ABB REM54 motor terminal troubleshooting

Control, tripping circuit monitoring and status monitoring: cannot only focus on protection tripping

The control functions of REM54 include circuit breaker control, isolation switch control, three state isolation switch, object indication, MIMIC dynamic data point, alarm channel, On/Off switch, and logic control position selector. The control function must be associated with the MIMIC configuration of the HMI, otherwise it cannot be correctly indicated and operated locally. If the on-site "protection action but circuit breaker does not trip", in addition to checking the protection trip output, it is also necessary to check the HSPO/PO/SO output type, control circuit power supply, auxiliary contacts, and trip circuit monitoring.

CMTCS1/CMTCS2 is a trip circuit monitoring system that monitors the integrity of the trip circuit based on constant current injection. If a tripping circuit fault is reported, the tripping coil, auxiliary contacts, terminal block, control voltage, and monitoring circuit current should be checked. CMCU3/CMVO3 monitoring excitation current/voltage input circuit; CMBWEAR1/2 monitors the electrical wear of circuit breakers; CMTIME1/2 is an operation time counter; CMTRAV1 is the travel time of the circuit breaker; CMSCHED is for regular maintenance; CMGAS1/3 is for gas pressure monitoring. The status monitoring data should be viewed in conjunction with event records and waveform recordings, rather than just looking at individual alarms.

The digital input is voltage controlled, optically isolated, can be reversed, and the filtering time can be set; Partial digital inputs can be programmed as pulse counters with a frequency range of 0... 100Hz. Digital outputs are divided into HSPO high-speed power output, PO power output, and SO signal output. HSPO bipolar contacts are suitable for tripping and circuit breaker control; SO is a common signal contact and cannot control heavy loads such as circuit breakers. If the control command is intermittent, check whether the output type is selected incorrectly, whether the contact capacity is sufficient, and whether the digital input filtering and oscillation suppression are too strong.

Communication and configuration: SPA, LON, Modbus, and external display

REM54 has three serial ports: front panel optical port RS232 for PC configuration, using SPA bus; The rear X3.2 is a 9-pin RS232 with optional SPA or Modbus RTU/ASCII; The rear X3.3 is a 9-pin RS485, with optional SPA or LON options. Fiber optic isolation requires RER123 (SPA) or RER103 (SPA/LON). Modbus requires a third-party fully isolated RS232/RS485 converter, and the documentation lists the Phoenix converter and dedicated cable. X3.4 is RJ45, used for external display modules, and the external display module requires independent auxiliary voltage from the same source as the host.

Communication troubleshooting should start with the physical layer: fiber optics, connectors, converter power supply, baud rate; Link layer: address, protocol selection, master-slave settings; Final application layer: event table, parameter table, SCADA point table. If the LON interlock does not work, check the LON network variable binding and LNT configuration; If Modbus cannot read data, the protocol selection, converter isolation, and cable should be checked. The configuration tools include CAP501/CAP505, Relay Configuration Tool, Relay Mimic Editor, and LON Network Tool. The parameters can be set locally on the HMI or externally on CAP501 or SMS510. After replacing the device, it is necessary to re download the configuration and settings, and verify the MIMIC, alarm LED, event, and communication mapping.

Whole machine replacement: REM54 cannot only replace one board

The REM54 document clearly states that in order to ensure operational accuracy, all components are calibrated together, and the product is considered as a whole and no spare parts are provided separately; When there is a malfunction, the supplier should be contacted. When replacing or modifying, one should not only look at the "REM543/REM545" model, but also verify the complete order number. The order number identifies the machine type, software version, functional level (M motor/G generator), hardware number, auxiliary power supply (A is PS1/240V, C is PS1/48V), sensor/transformer input (A has no sensor, B has a sensor), and display (A fixed display, B external display module). The display language is determined by the software number suffix, such as 001 English German, 002 English Swedish, 003 English Finnish, 009 English Russian. The Modbus option also needs to be confirmed according to the order, and some information is only marked as REM543.

Before replacement, the number of digital inputs and outputs should be checked (REM543 is 15 DI, REM545 is 25 DI; TCS input is 2; Whether there are RTD/analog modules, whether there are 4 channels of 0... 20mA analog outputs, whether sensor inputs need to be short circuited, external display module cables and auxiliary power supplies, communication modules and protocols. After replacement, secondary injection, differential polarity, and trip transmission should be performed TCS、 Verify point-to-point communication and HMI MIMIC. The configuration of the old device cannot be directly applied to the new hardware number, otherwise the sensor/transformer input and I/O mapping may be inconsistent.