STUCKE SYMAP relay



STUCKE SYMAP relay

In ship power, offshore platforms, and industrial power distribution systems, digital protection relays undertake the protection, control, and interlocking tasks of key equipment such as generators, motors, transformers, feeders, and busbars. The STUCKE SYMAP series, as a multifunctional protection and control device manufactured in Hamburg, Germany, is commonly used in scenarios that require high reliability and long-term availability due to its three microprocessor architecture, rich communication interfaces, maritime classification society certification, and IEC 61850 capabilities. For engineers who are maintaining old protective cabinets, preparing to replace discontinued relays, or troubleshooting communication and tripping anomalies on site, understanding SYMAP's hardware logic, wiring characteristics, and diagnostic methods is more important than simply replacing spare parts. This article summarizes the key technical points and on-site troubleshooting strategies of the SYMAP series from the perspective of engineering deployment and maintenance.

Product positioning and lineage division

SYMAP is not a single model, but a series that covers multiple protected objects. The SYMAP Y series includes versions such as EC, ECG, F, G, M, T, LD, DC, BAT, which are designed for engine control, engine control with generator protection, feeder protection, generator protection, motor protection, transformer protection, line differential protection, DC protection, and battery/hybrid energy applications. The SYMAP BC series includes BC and BCG, positioned as multifunctional protection relays, with BCG also integrating power management functionality. For replacement projects, the first step is not to look at the model label on the old cabinet door, but to verify the actual protected object, number of circuit breakers, engine communication protocol, and whether differential protection is needed. If the old device is responsible for both generator protection and multi machine power management, BCG or ECG versions are usually closer to the original system function than a single protection model.

This series supports low, medium, and high voltage power systems, with protection functions that can be activated simultaneously and can control up to five main circuit breakers. It has display, control, and lockout management capabilities. The built-in small PLC can complete interlocking and custom control logic, and digital and analog output can be connected to the switch cabinet control circuit. For ships and offshore projects, the SYMAP series has Lloyd's Register, ABS, DNV, BV, CCS, PRS, NK, RINA, KR and other classification society type approvals, as well as CE and IEC 61850 KEMA certificates. Some versions also meet the DNV Cyber Secure Essential Type Approval, corresponding to IEC 62443-3-3 security level 1, which is particularly important for ship power systems that require remote monitoring and parameter setting.

Redundant Architecture and Security Design

The core security concept of SYMAP is "mutual supervision among multiple processors". The device uses three microprocessors internally, which supervise each other and form a watchdog system. Important functions are combined with dual redundancy and run independently by the second processor. For short-circuit protection, in addition to device body protection, CMA 198 current fed short-circuit redundancy board can also be selected to form a self powered short-circuit protection independent of SYMAP. This board can still operate when the system voltage is completely lost, making it suitable for situations where high continuity of short-circuit protection is required. CMA 198 is divided into versions A, B, and C: A is 1A secondary rated current, three-phase, short-circuit setting 2.0 to 7.0 times In; B is 1A, three-phase, 1.2 to 3.5 times In; C is 5A, three-phase, 2.0 to 7.0 times In. When replacing or installing, it is necessary to check the CT secondary rated current and setting range, and not just look at the appearance.

The significance of this redundant design for on-site maintenance is that when the device self checks and finds abnormalities in the memory, analog reference voltage, control power supply, binary input/output, or automatic test sequence, maintenance personnel should prioritize reading diagnostic information and event records, rather than directly determining that the main board is damaged. SYMAP also monitors parameters such as the power supply of the trip coil, the status of the switchgear, the start stop status of the motor, the temperature and pressure inside the cabinet, and the operating life of the circuit breaker. These monitoring quantities can serve as important criteria for determining whether there is a "protection misoperation" or a "peripheral circuit fault".

