GE P50 Agile P253 Technical Manual
GE
Grid Solutions
P50 Agile
P253
Technical Manual
Motor Protection Relay
Hardware version: A
Software version: 01
Publication reference: P253/EN M/C
Conformity
This product complies with the directive of the Council of the European Communities relating to electromagnetic
compatibility (EMC directive 2014/30/EU) and product safety (Low-voltage directive 2014/30/EU). This conformity is the result
of a test conducted in accordance with the product standard EN 60255- 26 for the EMC directive, and with the product
standard EN 60255-27 for the low voltage directive. The IED is designed in accordance with the international standards of the
IEC 60255 series.
P50 Agile P253
1 Introduction
P253/EN M/C
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INTRODUCTION
CHAPTER 1
1 Introduction
P50 Agile P253
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P253/EN M/C
P50 Agile P253
1 Introduction
P253/EN M/C
1-3
1 CHAPTER OVERVIEW
This chapter consists of the following sections:
1
Chapter Overview
2 Introduction
2.1 Features
2.1.1 Protection & Control
2.1.2 Measurement, Recording & Post Fault A nalysis
2.1.3 Front Panel Interface
2.1.4 Communications
2.2 Functional Overview
2.3 Ordering Information
1 Introduction
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2 INTRODUCTION
2.1 Features
The P253 is a dedicated motor protection relay desi gned to protect motors in industrial networks and
power plants. It offers essential protection f unct i ons for motors deployed in installations from LV t o M V
voltage levels. The P253 relay performs an important rol e i n m any industrial processes with its
diagnostic features improving asset health monitoring.
The principal protection functions in the relay include thermal overload, negative sequence
overcurrent, loss of load, prolonged start, locke d rot or (starting/normal running), restricted earth fault,
excessive no. of starts and speed switch input for stall rotor detection. Additional versatility is provided
thanks to the inclusion of backup overcurrent and earth fault protection, with up to 3 independent
stages (IEC and IEEE curve types are provided for IDMT f unct i on), breaker fail and trip circuit
supervision functions. Multiple setting groups are included. The hardware capability is broadened by a
sensitive earth fault CT option, and a universal auxiliary power supply range to permit standardisation
in procurement and inventories.
The user can assign any of the logical/physical statuses to binary inputs, binary outputs and
programmable LEDs. This provides flexibility to program the relay as per the application requirements.
All the output contacts are changeover type for ease of i m pl ementing the desired wiring schematic.
The P253 offers supervision functions including measurement, monitoring and recording. The P 253
records the starting current which is very helpful in m onitoring motor performance during the critical
starting period. Industry and utility protocols such as MODBUS, IEC 60870-5-103 and DNP3.0 are
available for transmitting relay data to a supervisory control system via communication networks. The
intuitive operator interface facilitates easy reading of measured values and simple configuration of t he
relay.
2.1.1 Protection & Control
• Thermal overload
• Speed switch input (for stall rotor detection)
• Prolonged start (excessive long start)
• Locked rotor (during starting)
• Locked rotor (during normal running)
• Excessive number of starts
• Loss of load detection
• Negative sequence overcurrent
• Emergency restart
• Timed and instantaneous phase and earth fault prot ection (3 independent stages)
• Wide range of IEC/IEEE curves
• Inrush blocking
• Circuit breaker Fail
• Restricted earth Fault
• Trip circuit supervision
• 6 Digital inputs
• 6 Digital output (c/o)
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1 Introduction
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• 1A/5A CTs selection
• SEF option
• Latching of output contacts
• Universal auxiliary power supply range
• 2 Setting groups
• Password protection
• Self-supervision & internal diagnostics
2.1.2 Measurement, Recording & Post Fault Analysis
• Metering of Phase currents
• Metering of Neutral currents-derived and measured
• Measurement of thermal state
• Positive, Negative and Zero sequence current
• Load Current
• Time to Thermal trip
• Last starting current and time
• Time before a permitted start
• Authorised hot start number
• Authorised cold start number
• Motor running hours
• Total number of starts
• Total number of emergency starts
• Number of Thermal Trip
• Breaker operation counter
• Breaker trip counter
• Breaker operating time
• Up to 512 time tagged event records
• Up to 5 Fault records
• Up to 5 disturbance records
• 1 start-up current record
2.1.3 Front Panel Interface
• 8 LEDs for status indication
• Backlit LCD display (16 x 2)
• 8 navigation keys for setting and interrogation
2.1.4 Communications
• Front USB port for real-time data viewing, device setting, and upload/download.
