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Thinklogical Velocity KVM-34 series KVM fiber extender

Product positioning and core values

1. Product positioning

The Velocitykvm-34 series is a four screen single link DVI KVM fiber optic extension system that uses a “transmitter receiver” architecture to achieve remote separation and control of computers and peripherals through single-mode/multi-mode fibers. It supports video, audio USB、 The synchronous transmission of multiple signals through serial ports solves the three major pain points of “long-distance signal attenuation, high-resolution uncompressed transmission, and compatibility with multiple peripherals”.

2. Core values

Uncompressed high-definition transmission: relying on patented MRTS (Multi Rate Transmission System) technology, 6.25Gbps bandwidth supports all single link DVI resolutions (such as 1920 × 1080) 1200@60Hz )No frame loss, no compression, zero image delay;

Ultra long distance coverage: Single mode fiber can transmit up to 10km, and multimode fiber (OM3 enhanced type) can transmit up to 1000m, meeting the deployment needs of large parks, cross buildings, and other long-distance environments;

Multi interface compatibility: integrated with USB (HID/1.1/2.0), PS2, RS-232 serial port, bidirectional stereo audio, compatible with keyboards, mice, USB drives, high-speed storage devices, microphones and other peripherals;

High security: Provides “HID only” models (with USB storage devices disabled) to meet the security control needs of classified scenarios such as command centers and financial data centers.

Product classification and core differences

The series includes four core models, all of which support four screen DVI output, PS2, RS-232 serial port, and bidirectional audio. The core difference lies in USB function and network expansion capability. The specific classifications are as follows:

Model Type Core Interface Configuration Transmission Rate Applicable Scenarios

USB 1.0 HID (only) supports USB ergonomic devices (keyboard, mouse, drawing board), disabled USB storage – classified scenarios (such as military command center, financial data center), to prevent data leakage

USB 1.1 supports USB 1.1 full speed peripherals (USB flash drives, tablets, low-speed printers) at 12Mbps for regular office scenarios, without the need for high-speed USB devices

USB 1.1+Ethernet (10/100Base-T) USB 1.1 functionality+Ethernet expansion, capable of transmitting network signals via fiber optic USB 12Mbps; Ethernet 100Mbps requires simultaneous extension of network and KVM signals in scenarios such as remote laboratories and distributed offices

USB 1.1+USB 2.0 compatible with USB 1.1 (low-speed) and USB 2.0 (high-speed) devices. USB 2.0 can reach 480Mbps and requires high-speed peripherals, such as DVD drives, high-speed portable hard drives, and professional scanners

In addition, all models offer single-mode/multi-mode fiber options, and fiber connectors support LC, SC, and ST types to adapt to different fiber infrastructure.

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Key technical parameters

1. Transmission performance parameters

Parameter category specification details

Video signal single link DVI-D, supporting all resolutions (such as 1920 × 1080) 1080@60Hz 1920 × 1200@60Hz )

Transmission bandwidth of 6.25Gbps (MRTS technology), no compression, no frame loss

Fiber optic distance – multimode: OM1 (62.5/125 μ m) 50m; OM2(50/125μm)350m; OM3(50/125μm)750m; OM3 Enhanced 1000m

-Single mode: OS2 (9/125 μ m) 10km (for distances exceeding 10km, please contact the manufacturer for customization)

The standard number of optical fibers is 5 cores (4 cores for video/USB, 1 core for USB/DC feedback), supporting customized models with fewer cores

2. Physical and environmental parameters

Parameter category specification details

Size 19 inch rack mount (EIA standard), 1U height (4.40cm), width 44.5cm, depth 36.1cm

The weight of a single machine is 11lbs (4.99kg), and the transportation weight of the transmitter+receiver set is 27lbs (12.25kg)

Power supply wide voltage 100-240V AC (47-63Hz), single machine power consumption 40W

Working environment temperature 0-50 ℃ (32-122 ℉), humidity 5% -95% RH (non condensing)

Certified to comply with electrical safety standards in the United States, Canada, and the European Union (such as CE, FCC, cUL)

12 months warranty (expandable extended warranty)

3. Interface configuration (transmitter vs receiver)

Equipment interface type and quantity remarks

Transmitter – Video: DVI-D (4, connected to computer)

-USB: USB B (HID/1.1/2.0, depending on model), local USB A (keyboard/mouse, 2)

-PS2: MiniDIN 6 female head (keyboard/mouse, 1 each; local 1 each)

-Audio: 3.5mm interface (1 microphone, 1 line input)

-Serial port: DB9 female head (RS-232)

-Fiber optic: LC/SC/ST (single-mode SC/APC, multi-mode LC/SC/ST)

-Software upgrade: USB B (3) local interfaces support “near end control”, which means that the computer can be directly operated with a keyboard and mouse

Receiver – Video: DVI-D (4, connected to monitor)

-USB: USB A (4, connected to peripherals)

-PS2: MiniDIN 6 female head (keyboard/mouse, 1 each)

-Audio: 3.5mm interface (1 microphone, 1 line output)

-Serial port: DB9 male (RS-232)

-Fiber optic: Same transmitter

-Software upgrade: USB B (2) supports bidirectional audio transmission, enabling sound synchronization between the near end microphone and the far end speaker

System architecture and deployment specifications

1. Core architecture

Adopting a “point-to-point” fiber optic transmission architecture, the signal flow direction is as follows:

Signal acquisition: The transmitter is connected to a computer to collect DVI video, USB/PS2 (keyboard and mouse), audio, and serial port signals;

Fiber optic transmission: The signal is transmitted uncompressed to the receiver through a 5-core fiber optic cable (single-mode/multi-mode optional);

Signal output: The receiver is connected to the display and peripherals (keyboard, mouse, USB flash drive, etc.) to restore the signal and drive the peripherals;

Local control: The transmitter is equipped with a local USB/PS2 interface, supporting direct operation from the computer and achieving dual control of “local+remote”.

2. Key deployment requirements

Fiber selection: Strictly match single-mode/multi-mode models, prioritize OM3 (50/125 μ m) for multi-mode to extend transmission distance; Fiber optic cables must comply with TIA/EIA standards to avoid signal loss caused by the use of inferior fiber optic cables;

Interface connection: DVI cables require single link shielded cables (factory supplied 2-meter cables), and USB cables should not exceed 6 feet (approximately 1.8 meters) in length to avoid signal attenuation;

EDID/DDC configuration: The transmitter has a built-in universal EDID table and can also read the EDID of the local display; Support “Active DDC” to allow remote displays to provide resolution information feedback to the computer, ensuring display compatibility;

Power isolation: The transmitter and receiver need to be connected to independent power sources to avoid common ground interference (such as sharing sockets with high-power devices).

Selection method and ordering rules

1. Selection process

Confirm transmission distance and fiber type:

Short distance (≤ 1000m): Choose multi-mode model (suffix “M34”);

Long distance (≤ 10km): menu model number (suffix “634”);

Select interface function:

Confidential scenario: Select “USB 1.0 HID only” (model includes “H00”);

Ordinary office: select “USB 1.1” (model includes “000”);

Network expansion required: select “USB 1.1+Ethernet” (model includes “N00”);

High speed peripheral: select “USB 1.1+2.0” (model includes “U00”);

Determine the fiber optic connector:

Small scale deployment: choose LC interface (model including “LC”);

Traditional computer room: select SC/ST interface (model includes “SC”/”ST”);

Supporting selection: Select fiber optic modules according to requirements (such as VOP-M12 for multimode and VOP-S36 for single-mode).

2. Example of ordering code

Taking “multi-mode, USB 2.0, LC interface receiver” as an example: VEL-U00M34-LCRX

VEL: Product prefix;

U00: Function code (USB 1.1+2.0);

M34: Fiber type (multimode);

LC: connector type;

RX: Device type (receiver, TX is transmitter).

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Typical application scenarios

Broadcasting and post production: The studio computer is separated from the control room monitor (500m away), and four DVI videos are transmitted through multi-mode fiber optic cables. USB 2.0 is connected to high-speed storage devices to achieve real-time editing of 4K materials;

Command Center: The server room (remote end) is separated from the command hall (near end) (3km away), with a menu model number and “HID only” configuration. USB storage is disabled to ensure data security, and an RS-232 serial port control switch is extended;

University laboratory: The teacher’s computer (teaching building) is connected to the student’s experimental equipment (laboratory, 800m away) through multimode fiber optic cable. The USB 1.1+Ethernet model supports extended network and KVM, and students can remotely operate the experimental equipment;

Large digital signage: The central control computer (computer room) in the shopping mall is connected to multiple digital screens (on different floors, at a distance of 300m) through multimode fiber optic cables, and four DVI screens are used to drive screens in different areas, achieving unified content control.

Precautions and maintenance suggestions

Signal interference prevention: Fiber optic cables should be kept away from strong electrical lines (≥ 1m), and USB/audio cables should be avoided from being laid in parallel with power lines to prevent electromagnetic interference from causing image snowflakes and audio noise;

Regular maintenance: Check the cleanliness of fiber optic connectors every quarter (wipe with specialized fiber optic cleaning paper) to avoid signal attenuation caused by dust; Annual testing of power supply voltage stability to prevent voltage fluctuations from damaging equipment;

Troubleshooting: If there is no signal in the video, priority should be given to checking the fiber optic link (using an optical power meter to measure light attenuation); When there is no response from the USB peripheral, confirm whether the model supports the device (e.g. “HID only” model does not support USB drives);

Software upgrade: Upgrade firmware through the USB B interface of the transmitter/receiver, and do not turn off the power during the upgrade process to avoid device damage.

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Watlow MLS300 Series Controller

Product basic positioning and core features

1. Product positioning

The MLS300 series is a multi loop PID controller, available in two versions: 16 loop (MLS316) and 32 loop (MLS332), supporting thermocouples RTD、 Multiple sensor inputs such as linear voltage/current and pulse can achieve independent or linked control of process parameters such as temperature, pressure, and flow rate. The system adopts a modular design, compatible with multiple expansion modules (such as DAC/SDAC analog output modules), supports EIA/TIA-232/485 serial communication, can be connected to upper computer or PLC systems, and complies with CE and UL standards ®/ C-UL ®  Certification and EU EMC Directive (EN 61326).

2. Core advantages

Advantages Category Specific Characteristics Value Explanation

Multi loop control single device supports 16/32 independent PID loops, each loop can be configured with heating/cooling dual outputs to reduce the number of devices, reduce panel space occupation, and adapt to multi zone process scenarios (such as multi-stage extruders and large ovens)

Flexible input compatibility supports J/K/T/S/R/B/E type thermocouples, 100 Ω platinum RTD (2/3 wire system), 0-20mA/4-20mA current, 0-12V voltage, and pulse input (up to 2kHz) to reduce spare parts inventory and adapt to sensor requirements of different processes without the need for additional signal conversion modules

Advanced control function supports cascade control, proportional control, remote simulation set point, and differential control (enhanced firmware); Ramp/Soak batch control (optional firmware) to meet complex process requirements (such as temperature pressure linkage in chemical reaction vessels, staged temperature control for material aging testing)

High reliability built-in sensor fault detection (open circuit/short circuit/reverse connection), power failure protection, CPU watchdog; Supports storing and calling 8 job programs to shorten troubleshooting time, avoid process abnormalities, and adapt to switching between multiple varieties and small batch production

System composition and hardware architecture

1. List of core components

Component Name, Model/Specification, Function and Function

Processor module (PM) MLS300-PM system core, including CPU, 2-line 16 character fluorescent display screen, 8-key keyboard, responsible for data calculation, loop control, and communication management

The Analog Input Module (AIM) MLS300-AIM-16 (16 channels)/AIM-32 (32 channels) receives sensor signals, completes signal conditioning and A/D conversion, and communicates with the processor module through RJ45 cables

Compact Input Module (CIM) CIM316 (16 channels)/CIM332 (32 channels) high-density input module, using D-Sub 50 connector to reduce installation space and adapt to high integration scenarios

Terminal board (TB50) MLS300-TB50 50 50 pin SCSI interface terminal board, used for digital I/O, power and control output wiring, supports DIN rail or bracket installation

Expansion Module – DAC (Digital to Analog Converter): 2-channel configurable 4-20mA/0-5V/0-10V output

-SDAC (Serial Digital to Analog Converter): 1 high-precision analog output, supporting process variable retransmission to convert digital output to analog signal, suitable for analog control equipment such as valves and frequency converters

The MLS300-PS power module inputs 120/240V AC and outputs 15V DC/1.2A and 5V DC/4A, providing isolated power supply for the system

2. Hardware architecture logic

The system adopts a “master-slave” communication architecture, and the data flow is as follows:

Perception layer: Sensors (thermocouples/RTDs, etc.) transmit process signals to the AIM/CIM module, completing signal conditioning and A/D conversion;

Control layer: The processor module (PM) receives digital signals from AIM/CIM, generates control instructions through PID algorithm, and sends them to the TB50 terminal board;

Execution layer: TB50 transmits instructions to actuators such as solid-state relays (SSRs) and contactors to control heating/cooling equipment;

Monitoring layer: Implement parameter settings, status monitoring, and alarm processing through the front-end panel or upper computer (such as WatView software).

