoring, etc.
（3） Data and event recording
The internal event recorder can process and store up to 2000 events, each with a real-time timestamp.
The data logger includes a pre configured section that can record a large number of measurement values and internal signals. It will automatically trigger when a fault occurs, facilitating efficient troubleshooting and continuous improvement to maximize availability.
It also provides a freely configurable high-speed recorder for compliance testing or network event analysis.
（4） System time synchronization
The system clock of all controllers can be synchronized with the time source through the Simple Network Time Protocol (SNTP), with an accuracy of up to 1ms, making it easy to efficiently troubleshoot and keeping the excitation event log consistent with other logs in the power plant, shortening the time for the unit to reconnect to the grid.
（5） Power System Stabilizer (PSS)
The PSS function suppresses power oscillations and improves the stability of the generator and transmission system through excitation. UNITROL ® 6000 optional PSS types include:
Compliant with IEEE Standard 421.5-2016 PSS 2A/2B/2C.
Compliant with IEEE Standard 421.5-2016 PSS 4B/4C.
The Adaptive PSS (APSS) developed by ABB Switzerland can optimize PSS settings based on current network conditions, maximize availability, and avoid tripping due to insufficient damping in weak power grids.
Hardware and software
（1） Hardware components
The system is built on the AC 800PEC high-performance processor family, which is an extension of the ABB 800xA control platform developed specifically to meet the fast control requirements of power electronics.
Control section:
The AC 800PEC control system has extremely high processing speed, providing fast analog and digital process I/O with a typical cycle time of 400 µ s.
Implement fast closed-loop control and conventional process logic in a single controller.
The typical cycle time for low-speed I/O is 10ms.
Ultra fast programmable logic for converter pulse control and optical communication, with a cycle time as low as 25ns.
Power converter:
The power converter for each channel is selected based on the system requirements for maximum excitation current and voltage.
Up to three redundant channels can be equipped, and online maintenance options (optional) are provided to meet strict availability requirements.
ABB has developed a series of thyristor power converters specifically designed for direct (static) and indirect excitation systems, such as D1 to D5, UNL13300, and UNL14300.
The main features of D1 to D5 power converters are: single-phase or three-phase AC power supply voltage up to 1080V; rated power supply frequency 50 to 480Hz (16 ⅔ Hz can be provided according to requirements); The cooling fan has low noise, ≤ 70dB (A); Compact design, fully integrated converter and control, with integrated service panel.
The main features of UNL14300 power converter are: AC power supply voltage up to 1500V; insulation test voltage up to 7.5kV; low cooling fan noise, ≤ 70dB (A); Capable of active current balance control; Optional redundant fans (replaceable during operation) and “pull-out” design (convenient for safe online maintenance and functional testing).
（2） Software functions
The software includes all the necessary regulation, protection, and monitoring functions to ensure the safe operation of the generator as standard features. To meet the specific needs of any application, the software can be easily configured and adjusted.
Simulators and compliance with power grid standards
（1） SMTS-RT 6000 Simulator
SMTS-RT 6000 is a “hardware in the loop” simulator that can simulate generators/motors, their turbines/loads, and the power grid. The simulator is connected to the excitation system for closed-loop testing to analyze its static and transient behavior.
Function: Reduce motor testing time, save costs, and serve as an ideal training tool for maintenance and operation personnel.
Advantage: By using simulators and UNITOL ® Pre adjusting the control parameter set of the 6000 control device can further shorten the debugging time.
（2） Compliance with power grid regulations
UNITROL ® The control function of 6000 can support any grid specification. The extensive testing capabilities and powerful data logger of the excitation control terminal (ECT) are used to test, adjust, and demonstrate the performance of control, stabilizer, and limiter functions.
Testing tool: The built-in white noise generator can quickly and accurately analyze the system frequency response, and perform compliance testing in the least amount of time.
Data storage: Data records are stored in ECT’s dedicated memory, which can be easily copied and integrated into electronic documents.
Joint testing: When used in conjunction with SMTS-RT 6000, it can simulate the most critical power plant or grid conditions that are typically not safe to test in actual systems.
Communication function
UNITROL ® The communication function of the 6000 excitation system ensures convenient human-machine interaction and efficient integration with the power plant control system.
（1） Excitation Control Terminal (ECT)
ECT is a user-friendly human-machine interface that supports system operation, monitoring, and maintenance. It is a high-performance industrial grade touchscreen PC that operates independently of the system controller.
Function: Can record events and system data for a long time.
Display: LCD touch screens provide operators with multiple optional screens to display the actual status of the system in both graphical and numerical form.
Compatibility: Running on Windows 10 system, it can also be installed on any PC for debugging.
（2） Integration with power plant control system
Supports Ethernet and fieldbus protocols (Modbus RTU, Modbus TCP, Profibus DP-V0) as well as IEC 61850 as the primary choice for communication with power plant control systems. The emergency control signal can be directly hard wired to the control board.
（3） Remote service
UNITROL ® 6000 supports remote access through ABB RAP platform or customer internal tools. In this way, the local maintenance team can receive necessary support from ABB service experts, which helps to reduce maintenance and service related costs.
Service and Support
ABB for UNITOL ® The 6000 excitation system provides comprehensive services and support, covering installation, commissioning, training, lifecycle management, and other aspects to ensure the reliable operation of the system throughout its entire lifecycle.
（1） Installation and debugging
ABB engineers possess professional competence, extensive experience, and multilingual abilities to ensure satisfactory installation and commissioning of the system.
（2） Training services
ABB University offers services for UNITOL ® The standard and customized training courses for the 6000 excitation system have two options: virtual and on-site training. For a detailed training plan, please visit www.abb.com/abbuniversity.
（3） Lifecycle Management
ABB’s excitation system lifecycle management model helps customers extend and maximize the lifecycle of their assets at the lowest cost. Based on the lifecycle stages of the product, service experts will recommend necessary actions and proactively contact customers to inform them of all maintenance, service, and upgrade requirements.
Excitation care plan: comprehensively covering all maintenance needs of customers.
Example of lifecycle services: providing technical support for optimizing reliability, remote services, maintenance and repair, expansion, upgrading, and transformation.
Lifecycle Stage Services:
Active period: The product is available for purchase and provides a complete lifecycle service.
Classic period: The product can be used for power plant expansion, providing spare parts, maintenance, and repair services.
Limited term: As long as materials are available, spare parts, maintenance, and repair services are provided, but lifecycle services are limited.
Elimination period: Due to technical or cost reasons, ABB cannot guarantee the availability of lifecycle services, but will provide technical solutions for asset transformation or upgrading.
