Product overview

Positioning and Function: REF615 is an intelligent electronic device (IED) designed specifically for public substations and industrial power system feeders, used for the protection, control, measurement, and monitoring of radial, ring, and mesh distribution networks (including distributed generation). It is a Relion ®  The members of the 615 protection and control series products adopt compact and withdrawable unit designs, fully leveraging the potential of the IEC 61850 standard for communication and interoperability between substation automation equipment.

Core Capability: Provides primary protection for overhead lines and cable feeders, and can also serve as backup protection for independent redundant protection systems. Based on selected standard configurations, it is suitable for protecting overhead lines and cable feeders in isolated neutral points, resistance grounding, compensation, and solid-state grounding networks. After configuring specific parameters, it can be directly put into use and supports multiple communication protocols.

Standard configuration

Configuration type: REF615 has 8 standard configurations, and different configurations have different combinations of protection functions. For example, A and B configurations include non directional overcurrent and directional ground fault protection, while C and D configurations include non directional overcurrent and non directional ground fault protection.

Function support: The standard signal configuration can be changed through the graphical signal matrix or optional graphical application function of PCM600. Its application configuration function supports the use of various logic elements (including timers and triggers) to create multi-layer logic functions, combining protection functions with logic function blocks to adapt IED configuration to user specific application needs.

Protection function

Main protection function: Provides directional and non directional overcurrent, thermal overload protection, as well as directional and non directional ground fault protection. According to standard configuration, admittance type ground fault protection can replace directional ground fault protection, and also has sensitive ground fault, phase to phase open circuit, transient/intermittent ground fault, overvoltage and undervoltage, residual overvoltage, positive sequence undervoltage, and negative sequence overvoltage protection functions.

Additional protection function: The standard configuration H of the IED provides frequency protection (including over frequency, under frequency, and frequency change rate protection), enhanced by optional hardware and software, with three optical detection channels for metal enclosed indoor switchgear circuit breakers, busbars, and cable room arc fault protection. The arc fault protection sensor interface is on the optional communication module.

Application scenarios

Network type: Can be equipped with directional or non directional grounding fault protection. Directional grounding fault protection is mainly used for isolated neutral points or compensating networks, while non directional grounding fault protection is suitable for direct or low impedance grounded neutral point networks, and can be used for ring and mesh distribution networks as well as radial networks containing distributed generation.

Specific applications: Different standard configurations are suitable for different scenarios, such as standard configuration G containing one conventional residual current input and three sensor inputs, suitable for compact medium voltage switchgear with limited space, and standard configuration H suitable for industrial power systems, etc.

Supported ABB solutions

System integration: The 615 series of protection and control IEDs and COM600 station automation equipment form a true IEC 61850 solution for reliable power distribution in public and industrial power systems. Through the provided connection package, IEDs can be easily configured and integrated with COM600 or MicroSCADA Pro network control and management systems through the PCM600 protection and control IED manager.

Communication and Functionality: The 615 series IEDs natively support the IEC 61850 standard, including binary and analog level GOOSE message passing. The COM600 provides enhanced substation level functionality using interval level IEDs for data content, with a web-based HMI and gateway functionality, providing seamless connectivity between substation IEDs and network level control and management systems.

Control function 

Circuit breaker control: The IED provides control over a circuit breaker, equipped with dedicated buttons for opening and closing the circuit breaker. The optional large graphic LCD includes a single line diagram (SLD) indicating the position of the circuit breaker, and the interlocking scheme required for the application is configured through the signal matrix or application configuration function of PCM600.

Synchronization check: According to the standard configuration, the IED also includes a synchronization check function to ensure that the voltage, phase angle, and frequency on both sides of the disconnected circuit breaker meet the conditions for secure interconnection between the two networks.

Measurement and recording function

Measurement parameters: Continuously measure phase current, current symmetry component, and residual current. If voltage measurement is included, residual voltage, phase voltage, and voltage sequence component are also measured. According to the standard configuration, frequency measurement is also provided to calculate the current demand value within the user’s selectable preset time frame, thermal overload of the protected object, and phase imbalance value based on the ratio of negative and positive sequence currents. Three phase power and energy measurement, including power factor, are provided.

Product Overview and Core Features

The 3500/45 position monitor is a 4-channel precision monitoring device developed by Bently Nevada, specifically designed for monitoring position related parameters of rotating machinery. Its core function is to receive signals from proximity sensors (Proximitors), rotary position sensors (RPTs), AC/DC linear variable differential transformers (AC/DC LVDTs), and rotary potentiometers. Through signal conditioning and comparison with user programmable alarm thresholds, it achieves mechanical protection and status monitoring.

Core competencies:

Multi parameter monitoring: supports 8 measurement functions including axial (thrust) position, differential expansion, casing expansion, valve position, etc. Channels are programmed in pairs (such as channels 1-2 and 3-4 can perform different functions separately, but casing expansion only supports channels 3-4).

Flexible configuration: Customize the full-scale range, filtering parameters, and alarm thresholds through the 3500 configuration software to adapt to different mechanical operating conditions.

Redundancy design: Supports TMR (Triple Modular Redundancy) configuration, improves system reliability through a 2 out of 3 voting mechanism, and is suitable for monitoring critical equipment.

Application scenarios:

Used for monitoring parameters such as axial displacement of rotors, thermal expansion difference between shafts and casings, valve opening, etc. in large rotating machinery such as steam turbines and compressors, to prevent equipment failures such as rubbing and overload caused by abnormal positions.

Detailed explanation of technical specifications

1. Input characteristics

Signal type: Supports sensor inputs such as Proximitor (e.g. 3300XL series), DC LVDT (25-508 mm range), AC LVDT (25-254 mm range), rotary potentiometer (50 ° -300 ° rotation range), etc.

Impedance and power consumption:

The input impedance of DC LVDT is 1M Ω, the Proximitor/RPT is 10K Ω, and the rotary potentiometer is 200K Ω.

The power consumption varies depending on the I/O module: typically 7.7W when using position I/O modules, 8.5W for AC LVDT modules, and 5.6W for rotary potentiometer modules.

2. Sensitivity and accuracy

Thrust position: Sensitivity 3.937 mV/mm (100 mV/mil) or 7.874 mV/mm (200 mV/mil), accuracy ± 0.33% of full scale (typical), maximum ± 1%.

Differential expansion:

Standard single slope: Sensitivity 0.394-7.874 V/mm (10-200 mV/mil), accuracy varies depending on the slope angle and range, with a maximum error of ± 2% (such as when the full-scale span is less than 3 Vdc).

Shell expansion: DC LVDT sensitivity is 0.05-0.20 V/mm (1.25-5.00 V/in), AC LVDT is 9.45-28.74 mV/V/mm (0.24-0.73 mV/V/mil).

Valve position: The sensitivity of the rotary potentiometer is 41 mV/degree, the RPT is 50-140 mV/degree, and the AC LVDT is 3.94-28.74 mV/V/mm.

3. Output characteristics

LED indication:

OK light: It lights up when the module is running normally.

TX/RX light: Flashes when communicating with other modules in the rack.

Bypass light: It lights up when the channel is bypassed.

Analog output:

The recorder outputs 4-20 mA, proportional to the full range (such as 20 mA for a full range of 10 mm), with a load resistance of 0-600 Ω, a resolution of 0.3662 μ A/bit, and a temperature drift of ± 0.7%.

