Overview

Controller Introduction

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.

Product overview

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.

Product overview

Product positioning: MCU is an electronic motor control and protection device with fieldbus interface, mainly used for the protection, control, and monitoring of three-phase/single-phase AC motors and starting equipment. It is divided into MCU1 (basic type) and MCU2 (high-end type).

Mechanical structure: It consists of a base plate, a main unit, a current measurement unit, and a voltage unit (optional only for MCU2). The outer shell is made of polycarbonate containing 10% glass fiber, with a fire rating of UL 94 V-0, halogen-free, and a color of RAL 7012.

Model specifications: MCU2 has two current ranges of 0.1-3.2A and 2.0-63A, supporting 380-690VAC voltage and 24VDC/230VAC auxiliary power supply.

Interface function

Power interface: Supports 24VDC (MCU1 and MCU2) and 230VAC (MCU2 only) auxiliary power supplies, with power consumption of 4.7W and 8.2W (maximum), respectively.

Digital input: MCU1 has 12 channels, MCU2 has 17 channels, with a type of 10mA/24VDC, and can be configured as normally open or normally closed.

LED output: 9 channels, used to indicate motor operation status, alarms, and trips, requiring external current limiting resistors.

Contactor control output: MCU1 has 2 channels and MCU2 has 3 channels, equipped with a watchdog relay to prevent abnormal operation of the contactor in case of microprocessor failure.

Communication interface: LonTalk is used ®  Protocol, FTT-10A transceiver, supporting LONWorks fieldbus, can achieve parameter configuration and status monitoring through network variables.

Function characteristics

Starter type: Supports multiple starter types, including NR-DOL (unidirectional direct start), REV-DOL (bidirectional direct start), NR-S/D (star delta start), REV-2N (dual speed non reverse), etc. Each type corresponds to different contactor control logic and parameter settings.

Protection function:

Thermal Overload Protection (TOL): Simulate motor thermal capacity, calculate thermal accumulation based on current, and support both standard and EEx e models.

Phase loss protection: detects phase current imbalance to prevent motor phase loss operation.

Underload/no-load protection: detects motor load abnormalities based on current and power factor.

Locked rotor protection: monitors the overcurrent status during motor start-up or operation.

Ground fault protection: Detecting ground faults through residual current transformers or phase current vector sum.

Monitoring and Diagnosis:

Contactor watchdog: monitors the status of the contactor and cuts off the control voltage in case of abnormalities.

Feedback supervision: Verify the consistency between the contactor action and the control command.

Running time counting: records the number of motor running hours and the number of contactor actions, used for maintenance reminders.

Fault record: stores alarm and event information, with timestamps, supports network queries.

Communications and Networking

Protocol and Interface: Using LONWorks fieldbus, supporting SNVT (Standard Network Variable Type), it can communicate with other devices in the INSUM system (such as MMI, gateway).

Network configuration: Supports service/flashing installation mode, achieves device recognition and network connection establishment through testing location input.

Time synchronization: Receive system clock synchronization messages to ensure the accuracy of event timestamps.

​Parameter setting and maintenance

Parameterization process: To download parameters through INSUM Operator Station or MMI, the MCU needs to be set to offline mode and support partial or complete parameter file transfer.

Fault code: Display a fault code when parameter settings are incorrect, indicating specific parameter issues (such as out of range, invalid values, etc.).

Technical data: Operating temperature -5 ℃ to+55 ℃, storage temperature -25 ℃ to+85 ℃, protection level IP20, compliant with IEC 60947 and other standards, passed EMC compatibility testing.

ABB INSUM ®  Advantages of MCU

Strong communication and integration capabilities: Supports LONWorks fieldbus, can communicate with multiple devices, and achieve system integration. If combined with other ABB devices such as MMI and gateway, it can build an efficient motor management network in complex industrial environments. In the automated production lines of large factories, seamless integration with the upper control system enables centralized monitoring and management of a large number of motors, which is difficult for many other brands to achieve. In contrast, some other brands of motor control units support fewer types of communication protocols, making it difficult to integrate with devices from different manufacturers, which limits the scalability and compatibility of the system.