Key points for installation, wiring, and replacement

All connections of SYMAP are completed through back pluggable terminals, making it easy to replace the entire machine. The device size varies by series: the Y series is approximately 192 × 192 × 103 mm, weighing approximately 2.3 kg; the BC series is approximately 279 × 192 × 146 mm, weighing approximately 5 kg. The power supply options include 12-36 V DC, 36-72 V DC, 80-300 V DC, or 60-230 V AC, with a power consumption of less than 30 W. The working environment temperature ranges from -20 ℃ to+70 ℃, the front panel protection level is IP54, and the connection part is IP10. When replacing the old device, the power supply system, terminal spacing, and depth space inside the cabinet should be confirmed first to avoid the new device being able to power on but unable to close the door or terminal interference.

The CT circuit is the most risky part during the replacement process. The CT terminal plug of SYMAP will automatically short-circuit the CT circuit when disconnected, reducing the risk of open circuit, but this does not mean that it can be unplugged or unplugged freely with power on. The standard practice is still to cut off the power first, confirm that there is no current in the CT secondary, use a dedicated short circuiting piece for reliable short circuiting, and then remove the terminal and mark it properly. The CT/PT channels used for protection functions with analog inputs include typical configurations such as feeder CT, ground CT, feeder PT, first bus PT, second bus PT, and ground PT, and can provide up to 17 analog inputs. On site, the transformation ratio, polarity, grounding method, and shielding layer should be checked one by one, especially for the differential protection version LD. Polarity errors may cause tripping upon commissioning.

The control wiring of circuit breakers should be checked in conjunction with the control capabilities of five circuit breakers. SYMAP supports display, control, and locking, with a built-in PLC for interlocking; When manually controlling the circuit breaker, the programmed lockout is still valid. After replacement, the opening and closing commands, position feedback, locking conditions, and trip holding circuits should be verified one by one, rather than just performing protection sampling verification.

HMI、 Parameter management and debugging

The front panel of SYMAP is equipped with a large-sized graphic LCD and optional LED indicators, which can simultaneously display measurement values, circuit breaker positions, parameter settings, and event history. Four hotkeys enter Meters, Alarm, Process, and Breaker Control respectively: Meters to view current, voltage, power, energy, and operating hours; Alarm View current alarms, event logs, and locks; Process view synchronous display, motor thermal status, and circuit breaker operation count; Breaker Control can access and control up to five circuit breakers. Parameters and circuit breaker control data are password protected, and password grading and change records should be established on site.

Parameter programming can be completed through the front panel buttons or laptop. The advantage of using a laptop is that it can quickly copy a set of parameters to other SYMAP devices, making it suitable for batch debugging of multiple generators or feeder cabinets of the same type. Before replacing the old device, try to read the protection settings, circuit breaker control logic, communication mapping, and event records from the old machine as much as possible; If the old machine is unable to communicate, it needs to be rebuilt from the design drawings, protection setting list, and switchgear logic diagram. After the new machine is powered on, it first completes self inspection, then checks the CT/PT ratio, rated frequency, number of circuit breakers, and communication protocol, and finally performs sampling channel verification and outlet transmission.

Communication Integration and Network Security

SYMAP can serve as the main interval controller for power management systems or substation systems, supporting remote monitoring, remote control, remote parameter setting, centralized registration of measurement values, event recording, fault waveform analysis, and power plant management. The communication interface includes the front panel RS 232 for programming and data output RS 422/485、PROFIBUS DP、MODBUS RTU、MODBUS TCP、IEC 60870-5-103、IEC 61850 And two CANBUS routes. CANBUS 1 is used for power management and circuit breaker control interlocking between devices, while CANBUS 2 is used for engine control interfaces and can interface with engine protocols such as MTU, VOLVO, DEUTZ, etc. When replacing EC/ECG/BCG devices with engine control, it is necessary to confirm the CANBUS 2 protocol version and engine ECU address, otherwise there may be protection failure but speed regulation or start stop control failure.

In terms of network security, versions with DNV Cyber Secure certification are more suitable for accessing ship OT networks. Unused remote services should be closed on site, and protection and control network segments should be divided according to the IEC 62443 approach. The IEC 61850 network should use independent VLANs or physical isolation, and remote parameter settings should be limited to the maintenance window and operation records should be retained. Password protection can only solve local misoperation and cannot replace network boundary protection.