Key technical parameters

1. Input parameters

(1) Sensor support and accuracy

Input Type Range Accuracy (25 ℃ environment) Remarks

Thermocouple (Type J) -212~760 ℃ (-350~1400 ℉) ± 1.1 ℃ with cold end compensation, linearization, and open/short/reverse detection

Thermocouple (Type K) -268~1371 ℃ (-450~2500 ℉) ± 1.3 ℃-

RTD1 (high precision) -100~275 ℃ (-148~527 ℉) ± 0.35 ℃ (25 ℃) 0.1 ℃ resolution, only supported by MLS304/308

RTD2 (Wide Range) -120~840 ℃ (-184~1544 ℉) ± 0.9 ℃ (25 ℃) 1 ℃ resolution, only supported by MLS304/308

Linear current 0-20mA/4-20mA ± 0.03% full range requires external scaling resistor

Linear voltage 0-5V/0-10V/0-12V ± 0.03% full-scale-

Pulse input 0-2kHz resolution 0.006% used for encoder speed measurement (such as conveyor belt speed control)

(2) Input performance

Sampling rate: MLS316 is 1.5 times/second (60Hz), MLS332 is 0.75 times/second (60Hz);

Noise suppression: Common mode rejection ratio (CMR)>85dB at 60Hz, input filtering configurable (0-255 scan period);

Temperature coefficient: 40ppm/℃, ensuring measurement stability in a wide temperature environment.

2. Output and communication parameters

Parameter category specification value precautions

Digital output with 34 open collector outputs, each with a maximum sink current of 60mA (5V DC). The onboard power supply provides a total current of 350mA for controlling SSR, alarm indicator lights, etc. It can be configured as a control output or alarm output

Analog output without onboard analog output, needs to be expanded through DAC/SDAC module:

-DAC: 2-channel 4-20mA/0-5V/0-10V, accuracy ± 0.75%

-SDAC: 1 high-precision output with an accuracy of ± 0.05%. Full scale SDAC supports process variable retransmission and is suitable for scenarios that require high-precision analog signals (such as PLC analog inputs)

Serial communication interface: EIA/TIA-232 (single device, maximum 50m), EIA/TIA-485 (multi device, maximum 4000ft);

Baud rate: 2400/9600/19200bps;

Protocol: Modbus RTU, Anafaze protocol, Allen Bradley PLC/2 compatible protocol EIA/TIA-485 supports networking of 32 devices and requires 200 Ω terminal resistors to be configured at both ends of the bus

Power requirements: Processor module: 12-24V DC ± 15%, maximum 1A;

AIM/CIM module: 5V DC (provided by the processor module). It is recommended to use an isolated power supply to avoid sharing the circuit with high-power devices and reduce interference

Installation and wiring specifications

1. Pre installation requirements

Environmental conditions: working temperature 0-50 ℃, storage temperature -20-60 ℃, relative humidity 10% -95% (no condensation); Keep away from strong electromagnetic interference sources (such as frequency converters and high-voltage cables) and avoid vibration (amplitude ≤ 0.5mm, frequency ≤ 50Hz).

Qualification requirements: Installation personnel must have industrial electrical installation qualifications, and high-voltage wiring (such as power module input) must be operated by certified electricians; Prepare torque wrenches (0.5-0.6Nm), shielded cables, crimping tools, etc.

Space requirements: A 1.96 × 3.78-inch (50 × 96mm) opening should be reserved for the installation of the processor module panel, and a wiring space of ≥ 7.4 inches (188mm) should be reserved on the back; The AIM module requires a reserved installation space of 6.5 x 5 x 5.75 inches (165 x 127 x 146mm).

2. Installation steps of core components

(1) Processor module (MLS300-PM)

Cut 1.8 × 3.63 inch (46 × 92mm) openings on the panel, remove module brackets and baffles;

Insert the module into the opening, fit the installation ring on the back, fix the upper and lower brackets, and tighten the screws (torque 0.5Nm);

Connect the AIM/CIM communication cable (RJ45 interface, labeled “To AIM”), TB50 50 50 pin SCSI cable, and power supply (TB1 terminal:+V to 12-24V DC, COM to negative pole).

(2) Input module (AIM/CIM)

AIM module:

Fix the AIM-TB terminal board with 4 # 6 screws to ensure grounding (grounding resistance ≤ 4 Ω);

Connect sensor cables: thermocouple “+” is connected to A+, “-” is connected to A -; RTD 3-wire system requires the “common end” to be connected to A COM, and the “signal end” to be connected to A+/A -;

Connect AIM to the processor module via RJ45 cable and test AIM power supply (TB3 terminal:+5 IN to PWR COM voltage 4.75-5.25V DC).

CIM module:

Support DIN rail or direct installation, connect sensors through D-Sub 50 connectors (J1 for 16 channels, J2 for 32 channel expansion);

Communication cable (RJ45) connected to CIM J3 interface, power supply (TB2 terminal: EX connected to processor EX, COM connected to processor COM).

(3) Terminal board (TB50)

Choose DIN rail or bracket installation, connect 50 pin SCSI cable to the processor module;

Wiring specifications:

Digital output (terminals 9-42): When controlling SSR, connect+5V to the positive pole of SSR and connect the output terminal to the negative pole of SSR;

Digital input (terminals 43-50): One end of the external switch is connected to the input terminal, and the other end is connected to CTRL COM (terminal 3/4);

Power terminal (1-2):+5V is the output (for SSR, etc.), CTRL COM is the common terminal, and grounding is prohibited.

3. Wiring and anti-interference requirements

Recommended specifications for cable types and wiring requirements

Sensor cable thermocouple: 20AWG thermocouple extension wire; RTD: 22AWG shielded twisted pair cable; Linear signal: 22AWG shielded twisted pair cable should be kept away from high-voltage cables (≥ 10cm), and the shielding layer should be grounded at one end (processor end); RTD cable length ≤ 100m

Control the output cable with 24AWG multi-core shielded wire and separate it from the input cable to avoid parallel laying; SSR control line length ≤ 50m

Communication cable EIA/TIA-232: Belden 9729 (6-core shielded wire, ≤ 50m); EIA/TIA-485: Shielded 9843 (4-core shielded twisted pair, ≤ 1200m) with both ends of the shielding layer grounded; The EIA/TIA-485 bus requires a 200 Ω terminal resistor to be configured at both ends

Basic Operations and Configuration

1. Startup and initialization

After confirming that the wiring is correct, turn on the power and the processor module display screen will light up. After about 1 second, it will enter the “bar chart display” (default display shows 8 circuit statuses);

If an “AIM COMM FAIL” alarm occurs, it is necessary to check whether the AIM/CIM communication cable is securely plugged in and whether the power supply is normal;

The first startup requires the execution of the “NO key reset” (press and hold the NO key in the power-off state, press YES to confirm after powering on), and restore the factory default parameters (skip when backing up the configuration in advance).

2. Core operations (front-end panel)

(1) Loop monitoring and parameter adjustment

Display switching:

Press the BACK key to switch between “Bar Chart Display” (8 circuit status), “Single Circuit Display” (Single Circuit PV/SP/Output%), and “Job Display” (Current Running Job);

Under single circuit display, press the YES/NO key to switch circuits, press the CHNG SP key to modify the set point (press YES/NO to adjust the value, press ENTER to confirm).

Control mode switching:

Press the MAN/AUTO key to switch between “AUTO” and “MAN” modes; In manual mode, adjust the output percentage (0-100%) according to YES/NO;

Press MAN/AUTO+ENTER to start “TUNE”, and the controller will automatically calculate PID parameters (ensuring process stability and no severe disturbances).

(2) Alarm processing

When the alarm is triggered, the display screen automatically switches to the fault circuit, displaying the alarm code (such as “FS” for sensor fault, “HP” for high process alarm), and the buzzer is activated;

Press the ALARM ACK button to confirm the alarm. If there are multiple alarms, they need to be confirmed one by one; After troubleshooting, the alarm will automatically clear;

The global alarm output (terminal 8) is activated when any unconfirmed alarm occurs, and can be connected to an external alarm light or buzzer.

3. Basic parameter configuration (Setup menu)

Enter the Setup menu through the “three key combination” (ENTER → ALARM ACK → CHNG SP), and the core configuration items are as follows:

Menu Name Key Parameter Configuration Description

When communicating with multiple devices, a unique address (1-247) must be set for the SETUP GLOBAL ParameterS controller address, communication baud rate, and power on output status; The baud rate needs to be consistent with the upper computer (default 19200bps)

SETUP LOOP INPUT input type, unit, filter coefficient selection corresponding to sensor type (such as “J T/C” and “RTD1”); Input filtering (0-255 scan) is used to suppress noise

SETUP LOOP Control PARAMS heating/cooling PID parameters (PB/TI/TD), the smaller the output filter PB (proportional band), the higher the gain; The longer the TI (integration time), the stronger the ability to eliminate steady-state errors; TD (Differential Time) is used to suppress overshoot

SETUP LOOP OUTPUTS heating/cooling output enable, output type, sensor fault output type optional “TP (time ratio)” “DZC (distributed zero crossing)” “SDAC”; When the sensor fails, the output can be set to 0% (default) or a custom value

SETUP LOOP ALARMS high/low process alarm, deviation alarm, alarm dead zone high process alarm set point needs to be higher than the process upper limit; Set the deviation alarm to SP ± 5% (to avoid frequent alarms); Set the dead zone to 2-5 (unit consistent with PV)

Advanced features (firmware optional)

1. Enhanced Features firmware

(1) Cascade Control

Application scenario: Suitable for processes with “primary secondary” variables (such as reactor temperature jacket temperature control), where the main circuit output serves as the secondary circuit set point;

Configuration steps:

Enter the SETUP LOOP CASCADE menu and select “PRIM. LOOP” (such as reactor temperature loop 1);

Set the “Base SP”, “Minimum/Maximum Set Point”, and “Heating/Cooling Span (HT/CL SPAN)” to define the magnitude of the impact of the main circuit output on the secondary circuit set point;

The secondary circuit (jacket temperature circuit 2) needs to enable the “cascade mode” to ensure that the sampling period of the main and secondary circuits matches.

(2) Ratio Control

Application scenario: Suitable for processes that require proportional control (such as KOH solution dilution, water flow KOH flow 1:2);

Configuration steps:

Enter the SETUP LOOP RATIO CON menu and select “MSTR LOOP” (water flow circuit 1);

Set “CTRL RATIO” (e.g. 0.5, KOH flow=water flow x 0.5), “SP DIFF” (compensating deviation, default 0);

The proportional circuit (KOH flow circuit 2) automatically follows the changes in the main circuit PV and maintains the set ratio.