Comprehensive and precise protection functions: equipped with multiple protection functions such as thermal overload, phase loss, underload/no-load, locked rotor, grounding fault, etc. Its thermal overload protection simulates the motor’s thermal capacity and can accurately monitor the motor’s operating status, effectively avoiding damage to the motor due to abnormal working conditions. Taking the manufacturing industry as an example, in the application scenario of frequent starting and stopping of motors, timely response and protection of motors can be achieved, reducing equipment failure rates and ensuring production continuity. The protection functions of some other brands may not be complete enough, or there may be a lack of protection accuracy, which cannot be compared to ABB INSUM ®  MCU provides comprehensive and precise protection for motors.

High product stability: The hardware design adopts a polycarbonate shell containing 10% glass fiber, with a fire rating of UL 94 V-0, halogen-free, and good mechanical stability and electrical insulation performance. The working temperature range is -5 ℃ to+55 ℃, which can adapt to various industrial environments. In some high temperature, high humidity, or corrosive industrial environments, ABB INSUM ®  MCU can operate stably, while some other brands of motor control units may not be able to adapt to such harsh environments, resulting in decreased stability and affecting the normal operation of the motor.

Rich product selection: ABB offers different models such as MCU1 and MCU2, suitable for different motor powers and application scenarios. MCU2 has two current ranges to choose from, 0.1-3.2A and 2.0-63A, to meet diverse motor control needs. In contrast, some other brands’ product lines may not be rich enough to meet the specific needs of different users.

Product Core Value

REF 542plus, as an intelligent electronic device for medium voltage distribution systems, integrates protection, measurement, control, monitoring, and power quality analysis functions. The configuration tool enables device parameter customization, functional logic design, and system integration through a graphical interface and programmable logic, ensuring safe and efficient operation of equipment in scenarios such as substations and industrial automation.

Installation Guide for Configuration Tools

2.1 System Hardware Requirements

Processor: Intel Pentium series and above

Memory: At least 128MB RAM (recommended 256MB or more)

Storage: 50MB of available hard disk space (recommended to reserve over 100MB)

Peripherals: CD-ROM/VD-ROM drive, mouse

Interface: At least 1 RS-232 serial port (for serial connection), 1 Ethernet interface (for TCP/IP connection)

2.2 Software Environment Requirements

Operating systems: Windows NT 4.0 SP6, Windows 2000, Windows XP, Windows Vista

Supporting components: NET Framework 2.0 and above (some features depend on)

Language support: English, German, Italian, Czech, Slovak (default English)

2.3 Detailed explanation of installation process

Start the installation program: Insert the installation media, run setup. exe, and automatically detect the system language (such as English, German, etc.).

Select installation type:

Full installation: Includes all components (configuration tools, sample files, help documentation), occupying approximately 80MB of space.

Custom installation: Optional installation of components (such as installing only core tools or language packs).

Configuration options:

Select the installation path (default C: \ Program Files \ ABB \ REF 542plus).

Check the required language pack (such as English, German).

Optional installation of sample project files (for easy learning and use).

Installation completed: The program automatically creates desktop shortcuts and start menu folders, and some systems require a restart to take effect.

2.4 Unloading and Troubleshooting

Uninstalling steps: Use Control Panel → Add/Remove Programs → REF 542plus Configuration Tool to uninstall.

Common problems:

Installation failed: Check disk space and compatibility with the operating system, close antivirus software and try again.

Start error: Confirm NET Framework components are complete, reinstall the runtime environment.

Core operating interface of configuration tool

3.1 Main interface layout

Menu bar: Includes seven menus: File, Connect, View, Configure, Utilities, Options, and Help.

Toolbar: Shortcut buttons include New, Open, Save, Connect Device, Download Configuration, etc.

Project workspace: Display the current project structure, including hardware configuration, FUPLA diagrams, HMI settings, etc.

Status bar: displays information such as connection status, current operation progress, error prompts, etc.

3.2 Project Management Process

New Project:

Click on File ->New to automatically generate the new.ref project file.

Fill in project information (project name, feeder name, customer information, etc.).