Expansion board and event recording

SYMAP can only connect one type of expansion board at a time to increase I/O channels. CMA 216 provides 18DI+18DO or 24DI+24DO; CMA 216+237 adds 8AI+8AO on this basis; CMA 238 provides 8AI. CMA 215 is a high current relay card that can convert input channels to 12V (maximum 60V)/40A output contacts, used to directly control loads such as start/stop solenoid valves. The selection of expansion boards should be based on the main model and BC-BCG configuration to check the number of channels, and cannot be simply purchased based on the principle of "the more numbers, the better".

Event recording is crucial for troubleshooting. The protection function can store up to 1000 events, and the event history can store up to 5000 events. After overflow, it will be overwritten by FIFO. The event has a timestamp, appearance and disappearance status, and remains powered off. The optional data logger can record analog inputs, digital inputs, and digital outputs, with a sampling rate of 6 to 72, a recording period of 5 to 60 seconds, a pre trigger of 0 to 100%, and can be stopped by events or preset times. Event history and waveform data should be exported regularly on site to avoid FIFO overwriting critical trip records.

Common troubleshooting ideas

Phenomenon 1: No display when powered on. First check if the power supply system is within the range of 12-36 V DC, 36-72 V DC, 80-300 V DC, or 60-230 V AC, and check the polarity and fuse of the back power terminal. If the power supply is normal but the LCD does not display, check the device self-test and power ON/OFF monitoring information, and replace the power board or the entire machine if necessary.

Phenomenon 2: CT open circuit or abnormal sampling. Check if the CT terminal plug is fully inserted and if the automatic short-circuit mechanism is reset; Check the CT transformation ratio, polarity, and secondary grounding. If only one circuit is abnormal, priority should be given to checking for loose terminals and shielding grounding; If multiple channels drift simultaneously, check the analog reference voltage self-test and auxiliary circuit supervision.

Phenomenon 3: Communication interruption. Layered investigation according to protocol: RS 485 checks A/B polarity and terminal resistance; PROFIBUS DP checks address and bus terminals; MODBUS TCP/IEC 61850 checks IP, subnet, ports, and VLANs; CANBUS checks the 120 Ω terminal, protocol version, and engine ECU address. When the remote parameter setting fails, confirm the password permission and whether the device is in the allowed remote write state.

Phenomenon 4: The circuit breaker cannot be closed or reset after tripping. Check the locking conditions on the Breaker Control and Alarm pages, confirm the built-in PLC interlock, manual/automatic position, trip hold, and position feedback. When protecting the export transmission, the primary side should be disconnected or the testing mode should be used to avoid accidental tripping of the operating equipment.

Phenomenon 5: Protection misoperation. First, read the protection event and fault recording, and verify whether the fixed value, CT/PT polarity, time synchronization, and FIFO are covered. If the short-circuit protection is independently completed by CMA 198, it is necessary to verify whether the setting range of CMA 198 matches the CT secondary rated current. For generator/transformer differential, focus on checking the polarity, transformation ratio, and grounding method on both sides.

Phenomenon 6: Loss of event records. FIFO overflow will overwrite old records, and the export cycle should be shortened; Check the triggering conditions and pre triggering settings of the data logger, and confirm that the power-off hold function is normal.

Replacement and maintenance suggestions

When replacing a discontinued or malfunctioning SYMAP device, it is recommended to follow the six steps of "record backup isolation disassembly verification commissioning": record the model, size, power supply, expansion board, communication protocol, and number of circuit breakers; Backup protection settings, event history, waveform recording, and communication mapping; Power outage and reliably short-circuit CT secondary; Mark the terminals and disassemble them; Power on self-test and channel by channel verification of sampling and output; Complete the protection transmission and communication joint debugging before carrying the load. For maritime projects, it is also necessary to verify whether the classification society certification and network security certificate cover the new version. The advantages of the SYMAP series include pluggable terminals, front panel programming, rich protocols, and long-term spare parts support, but on-site reliability still depends on the standardization of CT/PT circuits, shielding grounding, communication terminals, and fixed value management. Treating replacement as a system review, rather than simply replacing boxes, is necessary to restore the old protective cabinet to a verifiable and maintainable level of safety.