Buffer sensor output: 1 coaxial interface per channel, short circuit protection, DC LVDT channel 3-4 offset -10 Vdc, AC LVDT output is the DC characteristic value of the AC signal.

4. Signal conditioning and filtering

Frequency response:

Thrust/differential expansion: Direct filter -3 dB at 1.2 Hz, gap filter -3 dB at 0.41 Hz.

Shell expansion/valve position: Position filter -3 dB at 0.41 Hz, suitable for low-frequency mechanical displacement monitoring.

Alarm mechanism:

The Alert threshold can be set to 0-100% full scale, and the Danger threshold supports any two proportional value configurations, with a time delay of 1-60 seconds (Alert) or 0.1 seconds (Danger), and an alarm accuracy of ± 0.13% of the target value.

Configuration plan and I/O module

1. I/O module types and adaptation scenarios

Module model and function applicable to sensors

01 Internal terminal module directly connects to Proximitors, RPTs, DC LVDTs, suitable for non hazardous areas such as 3300XL series, 25 mm Extended Range, etc

02 External terminal module is connected to external terminal blocks through cables, simplifying rack wiring as above

03 Discrete TMR External Module Triple Redundancy Configuration, with independent sensors for each channel, enhances reliability Proximitor/DC LVDT

05 AC LVDT internal module is dedicated to AC LVDT signal conditioning, supporting a range of 25-254 mm AC LVDT 25 mm/50 mm, etc

The internal module of the 07 rotary potentiometer is compatible with rotary potentiometers (50 ° -300 °) for valve opening monitoring

2. Key points of TMR configuration

Discrete and bus modes:

Discrete mode (module 03): Three independent sensors are connected to three modules respectively, suitable for critical measurements (such as thrust position).

Bus mode (module 04): Single sensor signals are distributed to three modules through the bus, which has lower cost but slightly lower reliability.

Voting mechanism: When the deviation between the output of a module and other modules exceeds the set threshold (such as 5%), an event log is triggered to ensure data consistency.

3. Typical configuration examples

Turbine thrust monitoring:

Sensor: 3300XL 8mm Proximitor with a sensitivity of 200 mV/mil.

Channel configuration: 1-2 channels are set as thrust positions, with a full range of 25-0-25 mil, an Alert threshold of 15 mil, a Danger threshold of 20 mil, and a filtering frequency of 1.2 Hz.

Boiler pipeline expansion monitoring:

Sensor: 50 mm DC LVDT, sensitivity 0.10 V/mm (2.50 V/in).

Channel configuration: 3-4 channels are set for chassis expansion, with a full range of 0-50 mm and an alarm delay of 2 seconds, adapted to the slow change characteristics of thermal expansion.

Ordering and installation information

1. Component numbering rules

3500/45-AXX-BXX：

AXX: I/O module type (e.g. 01=internal terminal, 05=AC LVDT).

BXX: Authentication options (01=CSA/NRTL/C Class I, Div 2).

Example: 3500/45-01-01 represents an internal terminal module with CSA certification.

2. External components and spare parts

Terminal block:

Proximitor/DC LVDT: 125808-06 (Euro interface) or 128015-06 (terminal block).

AC LVDT: 141208-01 (Euro interface), supports signal conditioning and isolation.

Cable:

Sensor to terminal block: 129525 series, length 5-100 feet, supports assembly/non assembly.

Spare parts:

Module spare parts: 176449-04 (3500/45 complete machine), 135137-01 (internal terminal module).

Consumables: 00530843 (I/O module four pin splitter), used for sensor type matching.

3. Installation requirements

Space occupancy: The monitor occupies one full height front slot, and the I/O module occupies one full height rear slot, which needs to be used in conjunction with a 3500 rack.

Environmental compatibility:

Working temperature -30 ° C~65 ° C, storage -40 ° C~85 ° C, humidity ≤ 95% non condensing, in compliance with EN 61000-6-4 electromagnetic compatibility standard.

Explosion proof certification: Equipped with CSA certification module, suitable for Class I, Div 2 Groups A-D hazardous areas, meeting the needs of petroleum, chemical and other scenarios.

Application precautions

Sensor matching:

Differential expansion requires the use of an Extended Range Proximitor (e.g. 25 mm) to ensure that the range covers the expansion difference between the shaft and the casing.

It is recommended to use DC LVDT for casing expansion to avoid AC LVDT phase drift affecting accuracy.

Software version requirements:

TMR configuration requires 3500 configuration software 2.41 or above, and when using RPT for valve position, software 3.00 or above is required.

Maintenance suggestion:

Regularly verify the alarm function (such as triggering Alert/Ranger with input analog signals), and check the consistency between the LED status and the recorder output.

When hot plugging modules, power should be turned off to avoid static electricity damaging the circuit board (it is recommended to wear an anti-static wrist strap).

Summary

The 3500/45 position monitor provides accurate position parameter monitoring for rotating machinery through multi-channel and high-sensitivity design. Its modular configuration and TMR redundancy mechanism ensure system reliability, making it suitable for key fields such as power, petrochemicals, and metallurgy. Users can choose the appropriate combination of I/O modules and sensors based on the type of machinery and monitoring requirements, and achieve customized protection solutions through flexible software configuration, providing data support for the safe operation of equipment.

Product Overview

Core functions

3500/42 Proximitor ®/  The earthquake monitoring module is a four channel monitoring device that can receive input signals from a proximity probe and seismic sensors, and achieve monitoring functions such as radial vibration, thrust position, eccentricity, differential expansion, acceleration, and velocity through configuration. Its core function is to drive alarm output by comparing the current machine vibration value with the preset alarm threshold, and provide machine status data for operation and maintenance personnel.

Key Features

TMR architecture: Supports triple modular redundancy (TMR) configuration, avoids single point of failure through a 2 out of 3 voting mechanism, and ensures system reliability.

Flexible configuration: Customize channel types, alarm thresholds, filtering parameters, etc. through 3500 rack configuration software to adapt to different monitoring scenarios.

Real time diagnosis: Built in self checking function, quickly locate faults through LED indicator lights and event logs.

Safety certification: Compliant with standards such as IEC 61508, suitable for hazardous areas (such as Class I, Division 1/2).

Product Architecture and Working Principle

Hardware Architecture

Input module: support multiple I/O modules, including internal terminal, external terminal, TMR terminal and terminal module with barrier, and adapt to different sensor wiring requirements (such as Proximitor, accelerometer, speed sensor).

Signal processing: Each channel integrates filtering, amplification, and digitization circuits, supporting bandpass, high pass, and low-pass filtering, with a configurable frequency response range (such as radial vibration channels supporting 1 Hz to 4000 Hz).

Communication interface: communicates with other modules through the rack backplane, supports serial protocols such as RS-232/485, and can be connected to the upper computer for data monitoring.

TMR redundancy mechanism

Voting logic: In the TMR configuration, three monitoring modules vote 2 out of 3 for the input signal. If the deviation between the output of one module and that of other modules exceeds the set threshold (such as% Comparison), event logging will be triggered.

Input configuration:

Bus configuration: A single non redundant sensor signal is distributed to three modules through the bus.

Discrete configuration: Three redundant sensors are connected to three modules respectively to improve reliability.

Data output and status monitoring

Proportional value output: Output different parameters based on channel type, such as Direct (peak to peak), 1X/2X amplitude, phase lag, etc. for radial vibration; Gap (gap voltage) and Direct (axial displacement) at the thrust position.

Status identification: Feedback module health status, communication status, and alarm events through LED (OK, TX/RX, BYPASS) and event logs (System Event List, Alarm Event List).