2. Slope – Insulation Fasteners (Ramp/Soak)

Application scenario: staged temperature control process (such as material annealing: heating → insulation → cooling), supporting 17 profiles, each profile containing 20 segments;

Core functions:

Ramp: Rise from the current SP to the target SP within a set time (e.g. 10 ℃/min to 200 ℃);

Soak: Maintain the target SP setting time (such as holding at 200 ℃ for 60 minutes);

Trigger and Event: Each segment can be configured with 2 digital trigger inputs (such as external signal activation) and 4 event outputs (such as initiating agitation);

Configuration steps:

Enter the SETUP RAMP/SOAK PROFILE menu, select Profile (A-Q), and set the “Time Reference” (HH: MM/MM: SS);

Edit Segment: Set “Segment Time”, “Target SP”, “TOLERANCE” (if ± 2 ℃, pause timing if exceeded);

Assign Profile to the target circuit, press the RAM/SOAK key to start, and the display screen will show the remaining time and current segment number in real time.

Troubleshooting and Maintenance

1. Common fault handling

Possible causes and solutions for the fault phenomenon

The display screen is not properly connected to the power supply, and the processor module is faulty. Check the TB1 terminal voltage (12-24V DC); Replace the processor module for testing

Abnormal sensor readings (high/low), incorrect sensor wiring, incorrect input type configuration, interference confirmation of thermoelectric dipole/RTD wiring; Check the “Input Type” in the Setup menu; Check the grounding of cable shielding

No response output enabled, SSR fault, loose TB50 wiring entering SETUP LOOP OUTPUTS confirmation output enabled; Measure the voltage at the SSR control terminal (conducting at 5V DC); Re tighten the terminal screws

Communication failure address/baud rate mismatch, cable failure, EIA/TIA-485 terminal resistance not connected, check the communication parameters between the controller and the upper computer; Use a multimeter to test the continuity of communication cables; Connect a 200 Ω resistor at the beginning and end of the bus

Alarm for “FS (sensor malfunction)” thermocouple open/short circuit, RTD disconnection, input module malfunction check sensor cable continuity; Replace the sensor for testing; Replace the AIM/CIM module for testing

2. Regular maintenance

Requirements for maintenance cycle operation content

Check the display screen daily for any errors and ensure that the alarm light is functioning properly; Do not wipe the display screen with alcohol when cleaning the panel and sensor; The sensor probe is free of oil stains/damage

Check the wiring terminals weekly for any looseness; Test the emergency stop and alarm function terminals and tighten the screw torque to 0.5-0.6Nm; confirm the ALARM ACK is valid after triggering the alarm

Monthly calibration of critical circuits (using standard signal sources to simulate sensor inputs); The calibration error of the cooling holes in the cleaning AIM/CIM module should be ≤ 0.1% of the full range; Compressed air blows away dust from the heat dissipation holes (pressure ≤ 0.3MPa)

Replace the processor module battery (CR2032, after power failure to avoid configuration loss) annually; Check that the battery replacement time for the shielding layer of the communication cable is ≤ 5 minutes; The shielding layer is undamaged and well grounded

Order

Ordering code rules (core position)

Code bit meaning optional values

Input module 16=AIM316 (16 channels), 32=AIM332 (32 channels) C1=CIM316、C2=CIM332 –

Firmware Type 1=Standard, 2=Extruder Specific, 3=Enhanced Features, 4=Ramp/Soak, C=Custom-

Terminal board 0=none, 1=18 pin terminal block, 2=50 pin terminal block (including 3-foot SCSI cable)-

Communication jumper 0=EIA/TIA-232, 1=EIA/TIA-485, 2=EIA/TIA-485 terminal matching-

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​DHR NLS3000 NLC System (Navigation Control System)

Product basic positioning and core functions

1. Product positioning

The NLS3000 NLC System is a high-precision real-time navigation and positioning control system, designed for devices that require precise position monitoring, path planning, and dynamic control. Typical applications include:

Port terminal: positioning and path correction of container cranes (shore bridges, yard bridges);

Industrial scenario: Autonomous navigation of heavy-duty transport vehicles (AGVs), position synchronization of track mounted equipment;

Maritime assistance: guidance for small ships to dock and fixing the position of water operation platforms.

The system supports multi-sensor fusion and can be combined with GPS, LiDAR, encoders and other devices to improve positioning accuracy, in compliance with EU CE certification and industrial equipment electromagnetic compatibility (EMC) standards.

2. Core functions

Specific Capability Value Explanation for Functional Categories

High precision positioning static positioning accuracy ± 5mm (close range laser assistance), dynamic positioning accuracy ± 10mm (speed ≤ 5m/s); Support switching between absolute coordinates (latitude and longitude) and relative coordinates (device local coordinate system) to meet the strict requirements of high-precision operations for position errors, avoiding accidents caused by equipment collisions or positioning deviations

Path planning and control support preset path storage (up to 100 custom paths) and real-time path correction (response delay<100ms); It is possible to set a “prohibited area” (electronic fence), which will automatically slow down/stop when triggered to reduce manual operation intensity, lower the risk of misoperation, and adapt to multi scene operation processes

Data collection and communication: Real time collection of position, velocity, attitude (inclination, heading) data, with a sampling frequency of 100Hz; supports industrial communication protocols such as RS485, EtherNet/IP, Profinet, etc., and can be connected to the upper computer (SCADA system) to achieve remote monitoring of equipment status, facilitating production scheduling and data tracing

Fault diagnosis and alarm built-in sensor fault detection (such as GPS signal loss, LiDAR obstruction), communication interruption alarm; Support fault code storage (up to 50 historical fault records), with sound and light alarm prompts to shorten troubleshooting time and improve system reliability

System composition and hardware architecture

1. List of core components

The NLS3000 NLC System is designed with modularity, and the standard configuration includes the following components, which can be added or removed according to the application scenario:

Component Name, Model/Specification, Function and Function

The main controller NLC-3000-MC system core is responsible for data computation, path planning, and device control, with a built-in Linux real-time operating system

Positioning sensor module – GPS receiver: NLC-GPS-01 (supports Beidou/GLONASS dual-mode, positioning update rate 10Hz)

-Lidar: NLC-LIDAR-20 (measuring distance 0.5-20m, accuracy ± 2mm)

-Incremental encoder: NLC-ENC-1024 (resolution 1024 lines/rev, adapted to wheels or tracks) multi-sensor fusion, ensuring positioning accuracy in different environments (such as indoor/obstructed areas with weak GPS signals)

Display and operation unit NLC-HMI-10 10 10 inch touch screen (resolution 1280 × 800), supporting parameter settings, real-time status display, and fault inquiry; Equipped with a physical emergency stop button human-machine interaction interface, convenient for on-site operation and status monitoring

The NLC-IO-16 execution control module has 16 digital inputs/outputs (DI/DO) and 4 analog inputs (AI, 0-10V/4-20mA), used to connect motor drivers, solenoid valves, and other actuators to achieve dynamic control of equipment by the controller (such as speed regulation, steering, braking)

The power module NLC-PWR-24 has an input voltage of 110-240V AC and an output of 24V DC/5A. It is equipped with overvoltage and overcurrent protection to provide stable power supply for various components of the system and is suitable for different on-site power conditions

2. Hardware architecture logic

The system adopts a “layered control” architecture, and the data flow is as follows:

Perception layer: GPS, LiDAR, encoder and other sensors collect position and motion data and transmit it to the main controller;

Control layer: The main controller performs fusion operations on data, generates control instructions based on preset paths and real-time status;

Execution layer: The execution control module receives instructions, drives the motor, brake and other execution mechanisms, and feeds back the execution status to the main controller;

Monitoring layer: HMI and upper computer receive status data sent by the main controller, realizing display, alarm and remote operation.

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Key technical parameters

1. Positioning and control performance

Parameter Category Specification Value Remarks

Static positioning accuracy: ± 5mm (laser radar assisted, measurement distance<10m); Dynamic: ± 10mm (speed ≤ 5m/s) accuracy is affected by the environment, such as the laser radar accuracy may drop to ± 5mm in rainy/dusty environments

The speed measurement range is 0-10m/s (effective range of dynamic positioning), and when the speed measurement accuracy exceeds 10m/s by ± 0.1%, it automatically switches to “rough positioning mode”

Attitude measurement inclination range: -15 °~+15 ° (roll/pitch), accuracy ± 0.05 °; Heading angle range: 0-360 °, accuracy ± 0.1 °, requires gyroscope module (optional NLC-GYRO-01)

Response delay sensor data acquisition:<10ms; control command output:<100ms to ensure real-time dynamic control

The path storage capacity is up to 100 paths, and a single path can support up to 1000 coordinate points. Coordinate points can be manually entered through HMI or upper computer

2. Electrical and environmental parameters

Parameter category specification value precautions

Power supply requirements: Main controller: 24V DC ± 10%, maximum current 2A; Sensor module: 12-24V DC ± 10%, total power consumption ≤ 15W, independent power supply circuit is required to avoid sharing power supply with high-power equipment (such as motors)

Communication interface – Industrial Ethernet: EtherNet/IP, Profinet (transmission rate 100Mbps)

-Serial communication: RS485 (baud rate 9600-115200bps, supporting Modbus RTU) communication cable needs to use shielded wire to avoid electromagnetic interference

Protection level main controller/sensor: IP65 (dustproof, waterproof); HMI: IP64 (dustproof, splash proof). It is prohibited to immerse or expose to corrosive environments for a long time (such as maritime scenes with high salt spray concentration that require additional protection)

Environmental adaptability working temperature: -20~+60 ℃; Storage temperature: -40~+85 ℃; Relative humidity: 0%~95% (no condensation). It is recommended to preheat for 30 minutes before starting in a low-temperature environment (<-10 ℃)

EMC compatibility complies with EN 61000-6-2 (industrial environment immunity) and EN 61000-6-3 (residential emission limits). When installing, it is necessary to stay away from strong electromagnetic interference sources (such as frequency converters and high-voltage cables)

Installation and commissioning specifications

1. Pre installation requirements

Environmental inspection: Confirm that the installation location has no strong electromagnetic interference and no severe vibration (vibration frequency ≤ 50Hz, amplitude ≤ 0.5mm); Outdoor installation requires reserved waterproof junction box positions, and sensor installation points should have a wide field of view (GPS receivers should be unobstructed, and LiDAR should avoid obstacles blocking the measurement path).

Qualification requirements: Installation personnel must have industrial automation equipment installation qualifications and be familiar with electrical wiring specifications (such as EN 60204-1); High voltage wiring (such as power module input) must be operated by a certified electrician.

Tools and spare parts: A torque wrench (recommended for fixing sensors with a torque of 2-3Nm), shielded cables (communication cables recommended to use CAT5e or higher specifications), and waterproof sealant (for outdoor wiring protection) need to be prepared.

2. Key points for installing core components

Common Error Avoidance in Component Installation Requirements

The main controller is installed in the equipment control cabinet, with a distance of ≥ 10cm from the heating element (such as the frequency converter); the fixed bracket needs to be grounded (grounding resistance ≤ 4 Ω) to avoid installation at the bottom (prone to water accumulation) or top (greatly affected by temperature) of the control cabinet

The GPS receiver is installed at the highest point of the device, with a horizontal deviation of ≤ 5 °; Antenna cable length ≤ 10m, avoid bending (bending radius ≥ 50mm). It is prohibited to install it under metal obstructions (such as equipment frames), otherwise it will cause signal loss

The installation height of the laser radar should be level with the measurement target (such as the positioning reflector), and the measurement path should be unobstructed; Avoid installing in areas with severe equipment vibration (such as near motors) at a distance of ≥ 50cm from moving parts, as it may affect measurement accuracy

The HMI is installed within the operator’s field of view, with the touch screen at an angle of 30 °~45 ° to the operating table; The emergency stop button should be easily accessible (≤ 50cm from the operating position) and should not be installed within the range of the device’s movement trajectory to prevent collision damage

3. Debugging process (key steps)

Check before powering on: Confirm that the wiring is correct (the positive and negative poles of the power supply are not reversed, and the shielding layer of the communication line is grounded), tighten all terminal screws (recommended torque 0.5-1Nm);

System initialization: When the power is turned on, the main controller automatically enters initialization mode (HMI displays “Initiat”), completes self-test after about 30 seconds, and displays “READY” if there are no faults; If the self-test fails, the HMI will display a fault code (such as “E01” indicating abnormal GPS signal), and the corresponding component needs to be checked;

Parameter calibration:

Positioning calibration: Input the device reference coordinates (such as starting position latitude and longitude) through HMI, activate the “automatic calibration” function, and the system will correct the coordinate deviation based on sensor data;

Path input: Manually operate the device to travel along the target path once, and the system automatically records the coordinate points, generates a path, and saves it (which can be named “PATH01”, “PATH02”, etc.);

Functional testing

Static testing: When the equipment is stationary, observe the position data displayed on the HMI to confirm that the error is within the allowable range (± 5mm);

Dynamic testing: Start the device to travel along the preset path, check if it follows the path, if it automatically stops when the “prohibited area” is triggered, and record the response delay (<100ms required).