1 Introduction
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• Rear EIA (RS) 485 port for SCADA communication
• Multiple protocols - Modbus/ IEC60870-5-103 or DNP 3.0 (orderi ng option)
2.2 Functional Overview
ANSI FUNCTION P253
14 Speed switch input (for stall rotor detection)
•
48 Prolonged start (excessive long start)
•
51S Locked rotor (during starting)
•
51L Locked rotor (during normal running)
•
66 Excessive number of starts
•
49 Thermal Overload
•
37 Loss of load
•
46 Negative sequence overcurrent
•
50 Definite time overcurrent (short circuit protection)
•
50N Neutral/Earth definite time overcurrent
•
51 IDMT overcurrent (short circuit protection)
•
51N Neutral/Earth IDMT overcurrent
•
68 Inrush Blocking
•
50BF Circuit breaker fail
•
64R Restricted earth fault
•
86 Latching of output contacts (Lockout)
•
Control Functions
74 Trip circuit supervision
•
Watchdog function
•
Self monitoring & diagnostics
•
Test/Commissioning facilities
•
Emergency restart
•
HMI
Back-Lit LCD display
•
8 x Touch Keys
•
8 x status LEDs
•
Communication
USB port
•
Modbus/IEC 60870-5-103 (RS485) (or)
DNP3.0
•
Binary Input/Output
Binary Input
6
Binary Output
6 (c/o)
Analogue Input
Phase current input 3x1 ph
•
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ANSI FUNCTION P253
Earth current input 1x1 ph (or)
SEF current input 1x1 ph
•
General
Setting Groups 2
Self diagnostics
•
Measurements
•
Event records
•
Fault records
•
Disturbance records
•
Start-up current record
•
Configurable BI/BO/LEDs
•
Hardware
Auxiliary supply 24-230 V AC/DC
Climatic conditions
Operating:
- 25
o
C to + 55
o
C
Storage:
-25oC to + 70oC
Housing
Front IP 52
Rear IP 20
1 Introduction
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2.3 Ordering Information
Variants
1 - 4 5 6 7 8 9 10 11 12-13 14 15
Model Type
Bas i c Motor Protec t i on Rel ay P253
Auxilliary Voltage Bina ry Input Threshold Voltage
24 – 230 V DC/AC 18V DC / 16V AC
1
24 – 230 V DC/AC 35V DC / 33V A C
2
24 – 230 V DC/AC 77V DC / 75V A C
3
24 – 230 V DC/AC 154V DC / 152V A C
4
Current Transformer
St andard CT 1
SEF CT 2
Hardware Options
EIA RS 485 onl y 1
I/O Options
St andard ( 6 logi c inputs + 6 relay output s ) A
Communication protocol
Modbus / IE C 60870-5-103
1
DNP3.0 2
Ca se
Non drawout A
Language
English 0
Software Reference
Initial rel ease (v1.xx ) 01
Customisation / Regionali sation
Default 0
Cust om er spec i fic A
Hardware design suffix
Initial rel ease A
Order Number
Figure 1: Ordering Information
SAFETY INFORMATION
CHAPTER 2
Safety Information
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1 HEALTH AND SAFETY
Personnel associated with the equipment must be famil i ar wit h the contents of this Safety Information.
When electrical equipment is in operation, dangerous voltages are present in certain parts of the equipment.
Improper use of the equipment and failure to observ e war ni ng notices will endanger personnel.
Only qualified personnel may work on or operate the equi pment. Qualified personnel are individuals who are:
● familiar with the installation, commissioning, and operation of the equipment and the system t o which it
is being connected.
● familiar with accepted safety engineering practises and are authorised to energise and de-energise
equipment in the correct manner.
● trained in the care and use of safety apparatus in accordance with safety engineering practises
● trained in emergency procedures (first aid).
The documentation provides instructions for installing, commissioning and operating the equipment . It
cannot, however cover all conceivable circumstances. In the event of questions or problems, do not take any
action without proper authorisation. Please contact your local sales office and request the necessary
information.
Safety Information
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2 SYMBOLS
Throughout this manual you will come across the foll owing symbols. You will also see these symbols on
parts of the equipment.
Caution:
Refer to equipment documentation. Failure to do so could result in damage to
the equipment
Warning:
Risk of electric shock
Earth terminal. Note: This symbol may also be used for a protective conductor (earth) terminal if that
terminal is part of a terminal block or s ub-assembly.
Protective conductor (earth) terminal
Instructions on disposal requirements
Note:
The term 'Earth' used in this manual is t he direct equivalent of the North Americ an term 'Ground'.
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Safety Information
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Caution:
All personnel involved in installing, commissioning, or servicing this equipment
must be familiar with the correct working procedures.
Caution:
Consult the equipment documentation before installing, commissioning, or
servicing the equipment.
Caution:
Always use the equipment as specified. Failure to do so will jeopardise the
protection provided by the equipment.
Warning:
Removal of equipment panels or covers may expose hazardous live parts. Do
not touch until the electrical power is removed. Take care when there is
unlocked access to the rear of the equipment.
Warning:
Isolate the equipment before working on the terminal strips.