Configuration Guide

Software Configuration Tool

Use 3500 Rack Configuration Software for parameter settings, with core configuration items including:

Channel type: Select radial vibration, thrust position, etc. Different types correspond to different filtering and scaling factors.

Full range: For example, radial vibration Direct can choose 0-10 mil pp (peak to peak), and acceleration can choose 0-20 g pk (peak to peak).

Alarm threshold: Set the Alert/Alarm 1 and Danger/Alarm 2 thresholds for each proportional value, and support lag adjustment (e.g., hysteresis is 1/64 of full scale).

Filter parameters: Set the cut-off frequency of the high/low-pass filter (e.g. acceleration channel supports 3 Hz to 30 kHz).

Example of Key Parameter Configuration

Radial vibration channel:

Select a 3300-8 mm Proximitor sensor and set the Scale Factor to 200 mV/mil.

Set the 1X Amplitude full-scale to 10 mil pp, the Alert threshold to 6 mil pp, the Danger threshold to 8 mil pp, and the delay time to 1 second.

Thrust position channel:

The Zero Position voltage is set to -9.75 Vdc (corresponding to the center value of the gap), the full range is set to 25-0-25 mil, and the direction is set to “Forward Probe” (displacement increases when the rotor moves towards the probe).

Key points of TMR configuration

Three monitoring modules need to be installed adjacent to each other and configured with Comparison Voting (if comparing 1X Amplitude, a deviation of 5% is allowed).

Bussed External Termination Block is used for bus configuration, while three independent sensors and terminal blocks are used for discrete configuration.

I/O modules and wiring

Module type and function

Internal terminal module: directly connected to sensors and recorders, suitable for non hazardous areas, wiring should pay attention to electrostatic protection (such as using anti-static wrist straps).

Internal Barrier Module: Integrated Zener Barrier, suitable for explosion-proof areas (such as Class I, Division 1), to restrict energy flow into hazardous areas.

External terminal module: Connect the sensor with a 25 pin cable and the recorder with a 9-pin cable to simplify the internal wiring of the rack.

Wiring specifications

Proximitor sensor: The power supply (PWR) is connected to -24 Vdc, the signal (SIG) is connected to the channel input, and the shielding layer (SHLD) is grounded.

Seismic sensors (such as Velomitor) require series connection of resistors and capacitors (such as 4 k Ω resistors+10 μ F capacitors) for signal conditioning.

TMR wiring: In discrete configuration, three sensors are connected to independent channels of three modules, and in bus configuration, sensor signals are shared through a Bussed Terminal Block.

Maintenance and testing

Regular verification testing

Testing cycle: It is recommended to conduct it once a year. If the equipment is a critical unit or operates in harsh environments, it can be shortened to once every quarter.

Testing equipment: function generator, multimeter, oscilloscope, Keyphasor Multiplier/Diverder, etc.

Test steps (taking radial vibration channel as an example):

Simulate sensor signals (such as a 100 Hz sine wave with a peak to peak value of 2 V).

Verify the display accuracy of proportional values such as Direct and 1X Amplitude (error ≤ ± 1% of full scale).

Trigger Alert/Arm 1 and Danger/Arm 2 thresholds, confirm that the alarm delay time is consistent with the configuration.

Disconnect the input signal and verify the OK state recovery time (Timed OK Channel Defeat set to 30 seconds).

Scale factor and zero position adjustment

Scale Factor: Used to calibrate the linearity deviation of sensors, such as the default 200 mV/mil for 3300-8 mm Proximitors, which can be adjusted by ± 15%.

Zero Position: For channels such as thrust position and eccentricity, adjust the voltage to make the displayed value zero (such as setting the zero position of thrust position to -9.75 Vdc, corresponding to mechanical zero position).

Recorder output verification

The 4-20 mA output should correspond to the full-scale proportional value. For example, when the full-scale is 10 mil pp, 20 mA corresponds to 10 mil pp, and 4 mA corresponds to 0 mil pp, with an error of ≤± 1%.

Troubleshooting

LED fault diagnosis

OK light off: It may be due to module failure, hardware malfunction, or sensor disconnection. Check the power and wiring, restart the module, or replace spare parts.

BYPASS light on: The channel is bypassed by software or the sensor is faulty. Check the Software Switches configuration and confirm that the sensor is in an OK state.

TX/RX light does not flash: communication failure, check the rack backplane connection and serial port parameters (baud rate, data bits).

Analysis of System Event List

Event 11 (Flash Memory Failure): Flash memory failure, module replacement required immediately.

Event 62 (I/O Module Mismatch): The I/O module type does not match the software configuration. Check the module model and reconfigure it.

Event 493 (Kph Lost): Keyphasor signal loss. Check the Keyphasor sensor and wiring to confirm if the speed is within the valid range (60-60000 cpm).

Common alarm handling

Alert/Arm 1 trigger: If the vibration value exceeds the threshold, check whether the machine is unbalanced, misaligned, or has bearing faults.

Trigger of Danger/Arm 2: Emergency stop condition, immediately stop the machine and troubleshoot equipment faults. If the shaft displacement exceeds the limit, it may cause dynamic and static friction.

Technical specifications and ordering information

key parameter

Input impedance: Proximitor channel 10 k Ω, TMR configuration with bus mode 50 k Ω and discrete mode 150 k Ω.

Frequency response: The radial vibration Direct channel supports 1 Hz-4000 Hz, and the acceleration channel supports 3 Hz-30 kHz.

Environmental conditions: Operating temperature -30 ℃~65 ℃ (non barrier module), storage temperature -40 ℃~85 ℃, humidity ≤ 95% non condensing.

Order Parts

Monitor module: 3500/42-01-00 (discrete internal terminal, no authentication), 3500/42-03-01 (TMR external terminal, CSA authentication).

Spare parts: I/O module (such as 128229-01), terminal block (125808-02 Euro style), cable (129525-0010-01, 10 foot assembly cable).

Safety and Compliance

Explosion proof certification: With barrier module supporting Class I, Division 1 (Groups A-D) and EEx ia IIC, suitable for explosive gas environments.

Static protection: When operating the module, wear an anti-static wrist strap and store it in a conductive bag to prevent static electricity from damaging the circuit board.

Maintenance warning: When hot plugging modules, ensure that the rack is powered off to avoid the risk of short circuit or electric shock caused by live operation.

Product Series and Certification

Series Overview

ABB’s Tmax, Isomax, and Emax series molded case circuit breakers comply with UL 489 and CSA C22.2 standards, covering a current range of 15A to 2500A with a breaking capacity of up to 150kA (480V AC).

The product belongs to the IndustrialIT certification system and can be integrated into the ProtectIT suite, supporting collaborative work with distribution board components. Some models (such as T4 and T5) have e-plug communication interfaces.

Core features

Compact design: The depth of small-sized models is unified (such as 70mm for T1-T3), saving installation space.

Double insulation: Except for Isomax S8, electrical accessories can be installed on site to enhance safety and convenience.

Modular design: supports fixed, plug-in, and pull-out installations, with standardized accessories for easy maintenance.

Product Classification and Technical Parameters

1. Tmax series (15A-600A)

Model subdivision: T1-T5, covering 15A-600A, supporting thermal magnetic or electronic release devices (such as PR221DS, PR222DS/P).

Technical highlights:

T4/T5 has high breaking capacity and low let through energy limitation, reducing the impact of short-circuit current.

