Data format and rate
Data frame format: Asynchronous transmission data frame consists of 1 start bit, 8 data bits and 1 stop bit, total 10 bits.

Data Rate: Supports 1200, 2400, 4800, 9600 and 19200 baud rates.

Packet Format: Contains slave address, function code, data and CRC check code, the packet format of master request and slave response are similar.

Error checking: CRC-16 (16-bit Cyclic Redundancy Check) algorithm is used to check for transmission errors, if there is a checksum error, the slave will not respond.

Timing: The receiving device maintains packet synchronisation by measuring the time between character receipts. If no new character is received for more than 3.5 characters or the packet has not been received, the communication link is reset.

Supported Modbus Functions
Reading of set and actual values (function code 03/04): The set (‘Holding register’) and actual (‘Input register’) values of the relay can be read, up to a maximum of 125 registers at a time, with the data being transferred in two bytes, the lower byte first. The data is transferred in two bytes, with the lower byte first.

Execute operation (function code 05): The master can use this function to request the relay to perform a specific command operation, which corresponds to the command code in the memory map.

Storing a single setpoint (function code 06): the master stores a single setpoint in the relay memory and the slave response displays the entire master transfer.

Read device status (function code 07): Used to quickly read the status of the selected device, each bit of the returned status byte indicates different status information.

Loopback test (function code 08): Used to test the integrity of the communication link, the relay displays the request.
Storing multiple setpoints (function code 16): multiple setpoints can be stored in the relay memory, Modbus allows up to 60 holding registers to be stored at one time, the slave response will display the relevant information.

Performance Advantages
Comprehensive protection functions: Thermal overload (15 selectable curves), phase short-circuit, mechanical fault, thermal memory blocking, single-phase/current imbalance, earth fault (trip and alarm), over-temperature (via thermistor or optional RTD input), under-current, circuit breaker failure, etc., which can provide all-round protection for motors and related mechanical equipment, and effectively respond to all kinds of electrical and mechanical faults.

Compact and cost-saving design: The compact design reduces installation costs, which is more advantageous in space-constrained installation environments.

Flexible settings: With multiple setting groups, the protection and control parameters can be flexibly adjusted according to different application scenarios and motor requirements to meet diversified usage requirements.

Convenient testing: Built-in simulation function simplifies the testing process and facilitates testing and debugging of relays in the field, which reduces maintenance time and cost.

Powerful equipment monitoring: Real-time temperature monitoring through optional RTD input can detect motor overheating problems in time, and display status, current, temperature and other information, with fault diagnosis, trip records (the last 5 times) and other functions, so that operators can easily understand the operating condition of the equipment, and troubleshooting in time.

Convenient communication and upgrading: It supports Modbus RTU communication protocol, which is convenient for data interaction and remote control with other equipments; it can be upgraded on site by using flash memory, which can follow the pace of technological development and keep the advanced performance of the product.

Product Specification
Communication protocol: support Modbus RTU protocol, to ensure the compatibility and stability of communication with other devices.

Control power supply: DC control power supply input range of 90 – 300Vdc, can adapt to a variety of power supply environment.

Overload protection: Locked rotor start protection range is 0.5 – 11.0 xflc; overload curve trip time pickup level is 1 – 1500A.

Other accuracy specifications: Thermistor accuracy is ±5% or 100Ω (whichever is greater); unbalance accuracy is ±2%.
Switch input type: Dry contact switch input.

Physical Characteristics: Approximate shipping weight of 5 lbs. or 2.3 kg, compact design, fits most starters.

User Interface: RS485 serial interface, keypad, 40-byte backlit display, 6 LEDs, and compatibility with Enervista setup software for easy parameter setting, status viewing, and control.

Product overview
Protection requirements and functionality: Modern three-phase AC motors require precise protection and the 169 Relay has been developed for this purpose. It thermally models the motor’s phase currents and stator RTD temperature readings, takes into account the effects of negative sequence currents, calculates cooling times and monitors faults.

With overload, short circuit and earth fault protection, as well as monitoring, diagnostic and communication features, the 169 Plus is even more versatile.

Typical applications: Suitable for a variety of scenarios, such as protecting motors and equipment, ensuring personnel safety, monitoring equipment operating status, and communicating with control systems.

Technical specifications: The measuring range, accuracy, conversion method and other performance indexes of the relay for various parameters such as phase current, ground fault current, etc., such as the accuracy of overload curve tripping time and relay locking time.