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Operation and Maintenance Guide

1. Daily operations (HMI interface)

Main interface: Display real-time position (coordinates, distance from target point), speed, attitude data, and system status (normal/alarm);

Path operation: Click on “Path Selection”, select the preset path and click “Start”, the device will automatically travel along the path; Support “pause” and “emergency stop” (click the HMI emergency stop button or physical emergency stop button);

Parameter settings: Enter the “Settings” interface to modify the positioning accuracy level (“High Precision Mode”/”Normal Mode”) and alarm threshold (such as speed upper limit and position deviation upper limit);

Fault inquiry: Enter the “Fault Record” interface, view historical fault codes and occurrence times, click on the code to display the fault cause and solution suggestions.

2. Maintenance cycle and content

Maintenance cycle operation content operation requirements

Check daily whether the HMI display is normal (no splash screen, no errors); Clean the LiDAR lens (wipe with a dust-free cloth); Check the function of the emergency stop button (whether the device stops when pressed) and prohibit wiping the HMI screen with alcohol or corrosive cleaning agents; If there are stubborn stains on the LiDAR lens, special lens paper is required

Check the sensor wiring for looseness every week; Test GPS signal strength (HMI displays’ GPS signal ≥ 3 stars’ as normal); Check the output voltage of the power module (within the range of 22.8-26.4V DC) and tighten the wiring terminals one by one to avoid omissions; When the GPS signal is weak, it is necessary to check whether the antenna position is obstructed

Monthly calibration of positioning accuracy (activate the “automatic calibration” function); Clean the heat dissipation holes of the main controller (blow off dust with compressed air); Check whether the protective shell is damaged (such as whether the IP65 sealing strip is aged) and calibrate it under the condition of no load on the equipment; Blocked heat dissipation holes can cause the controller to overheat and require thorough cleaning

Replace the laser radar lens protective cover (vulnerable parts) annually; Detecting the grounding status of the shielding layer of communication cables; The overall system function test (including all preset paths) requires the use of DHR original parts for replacing accessories to avoid compatibility issues; The grounding resistance needs to be remeasured to ensure it is ≤ 4 Ω

3. Common fault handling

Possible causes and solutions for the fault phenomenon

HMI displays “GPS signal loss (E01)” GPS antenna obstruction, antenna cable breakage, GPS module malfunction. Check the antenna position and remove the obstruction; Test cable continuity and replace damaged cables; If the fault persists, replace the GPS module

The device deviates from the preset path (deviation>10mm), causing contamination of the LiDAR lens, incorrect encoder parameters, expired path calibration, and cleaning of the LiDAR lens; Re enter the encoder resolution parameter; Activate the ‘Auto Calibration’ function

System unresponsive (HMI black screen), power module failure, main controller crash, power supply line interruption. Check the output voltage of the power module. If there is no output, replace it; Press and hold the “Reset” button on the main controller for 10 seconds to restart; Check the power supply line and repair the breakpoint

Alarm “Prohibited Area Trigger (E05)”: The device accidentally enters the electronic fence, coordinates are set incorrectly, press the emergency stop button, and manually operate the device to exit the prohibited area; Check the coordinates of the prohibited area and correct any incorrect settings

Safety operation instructions

Emergency stop: If there is an abnormality during equipment operation (such as collision risk, sensor failure), the HMI or physical emergency stop button should be immediately pressed to cut off the power supply of the actuator;

Permission management: The system sets three levels of operation permissions (administrator, engineer, operator), and only administrators can modify key parameters (such as positioning accuracy, prohibited areas) to avoid misoperation;

Environmental restrictions: Prohibited from use in flammable and explosive environments (such as oil and gas terminals), unless equipped with explosion-proof components (explosion-proof versions need to be ordered separately); It is prohibited to use in the environment beyond the protection level (such as rainstorm and strong dust);

Training requirements: Operators must undergo official DHR training and pass the assessment, be familiar with the fault handling process, and are prohibited from operating without certification.

Watlow Anafaze CLS200 Series Controller

Product basic positioning and core advantages

1. Product positioning

The CLS200 series is a compact loop control system designed in a 1/8 DIN package, offering three versions: 4-loop (CLS204), 8-loop (CLS208), and 16 loop (CLS216), which can cover multi scenario temperature control requirements (such as industrial heating/cooling control, batch processing, etc.). The device supports independent operation and can also be connected to a computer system through serial communication for data acquisition and remote control, in compliance with UL standards ®、 C-UL ®  Certification and EU EMC directive, with CE mark.

2. Core advantages

Advantage categories, specific characteristics, and value

Space and efficiency: Single circuit occupies less panel space, supports multi circuit integration to reduce installation time, and reduces panel layout complexity

Easy to use Auto tune function; 32 character vacuum fluorescent display screen+8-key keyboard, menu guided operation reduces debugging threshold, precise control can be achieved without professional skills; Quickly complete parameter settings

Flexibility supports thermocouples RTD、 Multiple sensor inputs such as linear voltage/current, frequency, etc; 8 homework programs are stored and called to reduce spare parts inventory and learning costs, allowing for quick switching between different process flows

Reliability sensor fault detection (open circuit, short circuit, reverse connection); 34 digital outputs (50 pin terminal board configuration) shorten troubleshooting time and flexibly adapt to control and alarm requirements

Scalability supports EIA/TIA-232/485 serial communication; Optional DAC/SDA analog output module for easy integration with PLC and upper computer, meeting the requirements of analog signal conversion (such as process variable retransmission, motor speed regulation)

Core functions and firmware options

1. Basic control functions

PID control: Supports closed-loop PID control for up to 16 heating/cooling circuits, with 1-2 control outputs per circuit (supporting on/off time ratio and distributed zero crossing triggering).

Alarm function: Each input channel is equipped with independent process alarms (high/low limit) and deviation alarms, supporting user-defined dead zone, delay time, and startup suppression. The global alarm output can be linked to the PLC, and the watchdog output indicates the controller’s operating status.

Data storage: capable of storing 8 job programs, supporting quick calling and switching of processes; The controller configuration can be imported/exported through the serial port.

2. Firmware version selection

Select firmware with different functions according to application requirements, and the core differences are as follows:

Firmware type, core functions, applicable scenarios

Standard firmware includes basic closed-loop PID, automatic tuning, alarm, job storage, sensor fault detection, and conventional temperature control scenarios such as constant temperature heating and simple cooling control

Ramp and Soak firmware includes standard functions+ramp heating/insulation control, process variable retransmission for complex batch processing (such as material aging testing, food processing, requiring staged temperature control)

Enhanced firmware includes standard functions+process variable retransmission, remote simulation set points, cascade control, proportional control, differential control, high-precision linkage control scenarios (such as multi loop coupling temperature control, remote set point adjustment)

Note: The serial control and remote simulation set point functions of the enhanced firmware require 2 controller channels to be occupied; Unused control outputs can be configured for process variable retransmission (with SDAC module).

Detailed explanation of technical parameters

1. Input parameters

(1) Analog input and sensor support

Input type, specific specifications, accuracy (25 ℃ environment)

Thermocouples support Type B/E/J/K/R/S/T, direct connection, with cold junction compensation and linearization; Type B has a range of 66-1760 ℃, while other types have a range of -268~1371 ℃ (depending on the type) ± 1.0~4.0 ℃ (Type E has the highest accuracy and Type B has the lowest accuracy)

RTD (CLS204/208 only) 2/3 wire platinum resistance (100 Ω @ 0 ℃, DIN 0.003850 Ω/Ω/℃), divided into 2 ranges:

-RTD1: -100~275 ℃ (0.1 ℃ resolution)

-RTD2: -120~840 ℃ (1 ℃ resolution) ± 1.1 ℃ (RTD1), ± 1.6 ℃ (RTD2)

Linear input requires an external scaling resistor, supporting 0-20mA/4-20mA DC, 0-5V DC, 0-10V DC, and other ranges can be customized-

Pulse input TTL level square wave, up to 2kHz-

(2) Input performance

Noise suppression: 120dB at 60Hz; Temperature coefficient: 40ppm/℃;

Sampling rate: CLS204 (6 times/second, update time 0.167 seconds), CLS208 (3 times/second, 0.333 seconds), CLS216 (1.5 times/second, 0.667 seconds);

Measurement resolution:>14 bits (0.006% range).

2. Output parameters

Digital output: 34 outputs when configured with a 50 pin terminal board, 10 outputs when configured with an 18 pin terminal board, with a maximum sink current of 60mA (5V DC) per output. The onboard power supply provides 350mA (5V DC);

Analog output: No onboard analog output, requires optional module expansion (DAC/SDC).

3. Communication and Power Supply

Serial communication: EIA/TIA-232 or EIA/TIA-485, baud rates 2400/9600/19200 can be set, supports ANSI X3.28-1976 (compatible with Allen Bradley PLC/2), Modbus ®  RTU protocol;

Power requirements: 15-24V DC ± 3V, maximum 1A (loaded), 300mA (unloaded), optional 120/240V AC to 15V DC adapter (UL) ®  Class 2 certification).

Optional modules (DAC/SDC)

Used to convert the digital output of the controller into analog signals to meet specific control requirements:

Module type, functional specifications, application scenarios

DAC (Digital to Analog Converter) 1-2 distributed zero crossing trigger (DZC) outputs are converted into analog signals, each of which can be configured as 4-20mA DC, 0-5V DC, or 0-10V DC for simple analog signal conversion (such as valve opening control, ordinary speed regulation)

SDAC (Serial Digital to Analog Converter) 1 high-precision analog output (voltage/current), supporting process variable retransmission, open-loop control, motor/belt speed regulation, phase triggered SCR power control, with CE/UL ®/ C-UL ®  Certification of high-precision signal requirements (such as precision instrument temperature control, remote monitoring of process variables)

Module power configuration

Power option specifications support module quantity

A has no power supply-

B 120V AC 60Hz wall mounted power supply (16V DC 300mA) with up to 10 dual DAC modules

H 120/240V AC 50/60Hz adapter (15V DC 1.2A) with up to 12 dual DAC modules

L 120/240V AC 50/60Hz adapter (5V DC 3A) with up to 10 SDAC modules

Ordering Rules and Selection Guide

1. Ordering code for the main controller (Series CLS200)

The code structure consists of 10 bits, and the key bits have the following meanings (see the document “Ordering Information” for the complete structure):

Code bit meaning optional values

② ③ Number of circuits: 04=4 circuits, 08=8 circuits, 16=16 circuits

④ Controller type (firmware) 1=standard, 3=slope insulation, 4=enhanced, C=customized

⑤ Terminal board 0=SCSI interface only, 1=18 pin terminal block (CLS204/208), 2=50 pin terminal block (including 3-foot SCSI cable)

⑥ Power adapter 0=none, 3=120/240V AC to 15V DC (UL) ®  Class 2)

⑦ SCSI cable 0=none (option 0/1), 1=6-foot straight head, 2=3-foot elbow

⑧ Serial communication cable 0=none, 1=10 feet DB-9 female head/bare wire

⑨ Communication jumper 0=EIA/TIA-232, 1=EIA/TIA-485, 2=EIA/TIA-485 terminal matching

⑩ Special input 0/00=thermocouple only/-10~60mV, N/NN=current/voltage/RTD quantity (N is the quantity), XX=custom code

2. Special input selection (10 digits)

If you need to support RTD and linear current/voltage input, you need to specify a special input code:

Special input code type applicable to controllers

20 RTD1 (-100~275 ℃, 0.1 ℃ resolution) CLS204/208

21 RTD2 (-120~840 ℃, 1 ℃ resolution) CLS204/208

44 0-20mA/4-20mA DC Full Series

55 0-5V DC Full Series

56 0-10V DC Full Series

3. DAC/SDAC module ordering code

Code structure: CLSSI+special input type+start channel+end channel, for example, “CLSSI 44 01 04” represents 4-20mA input, covering 1-4 channels.