The electronic release supports overload (L), short circuit (S/I), and ground fault (G) protection, with adjustable parameters (such as I ₁=0.4-1 × In).

Application scenarios: power distribution, motor protection (MCP), isolation switch (MCS).

2. Isomax series (800A-2500A)

Model subdivision: S6-S8, covering 800A-2500A, using electronic release devices (PR211/P, PR212/P).

Technical highlights:

S6-S7 supports pull-out installation, while S8 is fixed with a breaking capacity of 125kA (480V AC).

Equipped with Modbus/Lon communication interface (PR212/D), it can be integrated into industrial networks.

Application scenarios: Medium to large power distribution systems, emergency power switching.

3. Motor Control and Protection (MCP)

Special models: T2-T3, S6-S8, equipped with adjustable magnetic release (6-12 × In) or electronic release (PR221DS-I).

Function: For three-phase asynchronous motors, it supports instantaneous protection against overload and short circuit, and adapts to different starting modes.

4. Isolation switch (MCS)

Model: Based on T1-T5 and S6-S8, without trip function, used for line isolation or switching.

Key technical parameters

Electrical performance

Rated voltage: AC 480V/600V, DC 500V, supports three-phase/single-phase systems.

Breaking capacity: For example, T2 has a breaking capacity of 65kA at 480V AC, and S8 can reach 100kA at 480V AC.

Release characteristics: thermal magnetic release (fixed/adjustable threshold), electronic release (LSIG four stage protection).

​Machinery and Environment

Operating lifespan: Mechanical lifespan 20000-25000 cycles, electrical lifespan 8000 cycles (415V AC).

Working temperature: -25 ℃ -70 ℃, storage temperature -40 ℃ -85 ℃, humidity ≤ 90% (non condensing).

Attachments and Extended Features

Communication and Monitoring

The electronic release supports Modbus RTU and LonTalk protocols and can be connected to SCADA systems.

Display unit (FDU) monitors current and fault records in real-time.

Safety and Control Accessories

Release devices: shunt release (SOR), undervoltage release (UVR), residual current release (RC221/222).

Operating mechanism: rotary handle (RHD/RHE), energy storage motor (MOE), mechanical interlock.

Signal and indication: auxiliary contact (AUX), alarm contact (SY), position contact (AUP).

Installation accessories

Terminal cover (IP40), phase partition, DIN rail mounting bracket.

Installation and Design Specifications

Environmental requirements

When the altitude is ≤ 2000m, the rated voltage needs to be reduced to 522V if it exceeds 6600ft.

The working temperature under forced air cooling is ≤ 70 ℃, and heat dissipation needs to be evaluated in high-temperature environments.

Spacing and Protection

Center distance between adjacent circuit breakers: T1-T3 ≥ 76mm, S6-S8 ≥ 210mm.

Protection level: The terminal cover provides IP40 protection against electric shock and foreign object intrusion.

Wiring and Debugging

Supports copper/aluminum cables, with terminal types including front wire (F), rear wire (R), and extension wire (EF/ES).

The debugging tool (PR010/T) can test the trip function and configure protection parameters.

Application and Industry Solutions

Distribution system: used for main distribution boards and distribution boxes, supporting selective protection coordination.

Industrial automation: integrated into PLC control system to achieve remote monitoring and fault alarm.

Architecture and Infrastructure: Emergency Power Switching (ATS010 Controller) for Hospitals and Data Centers.

Standards and Compliance

Compliant with UL 489, CSA C22.2, IEC 60947-2, passed EMC, tropical, and vibration tests.

Environmental certification: compliant with ISO 14001, recyclable materials, and lithium battery processing must comply with safety regulations.

Hardware architecture and features

1. Core processor and architecture

Processor: Adopting a 25MHz 32-bit MC68040 or MC68LC040 microprocessor, the former integrates on-chip instruction and data cache, floating-point processor, while the latter has no floating-point unit.

Bus structure: The local bus is a 32-bit synchronous bus that supports burst transmission and snooping mechanisms. The arbitration priority from high to low is: LAN (82596CA)>SCSI (53C710)>VMEbus>MPU.

2. Memory configuration

DRAM: Supports 1MB, 4MB, or 8MB optional, non interleaved (1MB/8MB) or interleaved (4MB) architecture, with parity check, can trigger interrupt or bus exception in case of error.

SRAM: 512KB with battery backup (powered by Dallas DS1210S), battery life can be maintained for 200 days in the event of a power outage at 40 ° C. The backup power source (VMEbus+5V or onboard battery) needs to be selected through J20 jump pin.

Non volatile storage:

8KB NVRAM (MK48T08) integrates real-time clock, supports BCD format display of hours, minutes, seconds, year, month, and day, and automatically processes leap years.

1MB Flash memory (1 Intel 28F008SA or 4 28F020), can be selected to boot from Flash or EPROM through J22 jump pin.

1 JEDEC standard 32 pin PLCC EPROM socket (supporting 4Mbit density).

3. Interface and Expansion Capability

VMEbus interface: implemented by VMEchip2 ASIC, supporting A24/A32 addresses, D8/D16/D32 data transfer, including DMA controller, interrupt processor, system controller and other functions.

Serial port:

The two ports are driven by the Zilog Z85230 controller and support EIA-232-D (DCE/LTE) or EIA-530 interfaces, configured through the SIM module (SIM05-SIM08).

The baud rate range is 110b/s to 38.4Kb/s, supporting synchronous (SDLC/HDLC) and asynchronous protocols.

Network and Storage:

Ethernet interface: Intel 82596CA controller, supports 32-bit DMA, and each card is assigned a unique MAC address ($08003E2XXXXX).

SCSI interface: NCR 53C710 controller, supporting 32-bit local bus burst DMA, ensuring correct termination at both ends of the bus.

Industry Pack (IP) interface: 4 single size or 2 dual size IP interfaces, controlled by IPIC ASIC, supporting external cable connections.

4. Physical and electrical specifications

Size:

Double height VME board, with a height of 9.187 inches without connectors and a height of 10.309 inches with connectors and front panel, and a thickness of 0.8 inches.

Power Supply:

+5V (± 5%), typical 3.5A, maximum 4.5A;+12Vdc (± 5%) and -12Vdc (± 5%), maximum 100mA.

environment

Working temperature: 0 ° C to 70 ° C (forced air cooling), storage temperature: -40 ° C to+85 ° C, relative humidity: 5% -90% (non condensing).

Installation and configuration process

1. Hardware preparation

Jumping needle configuration:

J1: System controller selection (default enabled, system controller when installing jump pin).

J10: SIM module selection for serial port B (EIA-232-D or EIA-530, DCE/LTE mode).

J20: SRAM backup power selection (VMEbus+5V or onboard battery).

J22: Universal readable jump pin, where GPO3 (pins 9-10) is used to select Flash/EPROM boot mapping.

Safety precautions:

Anti static operation, avoid touching integrated circuits; Disconnect all power sources before installation.

Lithium battery handling: Short circuit, disassembly, and heating are prohibited, and polarity should be noted when replacing.

2. Installation steps

Installation of IP module:

Four IP modules are installed on connectors such as J2/J3, J7/J8, and dual size IP requires adjacent interfaces.

External cables are led out through connectors such as J6 and J5, and users need to provide 50 pin cables themselves.

Installation of VME chassis:

The system controller needs to be installed in slot 1 of the chassis, and non controllers can be installed in any double height slot.