Installation Guide
Physical dimensions and installation: the relay is compact, the installation needs to pay attention to the position and direction, the installation dimensions and methods are provided, and electromagnetic interference should be avoided .

External Connection: Connections include power supply, CT, RTD, and other inputs and outputs, which vary by model and function, and should be connected as required.

Control power supply: AC and DC voltages are available, AC voltage is selected by slide switch, make sure the voltage is correctly selected during installation, and the control power supply should be connected and programmed before the motor is started.

Setup and Use
Control and Display Mode: Operated by 12-digit keypad and 48-character display, there are four modes: actual value, set point, help and trip/alarm, which can view and set motor operating parameters, relay protection settings and other information.
Parameter setting: In setpoint mode, various parameters can be set, such as phase CT and motor full load current, acceleration time, number of start-ups, etc. When setting, it is necessary to pay attention to the range of parameters and the relationship between them.

Special functions: thermal memory function, can adjust the overload protection according to the motor running status; emergency restart can be forced to restart the motor under specific circumstances; the relay also provides statistical data records and factory preset values.

Relay Testing
Test Methods: Includes primary and secondary injection tests to check relay functions such as phase current input, ground fault current, RTD measurement, etc.

Routine Maintenance Verification: Periodic testing checks the protection system by simulating fault conditions to ensure that the relay is functioning correctly and that setpoints are restored after testing.

Working Principle
Hardware: Controlled by the 8031 microcomputer, it consists of several circuit modules such as power supply, signal processing, temperature monitoring, etc., which work together to realise the relay functions.

Firmware: Programmes stored in the EPROM control the mathematical, logical and control functions of the relay, performing various tasks such as data acquisition, fault judgement, display update, etc. through timed interrupts.

caveat
Mounting Environment and Physical Installation: The relay should be mounted in a location where the display is visible and the keypad is operable, and away from high current conductors or sources of strong magnetic fields to reduce electromagnetic interference.

Cut appropriately sized openings in the mounting panel as required and secure using the supplied mounting hardware. If using a 169 drawout relay, pay attention to the sequence of operations during installation and removal to prevent unintentional motor shutdown and risk of electric shock.

External Connections: The type of connection depends on the programming of the relay. Basic connections include power, three-phase current CT inputs, and trip relay contacts. When connecting, pay attention to the polarity and phase sequence of the CTs to ensure that the earth fault CTs are correctly installed, all current carrying conductors need to be routed through the earth fault CTs and the safety earth wire should be outside the CT window.

Output relays of different functions (e.g. trip, alarm, auxiliary relay, etc.) have different connection requirements and rated loads, and should be connected in strict accordance with the regulations.

Control power supply: The control power supply has a variety of voltages to choose from, the AC voltage is selected by a slide switch, before installation make sure that the switch is set correctly and that the control power supply label is consistent with the selected voltage.

The control power supply must be connected to the relay and programmed before the motor is energised. Also note that the chassis earth terminal should be connected directly to a dedicated cabinet earth conductor to prevent damage to the relay due to changes in earth potential.

Other considerations: When connecting RTD sensors, all RTDs must be of the same type, and the connecting wires should be shielded three-wire cables of the same length with resistance not exceeding the specified value, avoiding parallel laying with high-current wires.

If RTD #8 (RTD #10 for 169 Plus) is used to monitor ambient temperature, it needs to be properly selected and installed. Programming access terminals should be disconnected after programming is complete or safety measures should be taken to prevent inadvertent change of setpoints.

Product Overview
Functional features: All-round protection of three-phase AC motors, with overload, blocking, single-phase/unbalance, ground fault and other protection functions, but also diagnose faults, emergency restart and verification of relay operation status.

Application Scenarios: Suitable for a variety of industrial scenarios, such as pumps, fans, compressors and other equipment protection, can prevent equipment failure caused by personnel safety issues and equipment damage.
Relay selection: Horizontal and vertical mounting versions are available, depending on the application requirements and the type of current transformer (CT) (1A or 5A). Some features are optional and must be specified at the time of ordering.

Installation Guide
Physical dimensions and mounting: The relay is housed in a high-impact plastic case with a dust cover. The mounting is recessed and secured to the panel by U-clips. Check the options and switch settings on the product specification card before mounting.