CyberPower UT650EG / UT850EG User’s Manual

Core Security Directive (Must See)

To avoid fire, electric shock, or equipment damage, the following requirements must be strictly followed:

Installation environment: It can only be used in indoor temperature and humidity controlled environments (see technical parameters for specific range). It is forbidden to expose it to direct sunlight, heat sources (such as heaters and furnaces), do not cover the heat dissipation holes, and stay away from conductive pollutants.

Load limit: It is prohibited to connect non computer devices such as medical/life support equipment, microwave ovens, vacuum cleaners, etc; High power equipment such as laser printers, copiers, and shredders cannot be connected to battery powered sockets (which can easily overload and damage UPS).

Usage taboos: Do not allow liquids or foreign objects to enter the equipment, and do not place liquid containers around UPS; Power off before cleaning, and prohibit liquid or spray cleaners; Battery maintenance should be carried out by professionals and unauthorized personnel are prohibited from accessing it.

Emergency response: In case of emergency, press the “OFF” button and unplug the power cord to cut off the UPS power supply; If overload is detected, the device will sound a long beep alarm, power off and remove at least one load before restarting.

Equipment installation process

1. Open box inspection

The packaging box should contain:

Core components: UPS host (1 unit, UT650EG or UT850EG)

Accessories: User Manual (1 book), USB Data Cable (1 piece, only equipped with UT850EG)

2. Hardware installation steps

Battery charging: The device can be used directly after receiving it, but it is recommended to charge it for at least 8 hours (to offset the power loss during transportation and storage). Simply plug the UPS into an AC outlet (it can be charged in both on/off states).

Load connection: In the power-off state, connect the computer, monitor, and external data storage device to the “Battery Backup&Surge Protected Outlets” and disable high-power devices.

Power access: Insert the UPS plug into a grounded 2-hole 3-wire socket (wall plugs need to be protected by fuses or circuit breakers). Do not share the same circuit with high-power devices such as air conditioners and refrigerators, and try to avoid using extension cords.

Startup: Press the power switch, the power indicator light will turn on and the device will beep once, indicating successful startup.

Overload handling: If overload is detected, the device will sound a long alarm, and at least one load needs to be removed from the power supply. Wait for 10 seconds and confirm that the circuit breaker/fuse is normal before restarting.

Long term maintenance: To maintain the optimal condition of the battery, it is necessary to always connect the UPS to an AC socket; When storing for a long time, it is necessary to fully charge the battery and cover it for storage. Charge it every 3 months to extend the battery life.

Basic Operation Guide

1. Core buttons and interface functions

Function Description of Operating Components

Press and hold the power switch for 2 seconds to turn on/off the device; Quickly press twice to turn on/off the sound alarm (default on, 2 short beeps when turning off the alarm, 1 short beep when turning on the alarm)

The LED indicator light displays the UPS status (such as normal mains power, battery charging, fault, etc., see the “LED Status Definition Table” for details)

USB interface (UT850EG only) connects to the computer’s USB port through PowerPanel ®  Personal software for UPS status communication and monitoring

The battery powered socket provides battery backup and surge protection, providing continuous power supply to the load during power outages

The replaceable fuse provides overload protection. If it melts due to overload, it needs to be replaced according to the specifications

Communication protection ports (RJ11/RJ45) protect modems, fax machines, telephone lines, and network/Ethernet connections from surge damage

2. Definition of LED indicator status

Different colors and flashing modes correspond to different device states, and the key explanation is as follows:

LED color, light status, sound alarm, UPS status, specific description

Green constant light – Energy saving mode (ECO): The mains power is normal, and the UPS is running in energy-saving mode

Green slow flashing – Battery charging is normal, UPS is charging the battery

The yellow light stays on and beeps twice every 30 seconds. The battery mode is interrupted, and the UPS switches to battery power supply

Yellow flashing, fast buzzing, low battery level, battery is about to run out, data needs to be saved and power off as soon as possible

Red constantly on+flashing once every 5 seconds with a continuous beep. Battery output short circuit fault. Power off and remove at least one load before restarting

Red constantly on+flashing twice every 5 seconds, continuous long beep. Overload fault. The load exceeds the rated capacity of the UPS and needs to be powered off to remove some of the load

Red constantly on+flashing 3 times every 5 seconds with a continuous beep. If the charger is faulty, please contact CyberPower technical support

Red constantly on+flashing 4 times every 5 seconds with a continuous beep. Hardware failure requires contacting CyberPower technical support

Red flashing, continuous beeping, overload warning, load overload, power outage is required to remove part of the load

Technical parameters (UT650EG vs UT850EG)

Parameter category UT650EG UT850EG

Capacity (VA/W) 650 VA/360 W 850 VA/425 W

Input voltage range 165~290 Vac; Frequency 50/60 Hz ± 5 Hz (both versions are consistent)

Output battery mode output voltage 220/230/240 Vac; Frequency 50/60 Hz ± 1% (both identical)

Overload protection with built-in current limit and fuse (both versions are the same)

Physical dimensions (width x height x depth) 84 x 174 x 280 mm; weight 3.8 kg Dimensions (width x height x depth) 84 x 174 x 280 mm; weight 4.2 kg

Sealed maintenance free lead-acid battery (model RBP0119 × 1); Charge the sealed maintenance free lead-acid battery (model RBP0143 × 1) to 90% within 6 hours after complete discharge; Charge to 90% within 6 hours after complete discharge

Adapt to working temperature range of 0-40 ℃ in the environment; Relative humidity 0~90% (both versions are the same)

Communication interface without USB interface equipped with USB interface (supports PowerPanel) ®  Software monitoring)

Indicator light/alarm mains/battery/fault indicator light; Supports battery, low battery, overload, and fault alarms (both are the same)

Troubleshooting plan

Common problems, possible causes, and solutions

The UPS battery life did not meet expectations, and the battery was not fully charged; Keep the UPS connected to the power source for charging with slight battery loss; Contact CyberPower technical support to test batteries

UPS cannot be turned on and is not connected to an AC socket; Battery loss; Mechanical fault confirmation connected to 220-240V grounding socket; Contact technical support to replace batteries or repair hardware

The socket has no power supply to overload the load, causing the fuse to melt/the circuit breaker to trip; Battery depletion; The equipment is damaged by a surge, power is cut off, some loads are removed, fuses that meet specifications are replaced or circuit breakers are reset before restarting; Charge for at least 4 hours; Contact technical support for maintenance

Thermal Solutions EVS series gas regulated boilers

Product basic information

1. Core identification and certification

Product positioning: Gas driven modular regulating boiler (GAS-FIRED MODULATION BOILER), used for hot water systems, certified by AHRI, in compliance with the National Gas Code (NFPA 54/ANSI Z223.1) in the United States, the Gas Installation Code (CAN/CSA B149) in Canada, and local regulations such as Massachusetts 248 CMR 4.00/5.00.

Key information: Released in September 2024, replacing the old version, including bilingual warning content in English/French, to be posted and kept clear and readable. Boiler model and serial number (see rated label) must be provided during maintenance.

2. Model and core parameters

Covering 8 models (EVS-500 to EVS-3000), the core parameter differences are as follows (taking typical models as an example):

Model Input Power (MBH) Total Output (MBH) Net AHRI Rated (MBH) Water Capacity (gallon) Dry Weight (pound) Wet Weight (pound) Power Supply/Fan Power

EVS-500 500 431 375 6.1 722 823 120V/189 horsepower

EVS-1000 1000 850 739 16.4 1185 1322 120V/1.5 horsepower

EVS-2000S 2000 1732 1506 40.1 1835 2169 120V/1.5 horsepower

EVS-3000 3000 2610 2270 43.1 2193 2552 208V/2 horsepower

General restrictions: Maximum working pressure of 160 PSI, medium temperature -40~+90 ° C, ambient temperature -40~+85 ° C, condensate pH value 3-5 (requires neutralization treatment).

Installation specifications (key requirements)

1. Pre requirements

Installation qualification: It is required to be operated by a certified Plumber/Gas Fitter (mandatory in Massachusetts). Before installation, local regulations must be confirmed to ensure a safe distance from combustible materials (6 inches left/right/back, 24 inches front, 18 inches for flue connections, and 24-36 inches for maintenance spacing depending on the model).

Space and ventilation: Determine whether a “non confined space” (≥ 50 ft ³/1000 Btu/h) or a “confined space” based on the space volume and total gas input. A confined space requires two permanent ventilation openings (within 12 inches at the top and 12 inches at the bottom, with a minimum diameter of 3 inches); Sealed combustion engine models can be exempted from indoor ventilation, but the intake pipe needs to be installed according to regulations.

2. Core system installation

(1) Ventilation system

Type: Supports positive pressure ventilation (side wall/vertical, maximum equivalent length of 50 feet, non confluent) and negative pressure ventilation (traditional chimney, requiring a vertical height of 15 feet or more and double acting air pressure dampers), ventilation ducts require AL29-4C ®  Wait for condensation resistant materials, tilt the horizontal section at least 1 inch every 4 feet, and keep the terminal away from doors and windows (below 4 feet/horizontal 4 feet/above 1 foot) and gas meters (4 feet).

Special requirements: Massachusetts sidewall ventilation requires the installation of carbon monoxide detectors with backup batteries (1 per floor) and 8-foot high signage (“GAS VENT DirectLY BELOW. KEEP CLEAR”).

(2) Water system

Water quality requirements: hardness ≤ 8.5 grains (150 ppm), pH 8.8-9.2, requiring professional water treatment (anti oxidation, scaling), ethylene glycol usage not exceeding 50%, and rust inhibitor needs to be added; The new pipe needs to be cleaned with trisodium phosphate (TSP), and the old system needs to be equipped with a filter at the return water end.

Pipeline specifications: The supply/return water diameter should be 2-4 inches (depending on the model), and the flow rate should comply with Table 2 (such as EVS-500 minimum 22 gpm, maximum 43 gpm). The return water temperature should not be lower than 130 ° F (anti condensation), and the temperature difference should not exceed 40 ° F (anti heat exchanger damage); Safety valves (not shut-off valves), exhaust devices, and expansion tanks need to be installed.

(3) Gas system

Pressure requirements: The minimum inlet pressure for natural gas is 4-9 inches of water column (depending on the model), for propane it is 8 inches of water column, and for maximum pressure it is 14 inches of water column. For overpressure, an additional pressure regulator must be installed (no multiple boilers can share one); Gas pipes need to undergo leak testing (using soapy water, no open flames), and install sediment traps and manual shut-off valves.

Pipe diameter selection: Refer to Table 4 (such as the equivalent length of 10 feet for a 1-inch SCH40 pipe with a capacity of 514 ft ³/h), and consider the equivalent length of the pipe fittings (Table 6, such as the equivalent length of 1.55-20.2 feet for a 90 ° elbow).

(4) Electrical system

Power supply: requires independent circuit and fuse switch, voltage 120/208/230/460V (depending on model), grounding in accordance with NFPA 70; Do not connect the boiler and circulating pump to the same fuse switch. Isolation relays are required for low voltage control (24V), and short circuiting of safety controls is prohibited.

Operation and debugging process

1. Check before startup

Confirm that the installation of ventilation, water, gas, and electrical systems is compliant, turn off all power sources and gas valves, empty the air in the gas pipeline (wait for 5 minutes), check for no gas leaks, and then open the gas valve.

2. System startup steps

Water injection and exhaust: Close the boiler water supply valve, exhaust in zones (drain to no bubbles for 30 seconds in each zone), fill the system to working pressure, and check for water leakage.

Power on and debugging: Turn on the power, confirm the direction and flow switch function of the circulation pump, and set TSBC ™ Controller (see Chapter 9), check the fan direction (test during pre blowing).

Flame debugging: Verify the ignition flame (blue stable, signal 1.5-5.0 VDC) and the main flame (uniform orange), adjust the air-fuel ratio (high flame O ₂ 4-6%, low flame O ₂ 5.5-7%) to ensure CO ≤ 400 ppm.