Connect the P1 and P2 connectors to ensure they are securely fastened; Remove the IACK and BG jump pins from the corresponding slots on the chassis backplane.

Transition module connection:

Install MVME712 series transition modules (such as MVME712M, MVME712A) and connect serial ports, SCSI, and Ethernet interfaces through a P2 adapter board.

3. Cable and interface connection

Serial port:

Port 1 (CONSOLE) is connected through a DB-25 connector and defaults to asynchronous mode; Port 2 is configured through the SIM module and transition module.

SCSI and Ethernet:

The SCSI interface is connected through a P2 connector and requires the installation of a terminal resistor; The Ethernet interface is led out through the DB15 connector of the MVME712X transition module.

Debugging Tools and Firmware (162Bug)

1. Firmware Overview

Function: Integrated into Flash/PROM, providing functions such as memory debugging, program loading, hardware diagnostics, etc., supporting system self startup and network startup.

Startup mode:

Board Mode: default startup, displays the “162 Bug>” prompt, supports manual command operation.

System Mode: configured through ENV commands, supports automatic testing and system booting.

2. Core functions and commands

Memory operation:

MD: Displays memory content, supports byte/word/long word formats, and can be disassembled (DI option).

MM: Modify memory data and support direct writing of assembly instructions.

Program execution:

GO: Execute the program from the specified address and support breakpoint setting (BR command).

GT: Execute to a temporary breakpoint for single step tracking.

Disk and Network:

BO/BH: Start the operating system/load programs from the disk and pause.

NBO/NBH: Start the system through network (TFTP/BOOTP) and support IP configuration.

Diagnostic tool:

IOC/IOP: Directly operate the disk controller to test hardware functionality.

CNFG/ENV: Configure onboard information blocks (BIBs) and environment parameters (such as startup latency, memory mapping).

3. Automatic start mechanism

Autoboot: After powering on, it scans disk devices and starts in order of LUNs, which can be interrupted by pressing the<BREAK>key.

Network Boot: Obtain IP through RARP/BOOTP, load boot files through TFTP, and support diskless system boot.

ROMboot: User defined boot code that meets memory mapping and checksum requirements.

Safety and Compliance Standards

Electromagnetic Compatibility (EMC)

The device complies with FCC Part 15 Subpart J Class A standards and can avoid interference when used in commercial environments; If there is interference in the residential environment, users need to take measures on their own.

Safety operation standards

Grounding: Use a three core power cord to ensure that the chassis is grounded (connect the green wire to a safe ground).

Prohibited environment: Do not operate in flammable gas environments.

Maintenance restriction: Only authorized personnel are allowed to open the chassis, operate after power off and discharging.

Warning signs

SYSFAIL * signal: If a memory verification error, low battery voltage, or other fault is detected after power on, the VMEbus SYSFAIL * signal will be asserted.

LED indicator lights: FAIL (red) indicates hardware failure, RUN (green) indicates local bus activity, SCON (green) indicates system controller status.

Summarize

The MVME162 embedded controller, as a classic VMEbus architecture product from Motorola, integrates high-performance processors, rich interfaces, and reliable memory systems, making it suitable for industrial control, embedded computing, and other scenarios. The document provides users with full process support from hardware deployment to system startup through detailed hardware instructions, installation procedures, and debugging tool guides, while emphasizing security standards and compatibility design to ensure stable device operation.

Product Overview and Positioning

TU810/TU810V1 is a 16 channel 50V compact module terminal unit (MTU) designed specifically for ABB System 800xA automation systems, and is a key component of the S800 I/O system. As a passive interface unit, its core function is to achieve electrical connection between field wiring and I/O modules, while carrying the transmission and distribution of Module Bus signals. This MTU adopts a modular design, supports mechanical keying configuration, ensures compatibility with different types of I/O modules, and is suitable for signal access and system expansion in industrial automation scenarios.

Core functions and technical features

Module Bus Management

As the physical carrier of the Modulus Bus, TU810V1 is responsible for distributing bus signals to connected I/O modules and the next level MTU, forming a chain topology structure.

By shifting the output position signal to generate I/O module addresses, automatic addressing is achieved, simplifying the system configuration process.

Mechanical key control configuration system

Equipped with two sets of six position mechanical keys, compatible with the full range of S800 I/O modules such as AI810, AO810, DI810, DO810, etc. through different combinations (a total of 36 configurations).

Keying is only for mechanical positioning and does not affect electrical functions, but it can effectively prevent module misconnection and improve installation reliability.

Signal and power connection

16 channel on-site signal interface: supports standard industrial signals (such as 4-20mA, 0-10V, etc.), with a maximum current of 2A per channel.

Process power connection: Provide 2 × 2 or 5 × 2 power terminals (0V common terminal), supporting a maximum current of 5A, to meet the power supply requirements of sensors and actuators.

Wiring specifications: Solid wire 0.2-4mm ², stranded wire 0.2-2.5mm ² (24-12 AWG), compatible with mainstream industrial cables.

Installation and Protection Design

DIN rail installation: supports horizontal (up to 55 ℃) and vertical (up to 40 ℃) installation, with grounding locking device to ensure electromagnetic compatibility.

Compact structure: Size 170 × 64 × 64mm (height × width × depth), weight only 0.17kg, saving control cabinet space.

Protection level: IP20 (preventing solid foreign objects from entering), suitable for indoor industrial environments, pollution level 2 (IEC 60664-1).

Electrical and Environmental Parameters

Electrical performance

Dielectric strength: 500V AC test to ensure insulation safety between channels.

Overvoltage category: Compliant with IEC 60664-1 standard, suitable for industrial grade power systems.

EMC compatibility: Following EN 61000-6-4 (emission standard) and EN 61000-6-2 (immunity standard), it has strong electromagnetic interference resistance.

Environmental adaptability

Temperature range: working temperature 0-55 ℃, storage temperature -40-70 ℃, supports wide temperature operation.

Humidity conditions: 5% -95% without condensation, meeting the requirements of humid environments (IEC 61131-2).

Corrosive atmosphere: Complies with ISA-S71.04 G3 grade and is suitable for moderately corrosive industrial scenarios such as chemical and metallurgical industries.

Certification and Compliance

Safety certifications: CE, UL 508, cULus (Hazardous Area Class 1, Division 2/Zone 2), ATEX Zone 2, supporting applications in explosion-proof areas.

Classification society certification: ABS, BV, DNV-GL, LR, RS, CCS, applicable to ship automation systems.

Environmental standards: RoHS (EN 50581:2012) and compliance with the WEEE directive, supporting green manufacturing.

List of compatible I/O modules

Analog inputs (AI): AI810, AI815, AI820, AI830, AI830A, AI835, AI835A, AI845

Analog Output (AO): AO810, AO810V2, AO815, AO820, AO845, AO845A

Digital Input (DI): DI810, DI811, DI814, DI830, DI831, DI840, DI880, DI885

Digital Output (DO): DO810, DO814, DO815, DO840, DO880

Pulse/Count Input (DP): DP820, DP840

Application scenarios and system integration

Typical application areas

Process automation: signal acquisition and control in the chemical, petroleum, and power industries, such as temperature, pressure, and flow sensor integration.

Mechanical manufacturing: digital input/output control of machine tools and production lines (such as solenoid valves, encoder signal processing).

Ship and Maritime: Engine room monitoring, deck equipment control, meeting the requirements of marine environmental certification.

System topology

Chain extension: Multiple MTUs are connected in series through a Modulus Bus, supporting maximum I/O point expansion and suitable for large control systems.