Open project:

Support opening. ref format project files, allowing browsing of historical project records (last 4).

Product positioning and functional overview

Product positioning: PP886 is a standard touch screen in the Panel 800 series, belonging to the Compact Product Suite hardware product. It focuses on usability, high-performance graphic display, and multi protocol connectivity, suitable for human-machine interaction (HMI) needs in various industrial automation scenarios.

Core functions

Equipped with a 15.4-inch high-resolution TFT/LED display screen, supporting resistive touch, integrating rich templates and libraries, efficiently developing projects in Windows environment through Panel Builder tool, and supporting application simulation.

Core Features and Advantages

Usability: Provides comprehensive and integrated templates and libraries, Panel Builder tool is based on Windows environment, supports multiple languages, and facilitates rapid engineering development.

Graphic display: Using vector graphics technology, the TFT/LED display screen has a resolution of 1280 × 800 (16:10), a brightness of 450 cd/m ², supports brightness adjustment, and an icon based interface for easy navigation and control.

Durability: The shell is made of powder coated aluminum alloy, with a front panel protection level of IP65 (NEMA 4X/12), suitable for working temperatures ranging from -10 ℃ to+60 ℃ and non condensing humidity environments of 5% -85%. It is resistant to vibration of 1G and impact of 15G.

Openness: Based on The open architecture of the. NET framework supports multi brand controller connections, with 2 10/100 Base-T Ethernet ports, 2 USB 2.0 interfaces, and multiple serial ports (RS232, RS422/485, etc.) to meet local communication, expansion, and remote access needs.

Simulation function: The application can be directly simulated and run through Panel Builder 800 to reduce debugging risks.

Technical Parameter

Hardware configuration: Equipped with a 1 GHz ARM9 processor, 1 GB main memory, 2 GB SSD (1.5 GB can be used as application storage), and built-in real-time clock.

Power supply and power consumption: 24 V DC power supply (compatible with 18-32 VDC), power consumption of 31.2 W.

Communication interface: 2 Ethernet ports, 2 USB 2.0 ports, 1 RS232, 1 RS422/485 serial port (an additional RS485 is required when COM2 is RS485).

Certification and Compliance

Safety certification: Complies with CE, FCC, KCC, UL 61010-2-201 standards, certified by classification societies (DNV, KR, GL, etc.), meets RoHS (2011/65/EU) and WEEE (2012/19/EU) directives.

Physical specifications

Size and weight: The external dimensions are 410 × 286 × 61 mm, the cutting size is 394 × 270 mm, the installation depth is 53 mm (including a gap of 153 mm), the weight is 3.85 kg, and it supports panel installation and VESA 75 × 75 standard installation.

Environmental adaptability and certification

Protection level: front panel IP65 (NEMA 4X/12), rear shell IP20, suitable for humid and dusty environments.

Temperature range: working temperature -10 ℃~+60 ℃, storage temperature -20 ℃~+70 ℃, humidity 5%~85% (non condensing).

Mechanical performance: Resistant to 1 G of random vibration and 15 G of impact, meeting the stability requirements of industrial machinery.

Compliance certification: CE, FCC, UL 61010-2-201, classification society certification (DNV, KR, GL, etc.), compliant with RoHS and WEEE directives.

​Software and Development Support

Engineering tool: Developed using Panel Builder 800, compatible with Windows environment, supports multilingual programming and template library reuse.

Simulation function: It can directly simulate applications in Panel Builder, reducing on-site debugging risks.

Open Architecture: Based on NET framework, supporting multi brand controller connections (such as PLC, drivers), compatible with industrial protocols such as OPC UA, Modbus, etc.

Typical application scenarios

Manufacturing production line: Real time monitoring of equipment status, integrated MES system data, supporting formula management and alarm prompts.

Energy and Power: Substation human-machine interface, displaying grid parameters and fault diagnosis, compatible with IEC 61850 protocol.

Process control: Visualization of chemical/pharmaceutical industry processes, supporting PID regulation and trend curve display.

Ship and Ocean Engineering: Compliant with DNV certification, suitable for cabin monitoring and power system control.