External Connections: Connections include power supply, CT input, main relay contacts, etc. Some connections are optional. The power supply has two options, AC and DC, and the CT secondary side needs to be grounded.
CT Connection: One CT is required for each phase of the motor, and the secondary side of the CT should match the current of the relay. 5A CT has a specific connection method, and 1A CT can be adapted to the 5A CT design of the relay by changing the wiring method.

Other connections: earth fault CT for earth fault detection, main and auxiliary relay contacts for control and alarms, external reset and emergency restart functions can be realised with specific terminals, options such as temperature sensing, thermal capacitance meter and current outputs have corresponding connections.

Setup and use
Control and Indication: Parameters are set via the front panel control. Indicator lights are used to show the operating status of the relay and fault information.

Parameter setting: including maximum load control, unbalance control, undercurrent control, start timer setting, etc. Each parameter should be adjusted according to the actual situation of the motor.

Function options: Programmed by internal selector switch, such as cyclic overload compensation, immediate overload warning, emergency restart, memory function, etc., which can be switched on or off according to the application requirements.

Special functions: Ground fault protection can be set with different trip currents and delay times; over-temperature protection is realised by RTD sensors, which can be set for alarm and trip temperatures; the thermal capacity meter and 4 – 20mA output function are optional for easy monitoring and control.

Relay Testing
Test equipment: Commercial secondary injection test equipment or homemade test circuits can be used to test relays.

Test Items: Including overload, start timer, unbalance, undercurrent, ground fault, over-temperature and other functional tests, the test should pay attention to simulate the actual working conditions and operating specifications.

Daily maintenance verification: Regular testing can check the correct operation of the protection system, simulate various fault conditions for testing to ensure that the relay works properly.

Troubleshooting: Possible causes and solutions are provided for common fault symptoms, such as relays failing to reset, frequent overload trips, and so on.

Working Principle: Each phase current is isolated and converted by CT, then sampled and amplified by electronic switch. Fault judgement such as overload, unbalance, undercurrent is achieved by comparing with preset reference value. Overload timing is controlled by an integrator circuit with different charging rates in start-up mode. Alarm functions are implemented by separate relays, with separate detection and comparison circuits for RTD and earth fault alarms.

Product Overview: The 8 Series protective relay platform consists of four relays, the 850, 845, 869 and 889, which can be used for the protection and management of different power equipment. It has two levels of communication capability, with the base CPU supporting multiple protocols and the Ethernet port enhanced with the addition of a communication module.

Communication ports: There are four kinds of communication ports: RS485, Wi-Fi, USB and Ethernet; RS485 port supports multiple baud rates and protocols, and can be connected to multiple devices; Wi-Fi is based on the 802.11 standard, supports WPA2 encryption, and has specific network settings and connecting steps; USB port has a fixed IP, and can be connected to the device through the quick connect function; Ethernet port has different configuration modes, supports multiple protocols, and can be connected to different power equipment; Ethernet port has different configuration modes, and supports multiple protocols, and can be connected to different power equipment. Ethernet port has different configuration modes, supports multiple protocols, network settings, routing configuration and status view.

Time Protocol: Supports various time reference sources, such as internal clock, SNTP, IRIGB and PTP IEEE 1588 (version 2), you can select the time source for time synchronisation according to the priority level, and the PTP protocol has detailed configuration options and status display for accurate time synchronisation.

Communication protocols: Supports various communication protocols such as DNP, IEC 60870 – 5 – 104, IEC 60870 – 5 – 103, IEC 61850, OPC – UA, etc. Each protocol has specific configuration options and status displays for accurate time synchronisation. Each protocol has specific configuration parameters, functional characteristics and application scenarios. For example, DNP protocol is used for distributed network communication and supports multiple data types; IEC 61850 protocol supports GOOSE and MMS services, which enables fast data exchange and monitoring between devices.

Performance Benefits
Various and flexible communication functions: RS485, Wi-Fi, USB and Ethernet communication ports can meet the communication needs in different scenarios; RS485 port supports multiple baud rates and protocols, and can connect multiple devices, which is suitable for long-distance and multi-device communication scenarios; Wi-Fi is based on 802.11 standards, easy to configure, supports security encryption, and facilitates wireless communication in limited space; USB port can quickly establish a connection between the device and the computer through the quick-connect function, which is convenient for device configuration; Ethernet port supports multiple advanced protocols after adding the communication module, which can adapt to complex network environments. Wi-Fi is based on 802.11 standard, easy to configure, supports secure encryption, and facilitates wireless communication in limited space; USB port can quickly establish the connection between the device and the computer through the quick-connect function, which is convenient to configure the device; Ethernet port, with the addition of the communication module, supports a variety of advanced protocols, which is adaptable to complex network environments, and achieves high-speed and reliable data transmission.