Redundant configuration: Although MTU is designed as a single channel, it can be combined with redundant I/O modules to improve system reliability.

Installation and wiring precautions

Grounding requirement: Reliable grounding through DIN rail latch to reduce electromagnetic interference.

Cable management: It is recommended to use shielded cables and lay signal and power cables separately to avoid crosstalk.

Product Overview

Positioning: SPAJ 140 C is a combination overcurrent and ground fault relay used for selective short-circuit and ground fault protection of radial feeders in solid grounding, resistance grounding, or impedance grounding power systems. It can also be used in other application scenarios that require single-phase, two-phase, or three-phase overcurrent protection and non directional ground fault protection.

Core function: Integrated phase overcurrent unit and ground fault unit, with circuit breaker fault protection function, providing multiple output relay configurations and powerful data communication capabilities.

Core functions

Protection function:

Phase overcurrent protection: includes low setting stage I>(timed or inverse time characteristic) and high setting stage I>>(instantaneous or timed function).

Ground fault protection: Low setting stage I0>(timed or inverse time characteristic) and high setting stage I0>>(timed function).

Other protections: transformer surge detection, thermal overload protection, phase to phase circuit breaker protection, negative sequence overcurrent protection, circuit breaker fault protection.

Control and signal functions:

External control inputs can be used to block protection stages, reset latch output relays, or remotely control relay settings.

Provide two heavy-duty and four light-duty output relays, which can be configured through switch group functionality.

Measurement and recording:

Continuously measure phase current and neutral current, and display the highest load phase current and ground current by default.

The event log stores 100 timestamp events and records the simulated values of the last five trip events.

Self supervision and testing:

Built in self-monitoring system, monitoring hardware and software status, triggering alarms and blocking protection functions when faults are detected.

Support built-in testing mode to test HMI and binary output.

Technical characteristics

Hardware parameters:

The rated current is 1A or 5A, and the thermal withstand capacity is continuous 4A/20A and 100A/500A per second, respectively.

Power supply voltage range: SPTU 240 R1 is 80-265V DC/AC, SPTU 48 R1 is 18-80V DC, with a power consumption of approximately 4-6W.

Protection features:

The low setting stage of overcurrent and ground fault protection can select time limit (DT) and inverse time limit (IDMT) characteristics, supporting multiple standards and special curves.

The circuit breaker fault protection generates a trip signal after a set time (0.1-1 seconds) following the main trip signal.

Communication and Interface:

Built in serial port, supporting MODBUS RTU or IEC 60870-5-103 protocol, connected via fiber optic SPA bus.

Four binary inputs and six output contacts, the output contacts can be configured for different functions.

Application scenarios

Suitable for short-circuit, overcurrent, and grounding fault protection of incoming and outgoing feeders, overhead lines, and cable feeders in medium voltage distribution stations, as well as main protection of distribution transformers.

Different application configurations (B/C/D) provide different combinations of functions to meet different protection requirements.

Operation and Settings

Human computer interaction: The local HMI includes an alphanumeric LCD display screen, LED indicator lights, and navigation keys, supporting multiple languages.

Setting method: Use a portable PC and software to set parameters through the front panel buttons or serial port, supporting switching between two sets of parameters: main settings and second settings.

Switch group configuration: Configure relay functions and output signal routing through software switch groups SGF, SGB, and SGR.

Technical parameters

Size and Installation: Adopting a crimping panel installation, the size is about 130 × 160 × 151.5mm, the weight is about 3.5kg, the protection level is IP54 for the front panel, and IP20 for the back terminal.

Environmental conditions: working temperature -10 ℃~+55 ℃, storage temperature -40 ℃~+70 ℃, relative humidity<95% (no condensation), altitude up to 2000 meters.

Electromagnetic compatibility: Complies with standards such as IEC 60255 and has passed tests such as high-frequency pulses, electrostatic discharge, and rapid transients.

Product positioning and core values

AC 800PEC is a high-performance industrial control system launched by ABB, developed specifically to meet model-based design and high-speed control algorithm requirements. Its core advantage lies in integrating traditional separated high-speed control (such as power electronics applications) and low-speed process control (PLC tasks) into a single processor unit, achieving full range cycle time coverage from 100 microseconds to several seconds. This system is based on ABB’s ControlIT automation technology, combined with MATLAB ®/ Simulink ®  Model development tools significantly shorten the engineering cycle from simulation to implementation, suitable for scenarios such as traction, power generation, and industrial processing that require high real-time and reliability.

Hardware architecture and performance parameters

Processing Core and Architecture

Collaborative design of CPU and FPGA: The CPU is responsible for floating-point operations and complex logic, while the FPGA handles ultra high speed tasks (such as 25 nanosecond logic), forming a three-level performance hierarchy:

Ultra fast layer: 25 nanosecond task (VHDL programming, firmware module implementation);

Fast layer: 100 microsecond loop (MATLAB) ®/ Simulink ®  Control algorithm);

Slow layer: tasks lasting over 1 millisecond (programming in IEC 61131-3 language).

I/O system:

Fast I/O: Fiber optic connection, transmission time<10 microseconds (internal) to 25 microseconds (external), anti electromagnetic interference, no need to isolate transmitter;

Slow I/O: Compatible with ABB S800 module and supports millisecond level response.

Hardware scalability

Three architectural patterns:

Compact: Single processor integrated I/O, suitable for small devices or distributed subsystems;

Standard type: independent processor+fast I/O, suitable for central control scenarios;

Modularization: Multi processor+intelligent I/O, supporting redundant configuration of large systems.

Environmental adaptability:

Working temperature: -40 ℃ to+70 ℃ (traction field);

Anti vibration: Complies with traction industry standards and is designed with no moving parts.

Software Ecology and Programming System

Third level software architecture

Level 1: Systems Engineering

Tool: ABB Control Builder (Compact/Professional version);

Language: All 5 IEC 61131-3 languages (LD, FBD, ST, etc.);

Application: Non high speed logic (parameter configuration, system adaptation), can be integrated into 800xA automation systems.

Level 2: Control Algorithm Development

Tool: MATLAB ®/ Simulink ® +  Real-Time Workshop ®；

Process: Model simulation → Automatic generation of C code → One click download to controller;

Application: Core algorithms such as closed-loop control, protection logic, and state machines.

Level 3: Ultra High Speed Logic

Tools: VHDL+FPGA development framework;

Function: Communication protocol (such as Powerlink), pulse modulation, hardware level protection, firmware level packaging cannot be modified.

Model driven development process

Traditional vs Modern Workflow:

Traditional: specification definition → code handwriting → debugging (error prone, long cycle);

AC 800PEC：Simulink ®  Model → Automatic code generation → Real time debugging (online parameter optimization, direct deployment via Ethernet).

Communication and integration capabilities

Native protocol support

Industrial bus: Profibus DPV1 (master station), Modbus RTU/TCP, IEC 61850 (power system) CANopen；

ABB exclusive: Powerlink, Drivebus (DDCS), Modulabus (S800 fiber optic).

Expansion

Through the CEX module: Drivebus slave station ControlNet、DeviceNet；

Supports RS-232/422 serial port through Anybus modules such as Profinet, EtherCAT, Ethernet/IP, etc.

System integration

Deeply compatible with ABB 800xA automation platform, achieving unified monitoring from on-site equipment to factory level, supporting firewall and security authentication to prevent unauthorized access.