Selection comparison and adaptation suggestions

PP886:15.4 “, 1280 × 800, centralized monitoring of medium and large equipment, supporting wide temperature and high protection, suitable for complex environments

PP883:12.1 “, 1280 × 800, local operation for small and medium-sized devices, more compact, lower power consumption

PP895:19 “, 1280 × 1024 large control center panoramic display, higher resolution and brightness

Product positioning and core architecture

AC500 V3 is the third-generation programmable logic controller launched by ABB. As a technological iteration product of the AC500 series, its core positioning is to bridge industrial automation and the Internet of Things (IoT). This series extends the original AC500 V2 platform with four new CPUs (PM5630/5650/5670/5675), achieving comprehensive upgrades in performance, connectivity, and network security while maintaining hardware compatibility. Its 

Architectural features are as follows

Processor and Memory: Adopting a new generation processor, the computing speed has been significantly improved. Taking PM5670-2ETH as an example, the bit operation cycle is only 0.002 μ s, which is 10 times higher than the V2 platform. It is equipped with 160MB program memory and 8GB flash drive (PM5675), supporting complex algorithms and data storage.

Dual Ethernet architecture: Two independent Ethernet interfaces onboard, configurable as switches or independent ports, supporting IEEE 802.3 standard, integrated with web servers and multiple industrial protocol stacks, without the need for additional communication modules.

Core technical characteristics

1. Performance and computational capability

Instruction efficiency: Supports bit/word/floating-point operations, with the floating-point operation cycle shortened from 0.120 μ s in V2 to 0.002 μ s (PM5670), meeting the requirements of high-speed closed-loop control.

Memory allocation: Programs, data, and web memory are independently partitioned, supporting dynamic allocation. It can run up to 200+task instances simultaneously and is suitable for multi axis motion control and complex logical operation scenarios.

2. Industrial communication and protocol support

Fieldbus integration:

Control layer: Built in CANopen master station, Ethernet IP (under development) Modbus TCP/RTU， Supports PROFINET and EtherCAT (requires module expansion).

Management: OPC UA Server supports data access and alarm services, MQTT client connects to cloud platform through TLS encryption to achieve device data cloud (such as ABB Ability) ™ Platform).

Special fields: KNX (Building Automation), BACnet (Intelligent Buildings), IEC 61850 (Substation Communication) and other protocols are activated through license to adapt to cross industry requirements.

Network topology flexibility:

Dual ports can be configured as “redundant ring network” or “three-layer routing”, for example, port 1 connects to the factory intranet (OPC UA), and port 2 connects to the Internet (MQTT), supporting port mirroring and traffic monitoring.

3. Network security design

Firmware protection: Hardware security chips implement firmware digital signatures to prevent malicious tampering; The transmission of engineering files adopts AES encryption and is integrated with ABB Ability ™  Two way certificate authentication is required for Automation Builder.

Communication encryption: HTTPS/FTPS is used for file transfer, OPC UA supports role-based access control (RBAC), MQTT messages are encrypted through TLS 1.2 to block man in the middle attacks.

Special Version: AC500-XC V3 (Extreme Environment Type)

Designed for harsh industrial scenarios, with multiple environmental adaptability certifications:

Climate adaptability:

Temperature: -40 ° C to+70 ° C for continuous operation, meeting the needs of cold storage and metallurgical high-temperature areas.

Humidity: 100% humidity+condensation protection, meets G3 level corrosion standards, suitable for offshore platforms and chemical workshops.

Mechanical reliability:

Vibration: 4g root mean square random vibration (500Hz), 2g sine vibration, tested according to IEC 60068-2-6, suitable for construction machinery.

Altitude: 4000 meters (620hPa pressure), supporting the application of power stations in high-altitude areas.

Engineering Tools and Development Process

​ABB Ability ™  Automation Builder

Integrated development: integrating PLC programming (IEC 61131-3), safety logic (Safety PLC), HMI configuration, driver debugging, supporting cross device collaborative development.

Simulation and testing: Offline simulation function (under development) can simulate CPU operation, verify program logic without hardware, and shorten debugging cycle.

Version control: Built in Subversion client, supports collaborative development among multiple people, automatically records code change history, and reduces project risks.