Accurate time synchronisation mechanism: Supports a variety of time reference sources, including internal clock, SNTP, IRIGB and PTP IEEE 1588 (version 2). According to the actual demand, the time source with high priority and high precision can be selected for time synchronisation. For example, PTP protocol can provide high-precision time synchronisation, and through the configuration of the relevant parameters, it can compensate for the network delay, ensure the time consistency of the various devices in the system, and provide accurate timestamps for the event recording and data transmission to ensure the accuracy and reliability of the system operation.
Accuracy and reliability of system operation.

Wide range of protocol support and adaptability: Supports DNP, IEC 60870-5-104, IEC 60870-5-103, IEC 61850, OPC-UA and other communication protocols. Each protocol has specific functions and application scenarios. For example, DNP protocol is suitable for distributed network communication and supports multiple data types; IEC 61850 protocol supports GOOSE and MMS services, which can realise rapid data exchange and monitoring between devices; Modbus protocol is widely used, which can realise flexible control of devices and data reading/writing operations through multiple function codes, and supports compatibility mode, which can work with different types of devices. The Modbus protocol is widely used and can be used for flexible control and data reading/writing operation of devices through various function codes.

High security: In terms of communication security, 8 series protection relay platform can be used as a Radius client to authenticate with Radius server through EAP-TTLS protocol, and ensure the authenticity and legitimacy of the identities of both parties in the communication by using the certificate management mechanism to prevent illegal access and data leakage. Meanwhile, during data transmission, some protocols (such as WPA2 encryption for Wi-Fi) encrypt the data to ensure the security and integrity of the data.

Product Overview: The 8507-BI-DP BIM is used to connect PAC8000 series I/O modules and PROFIBUS-DP host to achieve high-speed data acquisition and transmission, supports redundant operation, and needs to be used with the 8701-CA-BI redundant BIM carrier for critical applications.

Functional features: The 8507-CA-BI-DP BIM supports up to 24 I/O modules, redundant operation, extended diagnostics, high-speed communication (up to 12 Mbaud), non-volatile memory configuration, configuration through the PROFIBUS host, and also supports HART transmission. 8701-CA-BI carriers can accommodate two BIMs, providing dual PROFIBUS The 8701-CA-BI carrier can accommodate two BIMs, provides dual PROFIBUS network connections, supports DIN rail or panel mounting, and can detect and report power failures.

Technical Specifications: The PROFIBUS interface of the 8507-BI-DP BIM is EN-50170 compliant and supports multiple transmission rates, RS-485 as standard, with 500V isolation. Input and output data are up to 240 bytes, and diagnostic telegrams are available in various lengths. 8701-CA-BI carriers use a specific power supply with an operating temperature range of – 40°C to 70°C (operating) and – 40°C to 85°C (storage), and a relative humidity of 5% to 95% (non-condensing).

Usage: The 8507-BI-DP BIM is parameterised via a PROFIBUS host and the configuration information is passed on by the PROFIBUS master at the start of communication. 8701-CA-BI carriers have rotary switches for setting the PROFIBUS slave address and buttons for changing the BIM status.

Compatibility and Limitations: The 8507-BI-DP BIM does not support some of the I/O modules and related functions, and there are compatibility issues with systems such as Delta V. There are also limitations with the configuration software. For example, it does not support modules such as 8129-IO-DC, and is not compatible with the event sequence function of 8127-DI-SE module.

Version update: Different hardware and software versions have different features and improvements. For example, GE02 Rev. B version has implemented digital signature for firmware update; some versions have solved the compatibility problem and added new functions, such as HART through-transmission support, master IP reset function, and so on.

Application Cases
Industrial automation production line: In the automation production line of an automobile manufacturing plant, the 8507-BI-DP bus interface module of PAC8000 series is used in conjunction with the 8701-CA-BI carrier. 8507-BI-DP is responsible for collecting the data from the sensors of each link of the production line (e.g., position sensors, pressure sensors, etc.) and transferring the data to the main control system through the PROFIBUS-DP network at a speed up to 12 Mbaud.

The 8507-BI-DP is responsible for collecting data from the production line’s sensors (e.g. position sensors, pressure sensors, etc.) and transmitting it to the main control system via the PROFIBUS-DP network at speeds of up to 12 Mbaud. 8701-CA-BI carriers provide stable support for the 8507-BI-DP to ensure that the data transmission is stable.