Typical application scenarios

Traction field (railway/rail transit)

Challenge: Wide temperature range, strong vibration, limited space;

Scheme: compact hardware+anti vibration design, stable operation from -40 ℃ to+70 ℃, integrated I/O and processor in the same module, meeting the space requirements of on-board equipment.

Power generation and excitation control

Requirement: High reliability, redundant and fault-tolerant;

Solution: Modular architecture+hot standby redundancy, automatically switches to the standby unit when the main controller fails, ensuring continuous operation of the generator excitation system, suitable for key equipment in power plants.

Industrial process control (such as cold rolling mill)

Challenge: Thickness control accuracy (MIMO multiple input multiple output system);

Solution: MATLAB ®/ Simulink ®  Develop model predictive control algorithm, combined with C code acceleration, to improve thickness deviation by 50%, surpassing traditional control schemes.

Engineering benefits and customer value

Performance improvement:

Control accuracy: The thickness deviation of the cold rolling mill is reduced by 50%;

Response speed: 100 microsecond cycle time, suitable for high-frequency switching requirements of power electronic devices.

Cost optimization:

Development cycle: The model automatically generates code, reducing manual programming workload by 50%;

Hardware investment: Integrating multitasking with a single processor to reduce the separate procurement cost of PLC and high-speed controller.

Sustainability:

Energy consumption: Efficient algorithms reduce device operating power consumption;

Lifecycle: Industrial grade hardware design, supports long-term upgrades, and protects user investments.

Service and Support System

Tool chain: AC 800PEC specialized tools cover the entire engineering cycle (design, commissioning, maintenance);

Training system: Provide courses such as model development and system integration to enhance user team skills;

Global service: 100+country offices, 24-hour technical support, combined with local experience and global resources.

Product positioning and overview

Product positioning 

REF601: Dedicated feeder protection and control relay, integrating protection, monitoring, and circuit breaker control functions, suitable for incoming and outgoing feeder lines in medium voltage distribution networks.

REJ601: Overcurrent protection relay, without circuit breaker control function, focusing on overcurrent and ground fault protection.

Series affiliation: Belongs to ABB Relion ®  The 605 series is designed based on professional knowledge in the field of digital technology and protection, and supports pre configuration to simplify debugging.

Core advantages

Compact design, suitable for the renovation of switchgear with limited space, using crimping installation without the need for additional accessories.

Provide three application configurations (B/C/D) to meet different protection requirements and support ANSI/IEC standards.

Core Function Analysis

1. Protection function (REF601/REJ601 universal)

Overcurrent protection:

Three stage non directional overcurrent: low setting stage (51P/3I>), high setting stage (50P-1/3I>>), instantaneous stage (50P-2/3I>>), supports IDMT (inverse time limit) and DT (definite time limit) characteristics, compatible with IEC 60255-3 and ANSI C37.112 standard curves (such as Normal Inverse, Very Inverse).

Two stage grounding fault protection: low setting stage (51N/Io>), high setting stage (50N/Io>>), which can calculate the grounding current through external zero sequence CT or internal phase current.

Auxiliary protection:

Transformer surge detection (68/3I2f>) to prevent accidental tripping when the transformer is closed.

Thermal overload protection (49/3Ith>), suitable for feeders, cables, and transformers, supports thermal aging simulation.

Phase to phase open circuit protection (46PD/I2/I1>), negative sequence overcurrent protection (46/I2>), identify asymmetric faults.

Circuit breaker fault protection (50BF/50NBF), activate backup protection when detecting circuit breaker refusal to move.

2. Control function (REF601 only)

Circuit breaker control: Switching is achieved through local HMI buttons or communication interfaces (MODBUS/103 protocol), equipped with two dedicated output contacts.

Automatic reclosing: Supports 4 reclosing cycles, configurable dead time, pulse time, and lockout logic, suitable for overhead line fault recovery.

3. Monitoring and recording

Real time measurement: Continuously monitor three-phase current, grounding current, optional negative sequence current, thermal level, and operation counting.

Event log: Stores 100 events with a 1ms timestamp (such as protection actions, trip circuit status), supports local/remote queries.

Fault recording: Record the analog data (three-phase current+ground current) of the last 5 tripping events for fault analysis.

4. Self supervision and safety

Self diagnosis: Real time monitoring of hardware (such as CPU, memory) and software status, blocking protection functions and alerting in case of faults.

Trip Circuit Monitoring (TCM): detects open circuit and loss of control voltage in the trip circuit, and supports monitoring of the opening and closing status of the circuit breaker.

Access control: three-level user permissions (operator/engineer/administrator), supporting alphanumeric password or key combination authentication.

Application scenarios and configurations

Typical applications

Medium voltage distribution station: short circuit, overcurrent, and grounding fault protection for incoming and outgoing feeder lines.

Distribution transformer: utilizing surge detection function as the main protection.

Overhead lines and cables: improve power supply reliability through automatic reclosing (REF601).

Configuration differences

Configuration B: Basic function, providing non directional overcurrent+ground fault protection, with ground current calculated from phase current.

Configuration C: Add thermal overload, phase to phase circuit breaker, and circuit breaker fault protection on the basis of B.

Configuration D (REF601 only): Add negative sequence protection and quadruple automatic reclosing on the basis of C, suitable for overhead line feeders.

Technical Parameter

1. Electrical parameters

Power supply: AC/DC 24-240V, fluctuation range AC 85-110%/DC 70-120%, static power consumption<5VA.

Current input:

Rated current: 1A or 5A (optional), continuous withstand current 4A/20A, 1-second withstand current 100A/500A.

Input impedance:<100m Ω (1A)/<20m Ω (5A).

2. Machinery and Environment

Dimensions: 130mm (width) x 160mm (height) x 151.5mm (depth), weight 1.43kg.

Environmental adaptation:

Working temperature: -25 ℃~+55 ℃, short-term storage -40 ℃~+85 ℃.

Humidity:<93% without condensation, altitude ≤ 2000 meters.

3. Electromagnetic compatibility (EMC)

Anti interference: Tested through electrostatic discharge (6kV contact/8kV air), radiated electromagnetic field (10V/m, 80MHz-2.7GHz), fast transient (4kV), etc.

Emission limit: Complies with EN 55011 standard, with conducted radiation<66dB (μ V/m) and radiated radiation<47dB (μ V/m).

4. Insulation and Protection

Dielectric strength: 2kV/1min, impulse voltage 5kV (1.2/50 μ s), insulation resistance>100M Ω.

Protection level: front panel IP54, back terminal IP20.

​Interface and Communication

Input/output

Analog input: 4-channel current input (3-phase+grounded), supporting 1A/5A CT.

Binary input: 4 channels, configurable for circuit breaker position, trip command, etc.

Output contacts: 6 channels (2 power outputs+4 signal outputs), with a maximum switching capacity of 240V/8A.

communication interface

Optional MODBUS RTU or IEC 60870-5-103 protocol, RS485 two-wire connection, supports remote monitoring and parameter configuration.

Ordering and Accessories

Order coding rules

Example: REF601 A E4 46 B D 1 B H, including relay type, standard (ANSI/IEC), current input specifications, communication protocol, application configuration, and other information.

Accessory

Communication card: CIM601BNNNNBANXG, used to add MODBUS or 103 protocol interfaces.

Summarize

ABB REF601/REJ601 relays provide a solution for medium voltage distribution systems that integrates protection, control, and monitoring through modular design and flexible configuration. Its core advantages lie in:

Comprehensive protection: covering multiple protection functions such as overcurrent, ground fault, thermal overload, etc., supporting custom characteristic curves.