Product overview

Positioning and Function: SyncHROTACT ®  5 is the fifth generation synchronous equipment produced by ABB Switzerland, used for automatic synchronization of generators and power lines, as well as parallel connection of synchronous lines. It is designed for fully automatic operation of dual channel or single channel systems and can be used as a manual parallel monitoring element or an independent fully automatic synchronization unit to ensure safe and reliable synchronization.

Application scenarios: including automatic synchronization and parallel connection of generators and power lines, automatic parallel connection of synchronous and asynchronous lines and busbars, automatic or manual parallel monitoring (synchronous inspection) of power lines, generators, and voltage free lines (no-load busbars).

Security and usability design

Safety design:

Dual channel system: adopting a compact dual channel system, including two hardware and software independent devices connected in series, the first channel performs automatic synchronization, and the other is independently monitored, designed by different engineers and using different microprocessors to prevent systematic failures.

Manual synchronous monitoring: Manual synchronization is ensured by connecting the monitoring device (synchronous check) in series with the manual parallel switch to ensure safety.

Usability Design: Provides multiple redundant configurations, such as a dual channel main synchronization system with manual parallel switch bypass synchronization system and synchronization check parallel, or two automatic dual channel systems, to achieve the highest safety and maximum availability. The dual channel, automatic channel, and single monitoring channel systems are each housed in one enclosure, while the redundant dual channel system is housed in one enclosure with interconnecting wiring.

Function and Type

Special function: It can store up to seven sets of parameters from different parallel points, with freely configurable digital inputs and outputs. It supports rated frequencies of 50Hz, 60Hz, and 16 2/3Hz and can replace the old SYNC HROTACT system or other manufacturers’ synchronization units.

Reduce engineering costs: The output contacts can carry higher currents, reduce the need for auxiliary relays, isolate all I/O, eliminate the need for a separate power unit, have prefabricated units to choose from, and reduce wiring through a bus control system.

Quick debugging: Use the “SynView” software to recommend parameter values and display ranges. The system includes an intelligent program that can recommend parameters based on generators, circuit breakers, etc., or control debugging through the front panel.

Easy to integrate: It can be easily integrated into modern bus control systems, with communication interfaces supporting MODBUS RTU, Profibus DP, or LON Bus protocols, while maintaining independent protection modules.

Remote maintenance: provide a remote maintenance interface, and communicate with TCP/IP protocol through the Ethernet interface after obtaining the IP address. The PC software “SynView” can directly access the device through the Internet.

Equipment types: including SYN 5100 for simple synchronization check, SYN 5200 for advanced functionality, SYN 5201 for single channel automatic synchronization with frequency and voltage regulation, SYN 5202 for dual channel automatic synchronization system with series synchronization check, SYN 5302 for redundant automatic dual channel synchronization system, and SYN 5500 for auxiliary equipment connecting multiple parallel points.

SynView tool

Function: Used for simple and fast debugging of SYNC HROTACT 5 devices, supports German, English or French, runs on Microsoft Windows 95, 98, 2000 or NT systems, and has four main functions: parameter setting, actual value display, transient recorder function, event and error recording, etc.

Technical Parameter

Power supply and power consumption: The nominal voltage range includes 24/48V DC, 100-125V AC/DC, 220-250V, and the allowable voltage range is DC 0.75-1.25 × Un. The maximum power consumption (SYN 5302) is 25W/35VA.

Measurement input: nominal voltage range 50-130V AC, allowable voltage range 0-1.3 × Un, nominal frequency 16 2/3/50/60Hz.

Digital input and relay: The digital input current consumes DC 6-8mA, the maximum switching voltage of parallel relays is 250V AC/DC, and the maximum switching current is continuously 5A. The maximum switching voltage of adjustment, command, and signal relays is 250V AC/DC, and the maximum switching current is continuously 1.5A.

Measurement range: Voltage 0-1.3 × Un, angle matching from α -179 to+180 degrees, frequency 10-100Hz, slip s0-50%, acceleration ds/dt0-10%/s, parallel time tON0-1s.