The redundant operation function ensures that if a module fails, the backup module can take over the work in time, avoiding production line downtime and improving production efficiency and reliability.

Smart Factory Monitoring System: In smart factories, the 8507-BI-DP and 8701-CA-BI are used to build monitoring systems. 8507-BI-DP connects numerous I/O modules, collects data on equipment operating status, environmental parameters, etc., and monitors the status of the modules and channels using the extended diagnostic function to detect potential problems in time. 8701-CA-BI carriers with dual PROFIBUS network connection enhances network reliability.

These data are transmitted to the monitoring host through the PROFIBUS network, which is convenient for the management personnel to grasp the real-time plant operating conditions and carry out remote monitoring and management.

Energy Management System: In the energy management system of a large energy enterprise, the 8507-BI-DP works in conjunction with the 8701-CA-BI. The 8507-BI-DP collects the operating data of energy production equipment (such as generators, transformers, etc.), including voltage, current, power, etc. With the HART Transparent Transmission function, it also collects data of the energy production equipment (such as generators, transformers, etc.).

With the HART Transparent Transmission function, it can also monitor and configure smart devices that support the HART protocol. 8701-CA-BI carriers provide a stable physical and electrical connection to ensure accurate data transmission. The main system uses this data for energy scheduling and management to improve energy efficiency.

Product Overview: The MM2 is a protection and management system for low-voltage AC motors that integrates process control and protection functions with full-featured protection, advanced automation capabilities, cost-effectiveness, compact design, and easy installation and integration for motor control centre application scenarios.

Functional features
Protection and control: covers a wide range of protection functions, such as motor thermal modelling, ground fault, under-voltage, over-voltage, over-temperature protection, etc. It also monitors a wide range of abnormalities and sends out alarms, and supports a wide range of motor starter types with under-voltage automatic restart function.

Monitoring and metering: It can measure and display a variety of motor operating parameters, process data, fault records and statistical information, which is convenient for real-time control of motor status and maintenance management.

User Interface: Provide 40 characters LCD display, operation buttons, programming keyboard and status indicator, support local control and programming, communication through ModBus RTU RS485, support various baud rates, can be connected to the host computer to achieve remote monitoring.

Software support: Equipped with Windows® -based configurator MM2PC and EnerVista™ software suite for easy parameter setting, equipment monitoring, data logging and system integration.

Technical Specifications: Includes technical specifications such as measurement accuracy, range and delay time for a wide range of parameters such as overload curves, ground faults, undercurrents, undervoltages, etc., as well as input/output characteristics, communication specifications, environmental suitability and certifications to ensure reliable product performance.

Selection and Configuration: Chassis-mounted and panel-mounted models are available, with two option packages available to enhance functionality. Option Pack 1 adds control and diagnostic functions, Option Pack 2 enhances protection functions and input options, and a variety of expansion modules can be selected to meet different needs.

Performance Advantages
Comprehensive protection function: It is equipped with rich protection mechanisms, covering various types of protection such as motor thermal overload, ground fault, under-voltage, over-voltage, over-temperature, phase imbalance and so on. Through accurate measurement and judgement, it can effectively prevent the motor from being damaged due to various abnormal conditions. For example, it adopts 12 different I²t time overcurrent overload curves, combined with True RMS current detection technology, which can accurately respond to
Ground fault protection detects overcurrent from the residual connection of phase CTs or zero sequence CTs, sets a delay time to prevent false alarms, and provides alarm and trip functions.

Advanced automation control: support a variety of motor starter type programming, can be flexibly configured according to different motor requirements start. With under-voltage automatic restart function, it can automatically resume motor operation after a short power failure, reducing production interruption time. Various parameters can also be programmed to achieve customised protection and control strategies to meet the needs of different industrial scenarios.

Highly cost-effective: The low-cost modular design reduces the number of devices, replacing multiple independent devices such as bimetallic overload elements, timers, relays, etc., reducing procurement and maintenance costs. Meanwhile, its compact design can be installed in standard MCC drawers, saving space and improving space utilisation.

Advantages of technical standards
Strict safety standards: Following EN 61010 – 1, CAN/CSA 22.2 No. 61010 – 1 – 12, UL 61010 – 1 and other safety standards, the safety requirements of electrical equipment in measurement, control and laboratory use are comprehensively regulated.