3. Conventional operations

Ignition command: via TSBC ™ Activate the controller or external thermostat, manual ignition is prohibited; When you smell gas, turn off all electrical appliances, stay away from the building, and contact the gas supplier/fire department.

Operation monitoring: Real time monitoring of outlet temperature, modulation rate, flame signal to ensure that safety controls such as safety valves, high limit temperature controllers (manually reset), and low water level cut-off devices are functioning properly.

Maintenance and troubleshooting

1. Maintenance cycle and content

Operational requirements for periodic maintenance projects

Daily inspection around the boiler, instrument readings, and flame observation to ensure that there are no flammable materials and no abnormal flames

Weekly igniter, flame signal, gas valve leakage testing, fuel valve closure testing, safety shutdown time

Monthly flue/condensate drainage, gas pressure interlock testing to clean condensate water and ensure pressure is within normal range

Half year instrument calibration, air filter replacement, circulation pump maintenance, filter cleaning with soapy water, pump maintenance according to manufacturer’s specifications

Annual heat exchanger inspection, air-fuel ratio re inspection, safety valve testing, disassembly panel inspection for corrosion, and safety valve testing in accordance with ASME specifications

2. Common fault handling

Possible causes and solutions for alarm information

Low Water Level: The low water level cut-off device triggers a manual reset to check the water replenishment system

Low Water Flow circulation pump malfunction or pipeline blockage, confirm pump operation, clean filter

Fuel Limit gas pressure too high/too low reset pressure switch, check regulator/gas pipeline

High Temp Limit: If the water temperature exceeds the safe value, manually reset the high temperature controller and check the load/circulation system

FSG Fault Flame Protection Device Fault Reset Device, Check Igniter/UV Sensor

3. Spare parts and maintenance

Spare parts ordering: obtained through Thermal Solutions distributors (Lancaster warehouse), providing model and serial numbers; Key spare parts such as heat exchanger (EVS-500:103530-01), fan (EVS-750:81156018), and gas valve (V4295A series) require original factory parts.

Maintenance taboos: Do not disassemble the burner (easily damaged). Before electrical maintenance, all power sources must be cut off and locked. Replacement of controls must be consistent with the original factory model.

TSBC ™ Thermal Solutions Boiler Control

1. Core functions

Support boiler modulation control, multi boiler master-slave linkage (up to 8 units, RJ11 networking), outdoor temperature reset (adjust water temperature according to outdoor temperature, energy-saving), domestic hot water priority (DHWP), fault diagnosis (store 10 alarm records).

2. Key settings

Basic parameters: Warm Season Shutdown (WWSD) set point at 70 ° F, master-slave start triggering 90% modulation rate, stop triggering 25%, rotation period of 168 hours (balanced wear); The default PID parameters are local P=20, I=30, and remote P=20, I=30 (adjustable as needed).

Operation modes: manual mode (setting modulation rate from 0-100%), automatic mode (controlled by outlet/remote temperature), automatic switching to standby mode in case of sensor failure (such as remote sensor failure → outlet sensor control).

Bosch Rexroth HM20 Hydraulic Pressure Sensor

Product basic information

Product model: HM20 (a product under Bosch Rexroth, document number RE 30272, February 2022 edition, replacing April 2018 edition)

Core application: Used for pressure measurement in hydraulic systems. All models with current output have obtained DNV marine certification and are suitable for marine scenarios (requiring additional surge protection)

Key certifications: CE, cUL US Listed, DNV, RoHS, compliant with EMC Directive and UK EMC Regulations (UKCA certification)

Core Features

Measurement capability: Provides 8 measurement ranges (10 bar, 50 bar, 100 bar, 160 bar, 250 bar, 315 bar, 400 bar, 630 bar), using thin film measurement units, with excellent accuracy performance – characteristic curve deviation<0.5% (including nonlinearity, hysteresis, zero and endpoint deviation), non repeatability<± 0.05% (within the reference temperature range)

Material and safety: The medium contact parts are made of stainless steel (1.4542/17-4 PH/630, etc.), and the shell material includes V4A (1.4404), PEI, HNBR; Equipped with high explosive pressure, reverse polarity protection, overvoltage protection, and short circuit protection, the pressure channel is equipped with a 0.3mm throttling element, which can reduce the risk of damage caused by dynamic effects such as pressure peaks and air pockets

Environmental adaptability: Environmental temperature range -40~+85 ° C, medium temperature range -40~+90 ° C, storage temperature range -40~+80 ° C; anti vibration (10-2000Hz/maximum 10g/3-axis), anti noise (20-2000Hz/14g RMS/24h/3-axis), anti transportation impact (15g/11ms/3-axis), protection level IP65/IP67 (requires correct installation of matching connectors)

Technical parameters

(1) General parameters

Category parameter values

Weight 0.06kg

Rated temperature range -25~+80 ° C

Pressure interface G1/4 thread (compliant with DIN 3852 E-type, requiring thorough venting)

Suitable for media HL, HLP, HFC, nitrogen (up to 300 bar), other media can be customized as needed

Tightening torque: 20-25Nm for hydraulic interface<400bar; 25-30Nm for ≥ 400bar; 0.6-1.5Nm recommended for connectors not specified

Life cycle of 60 million load cycles or 60000 hours (CE certified)

(2) Electrical parameters

Category parameter values

The rated power supply voltage is 24VDC, with a lower limit of 18VDC and an upper limit of 36VDC (maximum 30VDC under cULus certification), and the maximum allowable residual ripple is 2.5VSS (40-400Hz)

Current consumption voltage output ≤ 12mA

Protection level III

Insulation resistance>100M Ω (500VDC)

Output signal current output (4-20mA, load resistance R ₐ=(U ₛ -8.5V)/0.0215A); Voltage output (0.1-10V, load resistance R ₐ>2k Ω)

Response speed establishment time (10% -90%)<1ms

Temperature coefficient within the rated temperature range<0.1%/10K; outside the range<0.2%/10K

Long term drift (1 year, baseline conditions)<± 0.1%

(3) EMC compatibility

Immunity: Complies with EN 61000-4 series standards (ESD 4kV CD/8kV AD, surge 1kV, RF radiation 10V/m, etc.)

Emission limit: Complies with EN 55016-2 series standards (interference voltage 0.15-30MHz Class B, radiation field strength 30-1000MHz Class B)

Order code and accessories

(1) Order Code Rules (Example: HM20-2X/- K35-N)

Code bit meaning optional values

Product Type HM20 (Pressure Sensor)

02 Component Series 2X (20-29 Series, with unchanged installation dimensions and pin assignments)

03 Measurement range: 10/50/100/160/250/315/400/630 (corresponding to bar number)

04 Output Type C (4-20mA current output, with DNV certification), H (0.1-10V voltage output)

05 connector K35 (4-pin M12x1)

06 Throttle element N (0.3mm nozzle type)

(2) Optional accessories (need to be ordered separately)

Cable set: 4-pin M12x1 interface, including straight 2m (R900773031), straight 5m (R900779498), bent 2m (R900779504), and bent 5m (R900779503), corresponding to data sheet 08006

Matching connector: 4-pin M12x1 interface, straight PG7 (R900773042), curved PG7 (R900779509)

Replacement seal: NBR material sealing ring (R900012467)

ABB SPAU 341 C Voltage Regulator

Product basic positioning and core functions

1. Product positioning

Application scenario: Designed specifically for on load tap changers in distribution substations, the secondary voltage of the transformer is regulated by controlling tap changers to ensure stable load voltage and adapt to 50/60Hz power grids;

Core value: Supports independent voltage regulation of a single transformer and parallel operation of multiple transformers, with functions such as line voltage drop compensation, overcurrent/undervoltage lockout, overvoltage detection, etc., to meet the stability requirements of industrial power supply;

Module composition: It consists of an automatic voltage regulation module (SPCU 1D50), a manual voltage regulation module (SPCN 1D56), a power module (SPGU 240 A1/SPGU 48 B2), an I/O module (SPTR 6B32), and a motherboard. It supports fiber optic serial bus communication (requires SPA-ZC series bus modules).

2. Core Function List

Functional categories, specific abilities, and application value

Voltage control with automatic/manual dual-mode voltage regulation, adjusting the voltage to adapt to load changes through the “Raise/Lower” signal of the tap changer, and maintaining stable secondary voltage

Compensation function circuit voltage drop compensation (U ₐ), compensating for voltage loss caused by circuit resistance (R) and reactance (X) to ensure that the voltage at the remote load end meets the standard, avoiding high near end voltage/low far end voltage

Protection lockout overcurrent lockout (I>), undervoltage lockout (U<), overvoltage detection (U>), external lockout input prevents the tap changer from operating in fault states (such as short circuit, abnormal voltage), extending equipment life

Parallel operation supports three parallel control principles: Master/Slave, Negative Reaction, and Minimizing Circulating Current. When multiple transformers supply power to the same bus, they balance the load and circulating current to avoid equipment overload

Real time self inspection of self-monitoring hardware/software, triggering IRF (Internal Relay Fault) alarm in case of failure, blocking output to improve system reliability, and reducing the risk of fault expansion

Data exchange with digital display of set/measured values, RS485 serial interface, fiber optic bus communication for convenient on-site debugging and remote monitoring, compatible with substation automation systems

Core working principle and key parameters

1. Voltage regulation core logic

Control voltage calculation: The controller calculates the target control voltage (U ₚ) through “reference voltage (U ₛ) ± line voltage drop compensation (U_z) ± circulating current compensation (U_ci) – set voltage drop (U_rsv)”, and the formula is:

Uₚ = Uₛ ± U_z ± U_ci – U_rsv

Adjustment trigger mechanism:

Compare the measured voltage (U ₘ) with the control voltage (U ₚ). If U ₘ exceeds the “bandwidth (∆ U ₛ)” range (default ± 1.5% U ₙ), initiate the first delay (T1, default 60s);

If U ₘ still exceeds the hysteresis range (∆ U ₕ, default 90% ∆ U ₛ) during the delay period, the tap changer will be triggered;

If a single action does not cause U ₘ to return to bandwidth, initiate the second delay (T2, default 30s) and repeat the adjustment until the voltage meets the standard;

The delay feature supports both “definite time limit” and “inverse time limit” (the delay is inversely proportional to the voltage deviation, and the larger the deviation, the shorter the delay).

2. Key technical parameters (core indicators)

Specific specifications for parameter categories

Voltage input rated voltage U ₙ: 100V/110V/120V (line voltage), continuous withstand voltage 2U ₙ, power consumption<0.5VA, suitable for different regional power grid rated voltages

Current input rated current I ₙ: 1A/5A (optional), 1A model can withstand 4A and 25A continuously for 10 seconds; 5A model can withstand 20A and 100A continuously for 10 seconds, compatible with current transformers (CT) of different transformation ratios

Output contact adjustment contact (Raise/Power): 250V AC/DC, continuous 5A, 0.5s on-off 30A; signal contact (lockout/alarm): 250V AC/DC, continuous 5A, compatible with tap changer drive circuit and alarm circuit

Power module SPGU 240 A1: 80~265V AC/DC (compatible with 110/230V mainstream voltage); SPGU 48 B2: 18~80V DC (compatible with low-voltage DC system) to meet different substation power configurations

Environmental adaptability: working temperature -10~+55 ℃, storage temperature -40~+70 ℃, humidity 5%~95%, non condensing, protection level IP54 (embedded installation), suitable for industrial harsh environment, dustproof and splash proof

Communication capability: Fiber optic serial bus, ASCII encoding, speed 4800/9600 Bd, supports SPA-ZC series modules (SPA-ZC 17/21 for plastic fiber optic and SPA-ZC 17 MM/21 MM for glass fiber optic) to achieve data exchange among multiple regulators, supports parallel operation and remote monitoring

Core configuration and operation process

1. Key configurations before installation (mandatory steps)

(1) Hardware wiring specifications

Core input/output wiring:

Voltage input: X0/13-14 terminals are connected to the secondary side line voltage of the transformer (U ₁₂, 100/110/120V);

Current input: Connect the X0 terminal to three-phase current (1A to 1-3/4-6/7-9, 5A to 1-2/4-5/7-8), and a single transformer can only measure the L1 phase current (selected through SGF2/6/7 software switch);

Control output: X2 terminal outputs Raise/Power signal to the tap changer, X1 terminal connects external control signal (automatic/manual switching, external locking);

Grounding requirement: Connect the protective ground through the X0/63 terminal to ensure reliable grounding between the module and chassis, avoiding electromagnetic interference.