Strong adaptability: Three application configurations are suitable for different scenarios, and the compact design meets space constraints.

High reliability: Self supervision and trip circuit monitoring enhance system safety, while EMC and environmental testing ensure industrial grade durability.

Ease of operation: Local HMI and hierarchical permission management simplify on-site debugging, and communication interface supports remote operation and maintenance.

Suitable for urban distribution networks, industrial power systems, and other scenarios, especially for situations that require efficient fault protection and power supply reliability.

Document Overview and Core Positioning

Document property

This manual is the service manual for the RPH3 “Point on Wave (PoW)” controller, which is used to guide the synchronous switching operation of high-voltage switchgear and support equipment understanding, installation, use, and maintenance.

Copyright belongs to GE Grid Solutions. The content is informative and can be adjusted according to technical and commercial needs. Unauthorized reproduction and disclosure are prohibited.

Reference architecture

GE internal documents: such as D1621EN (User Manual), D1622EN (RPH Manager Software Manual), etc.

International standard: Following IEC 62271-302 (Non synchronous pole operation of high-voltage switchgear).

Industry Report: Cited from CIGR É 262-264 publication (HVAC Switchgear Control Switching Guide).

Safety and Operation Instructions

Static Electricity and Electrical Safety

Electrostatic discharge (ESD) may damage equipment and should comply with anti-static standards such as EN 61340-5-1.

Power off before operation, confirm that the power supply voltage is compatible (AC 100-240V or DC 48-353V), only qualified engineers can operate.

Storage and installation requirements

Store in a dust-free and dry environment at -40 ℃~+70 ℃, with moisture-proof bags retained; Installed in the control room or relay room, ensuring good grounding, away from vibration sources, supporting 19 inch rack or wall mounted installation.

Principle of PoW Switching Technology

Random switching vs synchronous switching

Random switching: When the coils are powered on simultaneously, it is easy to generate surge current and overvoltage, which can cause equipment aging or protection misoperation.

PoW switching: By delaying the control of coil energization time, the high-voltage contacts are made to contact at the target point of the voltage waveform (such as zero crossing or peak), reducing transient phenomena. For example:

Inductive load (transformer) closing selects peak voltage to reduce excitation inrush current;

Capacitive load (capacitor) closing selects voltage zero crossing to reduce charging current surge.

Key parameters and terminology

Pre arming Time: The current conduction time before the mechanical contact of the contacts during closing, influenced by the dielectric strength decay rate (RDDS).

Operating Time: The time it takes for the coil to be powered on until the contacts fully move, and it is necessary to compensate for the effects of environmental temperature, hydraulic pressure, and other factors.

Adaptive Control: Based on historical operational data, adjust control timing and compensate for unpredictable factors such as equipment aging.

RPH3 Hardware and Functional Architecture

Module composition

M1: Power module, providing internal DC power supply.

M2: Central processing and communication module, integrated with DSP and Linux system, supporting Ethernet and fiber optic communication.

M3: Analog acquisition module, sampling reference voltage, current, temperature, hydraulic pressure and other signals.

M4: Signal and coil drive module, processing switch commands and relay outputs.

M5: Front panel management module, controls LED indicator lights and serial communication.

Core functional modules

Reference voltage sampling: Obtain the grid voltage through VT as a timing reference, supporting L1/L2/L3 phase selection.

Neutral point mode detection: supports hardware jumpers (M4-J5) or software settings to distinguish between grounded, isolated, or unknown modes.

Coil driver: Supports common mode/differential mode wiring, outputs 80ms adjustable pulses, and drives the opening and closing coils of switch devices.

Operation time measurement: Detect contact action through auxiliary contacts or current transformers (CT) with an accuracy of ± 0.1ms.

Compensation mechanism and adaptive control

Compensation factors for operation time

Environmental temperature: Low temperature will prolong operation time. Real time compensation can be achieved through a temperature sensor (4-20mA input), and the compensation meter can be configured through Web MMI.

Control voltage: Voltage fluctuations affect the rate of rise of coil current. The compensation value is calculated using the formula Δ t voltage=(U meas U rate − 1) ⋅ kU ⋅ t OP_rated, where kU is the compensation coefficient (to be measured).

Hydraulic pressure: For hydraulic drive mechanisms, real-time sampling is carried out through pressure sensors, and compensation is made according to Δ t pressure=(P meas P rate − 1) ⋅ kP ⋅ t OP_rated.

Idle time: Devices that have not been operated for a long time will slow down, compensated by the exponential function Δ t idle=A ⋅ (1 − e − BT idle), where A and B are empirical parameters.

Adaptive control is based on historical operational data and utilizes Δt adapt=K⋅(t measured −t commissioning −Δt compensations)+(1−K)⋅Δt adapt_prev  Adjust the prediction time series, with K as the weight factor (default 0.3).

Alarm and Data Management

Alarm Type

System alarm: such as abnormal power supply, hardware failure, calibration failure, etc., triggering the red LED “3” on the front panel.

Application alarm: If the reference voltage exceeds the limit, the operation time is abnormal, the compensation value exceeds the limit, etc., the LED “4” will be triggered.

Relay output: 5 relays (1 monostable+4 bistable), which can be configured with alarm correlation logic through Web MMI.

Data recording and communication

Real time data: View parameters such as voltage, current, temperature, etc. through Web MMI, with a refresh rate of 3 seconds or 20 seconds.

Switching record: Stores the last 1025 operation data (“*. arch” file), supports downloading waveforms and event logs through RPH Manager software.

Network interface: Supports IP network (default IP 192.168.5.2), compatible with IEC 61850-9-2 communication protocol.

Application scenarios and switching strategies

Typical load switching scheme

Transformer/Three core Reactor:

Closing: Select the peak voltage (90 ° electrical angle) for the grounding neutral point, and select 0 ° or 180 ° for the isolation neutral point.

Trip: Select the current zero crossing point (corresponding to the peak voltage) to reduce overvoltage.

Single core reactor: The closing target point is the same as the transformer, and the tripping strategy is consistent.

capacitor:

Closing: Select voltage zero crossing (0 °) for the grounding neutral point and phase voltage zero crossing for the isolation neutral point.

Trip: Select the zero crossing point of the current to avoid heavy impact.

Transmission line:

Inductive VT: select voltage zero crossing for closing;

Capacitive VT: It is necessary to evaluate the residual charge in the circuit and select the peak voltage for closing.

Inductive load with NGR: Select the neutral point mode based on the inductance ratio r=LL N, and use a custom switching program when r ≥ 0.3.

Switch program configuration

Built in preset programs (transformers, reactors, capacitors), supporting user-defined modes (User Mode), can adjust the angle offset of each phase.

Technical parameters and specifications

Physical characteristics: 19 inch 4U rack, dimensions 483 × 177 × 452mm, protection level IP20.

Electrical parameters:

Power supply: AC 100-240V/50-60Hz or DC 48-353V, power consumption<20W;

Coil driving voltage: DC 33-300V, maximum current 30A (300ms).

Measurement accuracy: Voltage/current sampling error ≤ 1%, operation time measurement error ≤ ± 0.1ms.

Environmental adaptability: Operating temperature -25 ℃~+50 ℃, storage temperature -40 ℃~+70 ℃, compliant with RoHS and EMC standards (such as IEC 61000-4-2/3/5).