From electrical safety, mechanical safety to protection level and other aspects to provide protection, such as to meet the IP20 (NEMA 1) intrusion protection requirements, effectively preventing personnel from electric shock and intrusion of foreign objects, reduce the safety risk, to ensure the safety of operators and equipment.

Strong EMC performance: Complies with Directive 2004/108/EC and other EMC directives, as well as EN 55011, IEC 61000 series and other relevant standards. It has excellent performance in a number of EMC indicators such as radiated and conducted emissions, ESD immunity, RF radiation immunity, etc.

It can effectively resist external electromagnetic interference, ensure stable operation of the system in complex electromagnetic environments, and avoid equipment malfunctions or data errors caused by electromagnetic interference.

Suitable for hazardous areas: In terms of hazardous area applications, it meets ATEX Class I, Division 2, Groups A, B, C, D T4 standards and is suitable for a variety of hazardous environments.

This allows the product to be used safely in places where flammable and explosive gases, dusts and other hazardous substances are present, broadening the product’s range of applications and guaranteeing production safety in special industrial environments.

High level of functional safety: Mark VIeS safety controllers comply with functional safety standards such as IEC 61508:2010 Parts 1 – 7 and EN50402:2005 + A1:2008, and are SC 3 (SIL 3 Capable) system capable. This means that the controller can reliably perform safety functions in safety-critical applications, effectively reducing risks and safeguarding people, equipment and the environment.

Quality control norms: Product design, manufacturing, supply and service follow the ISO 9001:2008 quality management system standards, from raw material procurement, production process control to after-sales service, there are strict quality control processes.

It ensures stable and reliable product quality, reduces product defects, improves user satisfaction and enhances product competitiveness in the market.

Safety Specifications
Functional Safety: Mark VIeS safety controllers are IEC 61508 compliant and SIL 3 capable for safety critical applications.

Network Security: Provides multi-layer security protection, including network access control, intrusion detection, and device hardening. Role-based access control is used to ensure reasonable user privileges and encrypted data transmission processing to comply with industry security standards.

System Overview
Architecture core: single board controller as the core, integrated main processor and redundant Ethernet driver, running real-time multi-tasking operating system, control software using configurable control block language stored in non-volatile memory.

I/O network: IONet as a dedicated full-duplex point-to-point protocol network, providing high-speed deterministic communication, supporting copper and optical fibre interfaces, with single, dual and triple redundancy configurations to ensure stable data transmission.

I/O Modules: Consisting of terminal boards, terminal blocks and I/O packages, there are T-type and S-type modules; T-type modules are used for decentralised inputs, S-type modules are suitable for different redundancy configurations, and the I/O packages are hot-swappable, supporting online repair and automatic reconfiguration.

Redundant design: A variety of redundancy options are available, such as power supplies, controllers, I/O networks, and modules. Dual and triple redundant systems are available for different failure scenarios, reducing maintenance time and increasing system availability.

Control Software Suite
HMI: Windows-based system that can be used as an operator station or engineering workstation. It communicates with controllers and third-party systems via Ethernet, with redundant configurations to improve reliability, and a variety of functions such as alarm viewing and trend analysis.

WorkstationST: Integrates various functions, such as alarm management, historical data storage, network communication, etc. Provides various interface standards to support interaction with external systems, and has flexible alarm management tools to facilitate users to analyse and process alarm information.

ToolboxST: Used for hardware and software configuration, provides various editing tools, supports drag-and-drop operation, has powerful trend analysis functions, can perform complex calculations and spectrum analysis, and supports SFC programming, which is convenient to achieve the sequential control of equipment.

Features
Diversified communication interfaces and protocols: It supports a variety of communication interfaces and protocols, including industry-standard Ethernet for communication between I/O, controllers and operation and maintenance stations, etc.; IONet adopts protocols such as Ethernet Global Data (EGD) and is based on the UDP/IP standard, which ensures efficient communication between controllers and I/O modules. At the same time, it supports various protocols such as Modbus and OPC, which makes it convenient to interact with third-party devices and systems.

Highly reliable communication mechanism: the communication network is equipped with redundant design, and IONet has single, double and triple redundancy configurations, which can effectively respond to equipment failure and ensure stable data transmission. At the software level, precise time synchronisation mechanisms, such as the IEEE 1588 Precision Time Protocol, are used for the time alignment of I/O packet data on IONet to ensure the time consistency and accuracy of the data and improve system reliability.