Product overview

Positioning and Function: The SUE 3000 is a high-speed switching device mainly used to automatically switch to a backup power source in case of power interruption or voltage drop to ensure continuous power supply for users, protect auxiliary processes from expensive downtime, and also support manual start-up switching to simplify device operation.

Application scenarios: Suitable for occasions sensitive to power outages, such as auxiliary facilities in power plants (steam, gas turbines, combined cycles, nuclear power plants), environmental protection technology facilities (flue gas purification, waste incineration), continuous industrial processes (chemical plants, highly automated industrial facilities, fiber manufacturing, petrochemical processes), etc.

Switchgear configuration

Dual circuit breaker configuration (variant 1): commonly used in auxiliary facilities of thermal power plants. Under normal circumstances, one of the two power sources is supplied by the busbar, and the other is disconnected. It is not allowed for both to supply power simultaneously. In case of a fault, it switches to the second power source. The device is designed symmetrically and can be started and switched from either side.

Two line, one bus configuration (variants 2 and 4): The load is divided into two sections of busbars due to redundancy, and the contact circuit breaker is usually disconnected. Both lines are running. When one line fails, it switches from the fault line circuit breaker to the contact circuit breaker, and can be manually switched back after the fault line is restored.

Three line two option configuration (variant 3): Used for situations where three lines are needed and two options are available, only switching between the pre selected two lines, with fixed input signal connections, and pre selection logic can be combined with additional logic conditions.

Triple line selection configuration (variant 5): When the triple line is available, switching operations can be performed between any two lines. The input signal is hard wired, and the selection logic can be associated with other logic conditions.

Core functions

Working mode: Equipped with fast processing logic and high-precision analog signal processing, it permanently compares the bus voltage with the backup power supply voltage, generates synchronization standards such as phase angle, frequency difference, backup power supply voltage, and bus voltage, ensuring the shortest switching time during startup and reducing transient effects on users.

Permanent determination of network conditions: synchronous standard online calculation, with a determined switching mode at startup, can be started immediately to increase the probability of rapid switching, and the device is only ready when the two circuit breakers are in different states and in their working positions.

Switch Mode

Quick switching: Both the main power supply and the backup power supply are executed within the specified limits during startup, with two types of control: simultaneous control and sequential control. The no current switching time controlled simultaneously depends on the time difference between circuit breaker operation. Sequential control requires waiting for the disconnection indication of the incoming circuit breaker before issuing the command to close the backup circuit breaker.

First phase coincidence switching: When there is no synchronization condition during startup, disconnect the original incoming line first, determine the first phase coincidence point and the time when the closing command is issued through predictive calculation, and connect the backup power supply when the voltage difference is minimized. Careful engineering design and debugging are required.

Residual voltage switching: Used when the first phase coincidence switching is not feasible. When the bus voltage drops to the preset allowable value, connect the backup power supply without evaluating the angle or frequency difference. Transient effects are controllable.

Timed switching: Quick switching is executed when it is not completed within the preset time, which belongs to the safe stage and generally does not occur under normal operating parameters.

Special support functions: including decoupling (automatically reversing to avoid illegal network coupling when mechanical faults are detected), circuit breaker tripping switching (monitoring the position of the circuit breaker and performing switching when disconnected for no reason), and non independent network switching mode (using a programmed time frame to determine if the backup power source is ready).

Configuration and Parameters

Configuration method: LED indicators, single line diagrams, control schemes, automation sequences, etc. are configured through software functional modules. FUPLA programming language is used to provide multiple logic functional modules, and parameters can be modified through HMI control units or connected to configuration computers.

Variable functional parameters: including frequency difference for quick switching, network angle, bus voltage value, backup power supply voltage value, maximum frequency gradient for initial phase coincidence switching, bus residual voltage value for residual voltage switching, original power undervoltage value and delay time for undervoltage startup, timed closing command time, circuit breaker command delay time, etc.

Fault recording: Equipped with a fault recording module, it can record analog and binary data. The analog signal sampling rate is 1.2kHz, and the recording time includes pre trigger and post trigger times. It is stored in a circular buffer and can be exported for analysis.