(2) Core parameter setting (configured through panel buttons or serial port)

Parameter Name Setting Range Default Values Key Role

Reference voltage U ₛ 0.85~1.15U ₙ 1.00U ₙ Set target secondary voltage

Bandwidth ∆ U ₛ 0.60~9.00% U ₙ 1.50% U ₙ Voltage fluctuation tolerance range, avoiding frequent adjustments

Delay T1/T2 0.0~300s 60s/30s to prevent momentary voltage fluctuations from triggering misoperations

Overcurrent lockout I>1.00~2.00I ₙ 2.00I ₙ When overcurrent occurs, voltage regulation is prohibited to protect the tap changer

Line compensation U ᵣ/U ₓ 0.0~25.0% U ₙ 0.0% U ₙ Compensation line impedance voltage drop, U ᵣ=√ 3I ₗₒₐ𝒹 R × 100/U ₙ, U ₓ=√ 3I ₗₒₐ𝒹 X × 100/U ₙ

2. Operation mode and process

(1) Automatic voltage regulation mode (default, SPCU 1D50 dominant)

Trigger condition: If U ₘ exceeds the range of ∆ U ₛ and lasts for T1 time, the controller outputs Raise/Power signal to drive the tap changer;

Compensation logic: Based on the load current (I ₗₒₐ𝒹) and the line parameters (R/X), U_z is automatically calculated to increase the remote voltage (such as a line voltage drop of 2V, U_ is automatically increased by 2V).

(2) Manual voltage regulation mode (dominated by SPCN 1D56)

Activation method: Switch through the panel “MAN” button or external “MAN ‘” input, and the MAN indicator light will turn on;

Operation steps: Press the “Raise”/”Lower” button, the corresponding indicator light flashes → Confirm that there is no lock (I>/U<light is not on) → Press the corresponding button again to trigger the tap changer action, and the TCO light is on to indicate that the tap changer is running.

(3) Multiple transformers running in parallel (three modes)

Parallel mode is suitable for key configurations in applicable scenarios

Master/Slave mode: The main regulator of a transformer with the same capacity and tap voltage measures voltage/current and controls it. The slave regulator follows the action of the main regulator and needs to be directly wired to connect the master slave “up/down” output and input

Negative Reaction mode: Transformers with different capacities and tap voltages do not require physical connections. The “load phase shift” parameter is set, and the controller compensates for the voltage deviation between the measured phase shift and the set value, adapting to the parallel connection of dispersed substations

In scenarios where there are large differences in transformation ratio/capacity and large fluctuations in reactive load, the Minimum Circulating Current mode needs to be paired with the SPA-ZC 100 bus module. Multiple regulators exchange current/phase shift data, calculate and minimize circulating current, and support up to 3 parallel regulators

Fault handling and maintenance

1. Interpretation of status indicator lights (core fault diagnosis basis)

Suggestions for handling the meaning of indicator light status

Module status (MS): red, constantly on, unrecoverable fault (such as hardware damage). Power off and restart, if ineffective, check the connection between the I/O module and the motherboard, and contact after-sales service

Overcurrent lockout (I>), red constant light. If the current exceeds the set value, check if the load is overloaded and if the CT wiring is normal. After troubleshooting, reset

Under voltage lockout (U<), red constant light, voltage lower than U<set value (default 0.7U ₙ), check the grid voltage. If the grid is normal, adjust U<set value

Overvoltage detection (U>): The red constant light indicates that the voltage is higher than the set value (default is 1.25U ₙ), triggering “rapid voltage reduction” without manual intervention. After the voltage is restored, it will automatically exit

Self check fault (IRF): The hardware/software fault record of the red module is constantly on, and the display screen shows the fault code (such as 1-030=program memory fault). Contact after-sales maintenance for assistance

2. Common fault codes and their solutions

Fault code, fault type, handling measures

1-004 voltage regulation control circuit fault check tap changer “up/down” coil wiring, confirm power module output voltage

1-030 Program Memory (ROM) malfunction module internal failure, SPCU 1D50 module needs to be replaced

1-050 working memory (RAM) failure, power off and restart. If the failure persists, replace the motherboard

1-051 Parameter Memory (EEPROM) Failure: Format EEPROM with V167 parameters and reconfigure parameters

3. Key points of daily maintenance

Regular inspection: Check the terminal wiring for looseness and proper heat dissipation every month, and clean the module dust screen (if any) every quarter;

Parameter backup: Backup parameters (such as U ₛ, ∆ U ₛ, U ᵣ/U ₓ) through serial software to avoid module failure causing parameter loss;

Spare parts preparation: It is recommended to reserve key spare parts such as power module (SPGU 240 A1) and I/O module (SPTR 6B32) to shorten the time for fault repair.

Installation and selection suggestions

1. Installation requirements

Environmental conditions: Avoid high temperature heat sources (such as the transformer body), installation location temperature ≤ 55 ℃, humidity ≤ 95% non condensing, protection level IP54 (requires compatible casing);

Wiring specifications: Voltage/current signal lines and power lines should be laid separately. The length of the fiber optic bus cable should be ≤ 100m (plastic fiber)/2km (glass fiber), and the bending radius should be ≥ 10 times the cable diameter;

Size and fixation: Adopting embedded installation, the panel opening size needs to match (214 × 139mm ± 1mm), and the installation depth can be adjusted through the SPA-ZX series height increasing frame (3 specifications).

2. Selection and matching

Power module selection: Select SPGU 240 A1 (80~265V AC/DC) for conventional scenarios, and SPGU 48 B2 (18~80V DC) for low-voltage DC systems;

Bus module selection: SPA-ZC 17 BB/21 BB for plastic fiber optic, SPA-ZC 17 MM/21 MM for glass fiber optic, and SPA-ZC 100 BB/MM for parallel minimum circulating current;

Cable selection: 100V shielded wire is used for voltage signals, CT dedicated shielded wire is used for current signals, and ABB recommends plastic/glass fiber optic cables (such as SPA-ZP 25A05) for optical fibers.

Rockwell Automation 1585 Ethernet Media

Document Fundamentals and Product Positioning

1. Core positioning

Application scenario: Suitable for Harsh environment in industrial control field (high vibration, chemical corrosion, wide temperature range, high electromagnetic interference), supporting EtherNet/IP protocol (compatible with CIP protocol of DeviceNet and ControlNet);

Key advantages: The entire series of products comply with standards such as ODVA EtherNet/IP and ISO IEC 24702, providing protection coverage from IP20 (inside the control cabinet) to IP67 (outdoor/equipment end), and supporting a maximum transmission rate of 1Gb/s (Cat 6);

Product matrix: Classified by “cable form+connector type”, covering four major categories: cable reels, RJ45 series, M12 series, and adapters, to meet the needs of different installation scenarios.

2. Core parameters for environmental adaptation

Temperature range: Regular model -20~+60 ℃, wide temperature model -40~+80 ℃ (such as M12 Xcode Gigabit);

Protection level: RJ45 class IP20, M12 class IP67 (splash proof, dustproof);

Anti interference capability: Shielded version (foil+braided shielding) supports high noise environment (M ∝ I ∝ C ∝ E ∝ level), unshielded version reduces interference through twisted pair balanced design;

Weather resistance: TPE/PUR sheathed cables are resistant to welding spatter, ultraviolet radiation, and oil stains, while PVC versions are suitable for conventional industrial environments.

Core product classification and technical specifications

(1) Cable reel: Basic transmission medium

1. Unshielded twisted pair (UTP)

Core parameters: Cat 5e, 24 AWG tinned copper conductor, 4/8 cores (2/4 pairs), supporting 1Gb/s rate;

Sheath type and scenario:

Key Characteristics of Sheath Material Color Adaptation Scene Model Example

Robot TPE green/red bending resistant (10 million cycles), oil/UV resistant robotic arm, mobile device 1585-C4TB Sx (4-core)

Riser PVC green vertical wiring compliance (UL CMR) control cabinet vertical wiring 1585-C8PB Sx (8-core)

Plenum PVC grey smoke and toxic resistant (UL CMP) ventilation duct, cleanroom 1585-C8MB Sx (8-core)

Length options: x=100/300/600m (default unit), for example, 1585-C4TB-S600 is a 600m scroll.

2. Shielded Twisted Pair (STP)

Shielding structure: foil+braided double-layer shielding (some models use single-layer foil shielding), enhancing the ability to resist electromagnetic interference;

Special Style: 600V High Voltage Cable:

Parameters: 22 AWG, 8-core (4 pairs), -20~+80 ℃, UL PLTC/AWM 2570 certification;

Scenario: Installed on the same cable tray as the high-voltage power cable (such as near the motor control cabinet), models 1585-C8HB Sx (green) and 1585-C8EB Sx (red).

(2) RJ45 series: inside control cabinet/conventional connection

1. Conventional RJ45 jumper (IP20)

Core specifications: Cat 5e/Cat 6, 4/8 cores, supporting 6 connection combinations including straight head straight head, straight head elbow (left/right), etc;

Classification and Scenarios:

Type Sheath Material Shielding/Non Shielding Key Characteristics Model Example

Regular PVC (riser) unshielded/shielded control cabinet fixed wiring, UL CMR 1585J-M8PBJM-y (8-core straight head)

High flexibility TPE unshielded with 10 million bending cycles, compatible with mobile parts 1585J-M8TBJM-y

600V high voltage PVC foil shielding high voltage environment isolation, UL PLTC 1585J-M8HBJM-y

Length options: y=2/5/10m (default unit), for example, 1585J-E4TBJM-5 is a 5m right elbow jumper.

2. Gigabit RJ45 jumper (Cat 6)

Differentiated parameters: 8-core (4 pairs), foil+braided shielding, TPE sheath, -40~+75 ℃, supporting 1000Mbps;

Scenario: High speed industrial Ethernet (such as machine vision, large data transmission), model 1585J-M8TGJM-x (straight head straight head).

3. On site connectors can be connected

Two types of styles:

IDC tool free connector: Cat 6, 24-27 AWG (solid core/multi strand), 360 ° shielding, can be reused 5 times, model 1585J-M8CC-H (single pack);

Crimp connector: Cat 5e, 24~26 AWG, with protective boots, 50 pieces (1585J-M8CC-C);

Advantages: No need to strip wires, simplifying on-site wiring modifications, and adapting to custom cable length requirements.

(3) M12 series: Harsh environment specific

4-core D-code (conventional industrial)

Core features: IP67 protection, 4-core (2 pairs), Cat 5e, Support -40~+75 ℃ (TPE/PUR sheath);

Classification and Scenarios:

Example of Key Characteristics and Models for Shielded/unshielded Sheath Material (Jumper)

TPE unshielded high flexibility (10 times cable diameter bending radius) 1585D-M4TBJM-x (M12-RJ45)

PUR foil+woven shielding halogen-free, chemical corrosion resistant 1585D-M4UBJM-x

PVC foil shielding 600V high voltage isolation 1585D-M4HBJM-x

Special Edition: Red M12: Identify high voltage/safety circuit, model 1585D-M4VBDM-x (TPE unshielded).

2. 8-core X-code (gigabit high-speed)

Differentiated parameters: Cat 6, 8-core (4 pairs), foil+braided shielding, -40~+80 ℃, supporting 1Gb/s;

Scenario: High speed transmission in Harsh environment (such as outdoor sensor networking), providing M12-M12 (1585D-M8UGDM-1) and M12-RJ45 (1585D-M8UGJM-1) jumpers with customizable lengths.

3. M12 socket (front end installation)

Features: IP67, 4-core D-code, TPE/PUR sheath, suitable for fixed installation at the device end;

Model: 1585D-D4TBJM-x (unshielded TPE), 1585D-D4UBJM-x (shielded PUR), length 1-15m optional.