Powerful Data Processing and Interaction Capability: The software suite can collect, transmit and process large amounts of data in real time. In terms of alarm management, it can collect, analyse and display all kinds of alarm information in a timely manner; the trend analysis function can obtain data from multiple data sources for complex analysis. Smooth data interaction between different software modules, such as WorkstationST and ToolboxST can share data, which is convenient for operators to fully grasp the system operation status.

Product Specification
Hardware Specifications
Controller: Single board design with integrated main processor (Freescale 8349, 667MHz), Ethernet communication module for control and I/O networks, USB and COM ports. Operates at 18 – 36V dc, 12 watts, 0°C to +65°C, no fan required, for NFPA Class 1, Div. 2 applications.

I/O Modules: Contains various types such as General Purpose I/O and Turbine Specific I/O. T-Boards are available with two 24-point barrier type removable terminal blocks, and S-Boards are available in different versions for simplex and dual redundant systems with different wiring specifications and terminal layouts.

Network: The IONet is a 100MB Ethernet that supports non-redundant, dual-redundant and triple-redundant configurations, and is available in 100BaseTx (UTP Cat. 5, RJ-45 interface, max. segment length 100m) and 100BaseFx (fibre optic, SC interface, max. segment length 2km). The industrial-grade switches are for IONet, operate from -40°C to 85°C, and support redundant 10 – 30V dc power supplies.

Software Specifications: Application programs are written in a configurable control block language, compliant with IEEE-854 32-bit floating point format, and stored in non-volatile memory; ToolboxST software platform for programming, configuring I/O, trending, and diagnostics, with multiple layers of password protection, and the ability to download software changes while the system is running without rebooting the main processor.

Communication Specifications: Communication between I/O, controllers, operator stations, and third-party systems is via industry-standard Ethernet. Both the control network (UDH) and the information network (PDH) are Ethernet, and IONet is used for controller communication with I/O modules, supporting protocols such as Ethernet Global Data (EGD).

Performance advantages
High reliability: A variety of redundancy options are available, including power supplies, controllers, I/O networks, I/O modules, and Ethernet ports, which can be flexibly configured according to application requirements. Dual and triple redundant systems can maintain system operation in the event of a partial component failure, and diagnostic functions can quickly locate faults, reducing maintenance time and improving system reliability.
Powerful processing capability: the controller adopts a high-performance processor, combined with the QNX real-time multitasking operating system, with the ability to quickly process data and execute control algorithms, and the local processor of the I/O module can independently run algorithms to improve the overall performance of the system and meet the control requirements of complex industrial processes.

Flexible Configuration: Supporting a variety of I/O types, ToolboxST can meet the needs of different scenarios, such as turbine applications and process control. In terms of software, ToolboxST provides a rich library of function blocks, making it easy for users to program and configure the system according to the actual application and realise personalised control strategies.

High-efficiency communication: Adopting industrial standard Ethernet and IONet communication network, ToolboxST has high-speed and reliable communication performance, and the fibre optic interface of IONet can improve the communication distance and anti-jamming ability to ensure accurate and timely data transmission, which can meet the real-time requirements of industrial sites.

Convenient Maintenance: The operator interface (HMI) is based on Windows operating system, combined with the CIMPLICITY graphic display system, which is intuitive and convenient to operate, and the ToolboxST software platform provides powerful maintenance functions, such as on-line programming, trending and fault diagnosis, which helps to quickly locate and solve problems, and reduces the maintenance cost.

caveat
Follow the operating procedures: Strictly follow the steps in the manual, any deviation may damage the equipment and even lead to property damage, injury or death.
Professional operation: Installation and maintenance must be carried out by qualified personnel, the station operator needs to be notified before maintenance, operation inside the equipment may trigger an alarm.

Electrical safety: When making electrical connections, switch off the power supply at the fuse box or at the service panel, make sure that it is well earthed, use suitable cables and overcurrent protection, and use 2.08 mm2 (14 – AWG) cable within 15m of the power supply.
Installation location and environment

Choose a suitable location: give priority to typical locations such as a straight section of radiator return pipe, if this is not available, contact customer service to determine an alternative location, avoid installing in an unrecommended location such as the inlet side of a radiator pump.
Avoid unfavourable environments: Prevent the device and sensor from coming into contact with high-pressure water flow, do not paint or clean the sensor with solvents.