Operation interface

LCD display: Backlit LCD display, with a single line diagram on the left and measurement values, menus, protection signals, and event records on the right. It can display up to eight switch device icons and other motor, transformer, and other icons.

Status indication: including operating status (green LED “Ready”), communication status (green LED, turns red in case of fault), alarm indication (red LED), interlock status (unused).

Product positioning and system architecture

REF542plus is a new generation of intelligent electronic device (IED) for medium voltage distribution systems launched by ABB, designed specifically for scenarios such as gas insulated switchgear (GIS) and air insulated switchgear (AIS), integrating protection, measurement, control, monitoring, and power quality analysis functions. Its core architecture adopts a three processor separation design:

DSP (Digital Signal Processor): Independently executes protection algorithms and high-precision measurements to ensure that fault response is not affected by control tasks.

MC (microcontroller): handles switch control, logic interlocking, and automation sequences, supporting FUPLA graphical programming.

CP (Communication Processor): Supports protocols such as IEC 61850, Modbus, DNP3, etc., to achieve high-speed data exchange with substation automation systems.

Hardware is divided into central unit and HMI control unit:

Central unit: including power module, I/O interface (analog/binary) and optional communication board, supporting standard chassis (2I/O board+1 communication board) or wide chassis (3I/O board+1 analog output board).

HMI control unit: independently installed on the switchgear door panel, equipped with backlit LCD, 8 operation buttons, 3 sets of LED light columns, and electronic key interface, supporting RS485 communication with the central unit.

Core Function Analysis

1. Protection function system

REF542plus supports over 20 protection algorithms, covering all fault types in the entire distribution network scenario:

Overcurrent protection: three-stage non directional overcurrent (50/51), two-stage directional overcurrent (67), supporting ANSI/IEC inverse time characteristics (Normal/Very/Extreme inverse), starting accuracy ± 1.5%, instantaneous response time<16ms.

Ground fault protection: Directional grounding (67N) is based on the Io UO phase criterion, while non directional grounding (51N) supports admittance type protection (Yo criterion), suitable for ungrounded/resonant grounding systems, with a sensitivity of 0.01mS.

Voltage and frequency protection: three-phase overvoltage/undervoltage (59/27), residual overvoltage (59N), frequency anomaly (81), supports df/dt change rate monitoring to prevent system oscillation.

Equipment specific protection: Transformer differential (87), motor stalling (51LR), thermal overload (49), supporting thermal memory function and environmental temperature compensation.

Arc protection: 3-channel optical sensor input, combined with current criterion, can quickly trip within 9ms, reducing the risk of damage caused by switchgear faults.

2. Measurement and monitoring capabilities

Direct measurement: 8-channel analog input (3 sets of current/voltage), supporting traditional CT/PT or Roche coil/resistive voltage divider sensors, with accuracy up to Class 1 (measurement)/Class 3 (protection).

Calculation parameters: line voltage, positive and negative sequence components, active/reactive power, power factor, electrical energy, supporting maximum demand recording and historical data storage.

Equipment status monitoring: mechanical life counting of circuit breakers, spring energy storage status, SF6 gas pressure monitoring, assisted by event recording (30 recent events) and fault waveform recording (5 x 5s, 1.2kHz sampling) for fault analysis.

3. Control and Automation

Local/remote control: Circuit breaker opening and closing can be achieved through HMI buttons or station control system, supporting electronic key permission management (protection parameter setting/control mode switching).

Interlocking and Automation Sequence: Based on FUPLA programming, cross interval interlocking (such as interlocking between bus tie switch and incoming switch), automatic reclosing (three-phase primary/secondary reclosing), and synchronous inspection (25) are implemented to meet the requirements of power grid interconnection.

Technical parameters and interface characteristics

Electrical parameters

Analog input:

CT input: 1A/5A, dynamic range 0.5-200In, supports Roche coil（ 150mVrms@In ）.

PT input: 100V (compatible with 110V), supports resistive voltage divider（ 2Vrms@Un ）.

Binary I/O:

Mechanical relay output: 8A/250VAC, supports coil breakage monitoring.

Static output: 12A/265VDC (short-term), suitable for motor drive.