(4) Adapter: Transition across protection levels

1. M12-RJ45 wall adapter

Core function: Implement the transition from IP67 (M12 at the device end) to IP20 (RJ45 inside the control cabinet), and support panel installation (PG9 thread);

Parameters: 4-core D-code, IP67, -20~+85 ℃, 22 AWG, model 1585A-DD4JD;

Scenario: Connection between on-site equipment such as motors and sensors and control cabinets.

2. M12 IDC on-site connector

Features: Tool free installation, 4-core D-code, optional shielded/unshielded, IP67, -25~+85 ℃;

Model: 1585D-M4DC-SH (shielded straight head), 1585D-F4DC-SH (shielded elbow), compatible with 22-26 AWG cables.

Key selection dimensions and precautions

1. Three core dimensions for selection

(1) Environmental protection requirements

IP20 scenario (inside control cabinet): Select RJ45 unshielded/shielded jumper (such as 1585J-M8PBJM-y);

IP67 scenario (device side/outdoor): Select M12 series (such as 1585D-M4TBJM-x);

High voltage/strong interference scenario: Choose a 600V shielded version (such as 1585-C8HB Sx cable, 1585J-M8HBJM-y jumper).

(2) Transmission rate and distance

100Mbps (regular control): Cat 5e, with a maximum length of 100m for unshielded models (at 500kbps), and up to 150m for shielded models;

1Gb/s (high-speed data): Cat 6 (M12 Xcode), up to 100m (twisted pair), requires matching shielding design to reduce crosstalk.

(3) Mechanical characteristics

Fixed wiring: choose PVC sheath (low cost, high stability);

Mobile components (such as robotic arms): Choose TPE/PUR high flexibility models (10 million bends, such as 1585-C4TB Sx cables).

2. Precautions for installation and use

Bending radius: High flexibility cables should be ≥ 10 times the cable diameter, while conventional cables should be ≥ 20 times to avoid excessive bending and transmission attenuation;

Shielding grounding: Shielding models require single ended grounding (on the control cabinet side) to avoid ground circulation caused by double ended grounding;

Color identification: The red version is used for high-voltage/safety circuits, while the green and green versions are used for regular signals to avoid mixing;

Tool adaptation: IDC connectors do not require tools, while crimping connectors require specialized crimping tools (such as 1585A-JCRIMP).

Certification compliance

Safety certifications: UL Listed, cUL, CE (EN 61000-6-2/-4), C-Tick (Australia);

Industry standards: ODVA EtherNet/IP, ISO IEC 24702, TIA 568-B (wiring standard).

Typical application scenario configuration example

Robot workstation: M12 D-code high flexibility jumper (1585D-M4UBJM-2)+TPE cable reel (1585-C4TB-S300), suitable for -40~+75 ℃, high vibration environment;

Outdoor sensor networking: M12 Xcode Gigabit jumper (1585D-M8UGDM-5)+600V shielded cable (1585-C8HB-S600), resistant to ultraviolet and high-voltage interference;

Wiring inside the control cabinet: RJ45 straight head elbow jumper (1585J-E8PBKM-3)+PVC cable reel (1585-C8PB-S100), low-cost compatible with IP20 environment.

Through the above product combination, industrial Ethernet can achieve full scene coverage from “control cabinet field equipment outdoor node”, ensuring stable transmission in Harsh environment.

Rockwell Automation SmartGuard 600 Controller

Basic and Controller Core Positioning

1. Basic information

Document purpose: To guide the installation, parameter configuration, wiring, and status interpretation of safety controllers, suitable for deployment in industrial safety scenarios such as emergency stop and safety door monitoring;

Controller positioning: Programmable Electronic Safety System (PES), supporting 16 digital inputs, 8 digital outputs, 4 test pulse outputs, 1752-L24BBBE with additional support for EtherNet/IP communication;

Safety certification: meets high safety level requirements – IEC 61508 SIL 3, ISO 13849-1 PL (e), EN 954-1 CAT 4, suitable for hazardous environments (North American Class I Div 2 Groups A-D).

2. Comparison of Model Differences

Model Core Differences Communication Interface Applicable Scenarios

1752-L24BBB Basic Security Control USB+DeviceNet Security Scenarios without Ethernet Requirements (such as Single Device Security Monitoring)

1752-L24BBBE adds Ethernet functionality USB+DeviceNet+EtherNet/IP for distributed security systems that require remote Ethernet monitoring (such as production line level security linkage)

Key configurations before installation (mandatory steps)

1. Safety prerequisite requirements

Precautions for hazardous environments:

It is strictly prohibited to plug and unplug wires with electricity (which may cause arcing and explosion). Power must be cut off or the environment must be confirmed to be in a non hazardous area first;

Prohibition of replacing non original components (which may damage Class I Div 2 compatibility);

Battery replacement is only allowed in non hazardous areas.

Electrostatic protection: Before operation, touch a grounded object to discharge electricity, wear an anti-static wristband, prohibit touching circuit board pins, and store in anti-static packaging when idle.

2. Core parameter configuration (power-off operation)

(1) DeviceNet node address setting

Configuration method: Set through the two rotary switches (ten position+one position) on the front of the controller, with a range of 00~63 (default 63);

Software configuration compatibility: If setting the address through RSNetWorx for DeviceNet software, the rotary switch needs to be turned to 64~99;

Key reminder: Avoid duplicate node addresses, otherwise communication errors may be triggered.

(2) DeviceNet communication rate setting

Default speed: 125 kbps, supports three speeds of 125/250/500 kbps, configured through a 4-digit DIP switch:

DIP switch (1-4) communication rate description

OFF-OFF-OFF-OFF 125 kbps default value

ON-OFF-OFF-OFF 250 kbps medium range networking

OFF-ON-OFF-OFF 500 kbps short distance high throughput scenario

The software configuration of ON-ON-OFF-OFF needs to be set through RSNetWorx

Speed and distance matching: The higher the speed, the shorter the supported cable length (such as 75m for flat cables and 100m for thick cables at 500 kbps), which needs to be selected according to the network size.

(3) EtherNet/IP IP Address Setting (1752-L24BBBE only)

Default mode: BOOTP enabled, IP needs to be allocated through BOOTP server (recommended Rockwell free tool, download link: http://www.ab.com/networks/bootp.html );

Configuration steps:

Run the BOOTP tool and double-click on the device MAC address;

Enter the target IP in the pop-up window and click confirm;

The IP address of the controller can be viewed on the display screen through the front “IP Address Display Switch” (long press for more than 1 second), and error code “n4” indicates abnormal Ethernet configuration.

Controller installation and wiring specifications

1. Physical installation (DIN rail fixation)

Installation requirements:

Only supports EN 50022 standard DIN rails (35×7.5mm or 35x15mm), horizontal installation (vertical installation may affect heat dissipation);

Heat dissipation gap: at least 50mm (2.0in) up and down, and at least 5mm (0.20in) left and right, avoiding installation above heating equipment;

Installation steps:

Hang the top card slot of the controller on the DIN rail;

Press the bottom of the controller and tighten the bottom buckle (1752-L24BBB single buckle, 1752-L24BBBE double buckle);

Install end plates at both ends of the guide rail to ensure stability.

Grounding requirements: Chassis grounding is achieved through DIN rails, which require the use of galvanized yellow chromium steel rails (aluminum/plastic rails may cause poor grounding), and the rails should be fixed every 200mm (7.8in).

2. Power wiring (safety power supply is the core)

Power specifications:

External power supply: 24V DC (allowable range 20.4~26.4V DC), output holding time ≥ 20ms;

Safety compliance: Must meet SELV/PELV (CE LVD), Class 2 (UL 508), and recommend Rockwell 1606 series power supplies (such as 1606-XLP30E, 1606-XL60DR);

Terminal wiring:

The controller includes 3 sets of V/G terminals (V0/G0: internal logic power supply; V1/G1: Input and test output power supply; V2/G2: Safe output power supply);

The V0/G0 two sets of terminals are internally connected, only one set needs to be connected, and the other set can be used to distribute power to other devices.

3. I/O and communication wiring (according to scene specifications)

(1) Input wiring (compatible with two types of devices)

Mechanical contact equipment (such as emergency stop button): It is necessary to simultaneously connect the “safety input terminal (INx)” and the “test output terminal (Tx)” to achieve CAT 4 level, with a wiring length of ≤ 30m;

PNP semiconductor devices (such as safety light curtains): only connected to the safety input terminal (INx), no need to test the output, typical current is 4.5mA.

(2) Output wiring (distinguishing between safety and test outputs)

Safe output (OUT0~OUT7): Maximum load 0.5A, wiring beyond the rated value is strictly prohibited, and it is not allowed to be used as a test output;

Test output (T0~T3): Only used for input circuit testing, T3 additionally supports wire breakage/bulb burnout detection and cannot be connected to safety loads.

(3) Communication wiring

DeviceNet wiring: 5-wire connector, corresponding by color (red V+, white CAN H, blue CAN L, black V -, empty Drain), screw torque 0.25~0.3N · m;

USB wiring: only for temporary configuration (non permanent connection), cable length ≤ 3m, USB-A to USB-B male to male cable is required;

EtherNet/IP wiring (only 1752-L24BBBE): RJ45 interface, CAT5e/CAT5 cable, length ≤ 100m, pins 1 (TD+), 2 (TD -), 3 (RD+), 6 (RD -).

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Interpretation of Status Indicators and Troubleshooting

1. Meaning of core indicator lights (sorted by classification)

(1) Module status (MS) indicator light

Suggestions for handling the meaning of indicator light status

Turn off the power supply and check the power wiring. Restart the power supply

Green constantly on, normal operation (Run mode), no operation required

Green flashing standby mode (Idle) to confirm if the configuration is complete

Red flashing can restore faults (such as configuration errors). Check the switch configuration and reset the configuration data

The red light is constantly on and cannot be restored due to a fault (such as hardware damage). Check the wiring, eliminate interference, and contact after-sales service

Red green alternating flashing self-test/configuration download waiting for completion. If it continues to flash, it needs to be reconfigured

(2) Network status indicator light

DeviceNet (NS D): Green constant light=online and connected, red constant light=MAC address conflict/bus disconnection, address and cable need to be checked;

EtherNet/IP (NS E, BE only): Green constant light indicates Ethernet connection, red constant light indicates IP address conflict, IP needs to be reassigned.

(3) I/O status indicator light

Yellow constant light=signal normal, red constant light/flashing=circuit fault (such as disconnection, short circuit, overcurrent), wiring and load need to be checked.

2. Interpretation of Display Screen Information

Normal state: Display node address (00~63), standalone mode displays “nd”;

Fault status: alternately display error codes and node addresses (such as F0=MAC conflict, F1=bus disconnection);

Special function: Press the “Service Switch” to display the security configuration signature (verifying that the program has not been tampered with), press the “IP Display Switch” to display the Ethernet IP.

Key specifications and supporting resources

1. Core technical parameters

Specification item 1752-L24BBB 1752-L24BBBE

Size (HxWxD) 99×99.4×131.4mm 99x113x131.4mm

Weight 460g 575g

Working temperature -10~55 ℃ (14~131 ℉) same as left

Protection level IP20, same as left

Input current 4.5mA (per channel) same as left

Output current 0.5A (per channel, maximum) same as left

Ethernet speed -10/100Mbps (full/half duplex)

2. Supporting resources

Key manuals:

SmartGuard 600 User Manual (1752-UM001): Controller Configuration and Troubleshooting;

SmartGuard 600 Safety Reference Manual (1752-RM001): Safety Concepts and PFD/PFH Calculations;

tool

Configuration software: RSNetWorx for DeviceNet (DeviceNet configuration), BOOTP tool (IP configuration);

Core safety operation reminder

Prohibited behavior:

Test outputs cannot be used as safety outputs, and safety signals cannot be transmitted using DeviceNet standard I/O data;

It is prohibited to disassemble/modify the controller (which may damage safety functions);

Do not allow the 24V DC line to accidentally touch the output terminal to avoid starting the load.

Wiring specifications:

Input/output cables should be arranged separately from high-voltage/high current cables to avoid interference;

Stranded wires require the installation of DIN 46228-4 standard insulated Ferrules (non-standard Ferrules may not match the terminals).

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