Sensor Protection
Prevent damage: Do not touch the sensor membrane to avoid puncturing or scratching, keep the plastic cover in place before installation, and install without blocking the breathing hole or puncturing the membrane.

Proper Installation: Wrap the sensor threads with PTFE tape during installation, install horizontally with the exhaust screws at the 12 o’clock position, exhaust and clean up any oil after installation.

Use of tools and installation operations
Use of the right tools: The installer provides some of his own tools and selects and uses them according to the requirements, such as tightening the sensor with the right spanner.
Standardise the installation process: Standardise the installation process, e.g. install the housing by tightening the 4 screws evenly and diagonally to a torque of not less than 50 lbf – in (5.6 N – m) to prevent the ingress of water.

Electrical Connections and Wiring
Connect the cables correctly: Connect the analogue inputs, outputs, alarm relays and AC power cables according to the different types, make sure that they are connected correctly, ground all metal conduits, and plug any unused openings.
Pay attention to the communication wiring: RS-485 wiring as required, when connecting to the Hydran 201Ci controller or other equipment, pay attention to the parameter settings and cable connection methods.

Software configuration and commissioning
Parameter setting: Set the date and time, gas and humidity alarm parameters, network communication parameters, etc., wait for the device readings to stabilise and then set the alarm parameters, and set the parameters of the devices in the network as required.
Sensor Test: After testing the sensor, readings are not available for 2 minutes, compare gas level readings and recent DGA data during commissioning.

Detection performance advantages
Accurate monitoring of gas and humidity: real-time monitoring of gas content and humidity level inside the transformer, through setting gas and humidity alarm parameters, it can timely detect abnormalities, such as excessive gas concentration or humidity exceeding the standard, which provides key data support for the safe operation of the transformer.
Trend analysis function: with gas hourly trend and daily trend monitoring function, it helps to analyse potential problems inside the transformer and predict the risk of failure in advance, so as to take preventive maintenance measures and reduce the loss caused by sudden failure.

Installation Advantages
A variety of installation position options: Provide a variety of installation positions suitable for different transformer structures, including the straight section of the radiator return pipe, filling valve, top of the radiator, drain valve, etc., and detailed description of the advantages and disadvantages of each position, which is convenient to choose flexibly according to the actual situation, and improve the adaptability of the installation.

Installation Convenience: Equipped with some installation tools, such as 3/16 – in hexagonal key, 1/16 – in and 5 – 32 – in standard hexagonal (Allen) L-type key, wrenches, PTFE tape, etc., which reduces the trouble of installers to prepare additional tools; at the same time, the installation steps are clearly defined, from the separation of the sensor from the device, to the installation of valves, and then the connection of cables, etc., there is a detailed operation guide, which reduces the difficulty of installation. At the same time, the installation steps are clear, from the separation of the sensor and equipment to the installation of the valve and cable connection, there are detailed operating instructions, reducing the difficulty of installation.

Communication and Networking Advantages
Flexible communication methods: Supporting a variety of communication methods, such as RS-485, RS-232, but also through the Ethernet (wired or optical fibre), modem data transmission, to meet the needs of different scenarios and other equipment or system communication.
Powerful Networking Capability: It can be daisy-chained via RS-485 link to build a local network, connecting up to 32 Hydran M2 devices, with a maximum cable length of 1200m (4000ft), which is easy to set up and expand a large-scale transformer monitoring system, and achieve centralised management and monitoring.

Software Configuration Advantages
Friendly user interface: The user interface is easy to operate, and various parameter settings, function selections and data viewing can be easily carried out by pressing the keys. Such as the use of arrow keys to navigate options, parameters or numbers, Esc key to return to the previous level of the menu, the context key according to the content of the screen to perform different functions, reducing the user’s operating difficulties.

Flexible parameter setting: it can flexibly configure a variety of parameters, including date and time, gas and humidity alarm thresholds, network communication parameters, analogue input and output parameters, etc., which can be personalised according to the actual needs to meet the requirements of different transformer operation monitoring.

Maintenance and Warranty Advantages
Complete Warranty: GE Energy offers a standard warranty that the product is guaranteed to be free from defects in material, workmanship and ownership. Software is covered by a 90-day warranty, and hardware is covered by a warranty based on the time of use or delivery, during which time problems can be repaired or replaced in a timely manner.
Comprehensive technical support: Provide global 24-hour customer service support, users in the installation, use and maintenance of the process encountered problems, you can contact the customer service centre at any time to get help to ensure that the normal operation of the equipment.