Warning:
Use a suitable protective barrier for areas with restri cted space, where there is a
risk of electric shock due to exposed terminals.
Caution:
Disconnect power before disassembling. Disassembly of the equ ipment may
expose sensitive electronic circuitry. Take suitable precautions against
electrostatic voltage discharge (ESD) to avoid damage to the equipment.
3 INSTALLATION, COMMISSIONING AND SERVICING
3.1 LIFTING HAZARDS
Many injuries are caused by:
● Lifting heavy objects
● Lifting things incorrectly
● Pushing or pulling heavy objects
● Using the same muscles repetitively
Plan carefully, identify any possible hazards and det ermine how best to move the product. Look at other
ways of moving the load to avoid manual handling. Use the correct lifting techniques and Personal Protective
Equipment (PPE) to reduce the risk of injury.
3.2 ELECTRICAL HAZARDS
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Caution:
NEVER look into optical fibres or optical output connections. Always use optical
power meters to determine operation or signal level.
Caution:
Testing may leave capacitors charged to dangerous voltage levels. Discharge
capacitors by rediucing test voltages to zero before disconnecting test leads.
Caution:
Operate the equipment within the specified el ectrical and environmental limits.
Caution:
Before cleaning the equipment, ensure that no connections are energised. Use a
lint free cloth dampened with clean water.
Note:
Contact fingers of test plugs are normally protected by petroleum jelly, which should not be removed.
3.3 UL/CSA/CUL REQUIREMENTS
The information in this section is applicable only to equipm ent carrying UL/CSA/CUL markings.
Caution:
Equipment intended for rack or panel mounting is for use on a flat surface of a
Type 1 enclosure, as defined by Underwriters Laboratories (UL).
Caution:
To maintain compliance with UL and CSA/CUL, install the equipment using UL/
CSA-recognised parts for: cables, protective fuses, fuse holders and circuit
breakers, insulation crimp terminals, and replacement internal batteries.
3.4 FUSING REQUIREMENTS
Caution:
Where UL/CSA listing of the equipment is required for external fuse protection, a
UL or CSA Listed fuse must be used for the auxiliary supply. The listed
protective fuse type is: Class J time delay fuse, with a maximum current rating
of 15 A and a minimum DC rating of 250 V dc (for example type AJT15).
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Caution:
Where UL/CSA listing of the equipment is not required, a high rupture capacity
(HRC) fuse type with a maximum current rating of 16 Amps and a minimum dc
rating of 250 V dc may be used for the auxiliary supply (for example Red Spot
type NIT or TIA).
For P50 models, use a 1A maximum T-type fuse.
For P60 models, use a 4A maximum T-type fuse.
Caution:
Digital input circuits should be protected by a high rupture capacity NIT or TIA
fuse with maximum rating of 16 A. for safety reasons, current transformer
circuits must never be fused. Other circuits should be appropriately fused to
protect the wire used.
Caution:
CTs must NOT be fused since open circuiting them may produce lethal
hazardous voltages
Warning:
Terminals exposed during installation, commissioning and maintenance may
present a hazardous voltage unless the equipment is electrically isolated.
Caution:
Tighten M4 clamping screws of heavy duty terminal block connectors to a
nominal torque of 1.3 Nm.
Tighten captive screws of terminal blocks to 0.5 Nm minimum and 0.6 Nm
maximum.
Caution:
Always use insulated crimp terminations for voltage and current connections.
Caution:
Always use the correct crimp terminal and tool according to the wire size.
Caution:
Watchdog (self-monitoring) contacts are provided to indicate the health of the
device on some products. We strongly recommend that you hard wire these
contacts into the substation's automation system, for alarm purposes.
3.5 EQUIPMENT CONNECTIONS
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Caution:
Earth the equipment with the supplied PCT (Protective Conductor Terminal).
Caution:
Do not remove the PCT.
Caution:
The PCT is sometimes used to terminate cable screen s. Always check the PCT’s
integrity after adding or removing such earth connections.
Caution:
Use a locknut or similar mechanism to ensure the integrity of stud-connected
PCTs.
Caution:
The recommended minimum PCT wire size is 2.5 mm² for countries whose
mains supply is 230 V (e.g. Europe) and 3.3 mm² for coun tries whose mains
supply is 110 V (e.g. North America). This may be superseded by local or
country wiring regulations.
For P60 products, the recommended minimum PCT wire size is 6 mm². See
product documentation for details.
Caution:
The PCT connection must have low-inductance and be as short as pos sible.
Caution:
All connections to the equipment must have a defined potential. Connections
that are pre-wired, but not used, should be earthed, or connected to a common
grouped potential.
Caution:
Check voltage rating/polarity (rating label/equipment documentation).
Caution:
Check CT circuit rating (rating label) and integrity of connections.
Caution:
Check protective fuse or miniature circuit breaker (MCB) rating.
3.6 PROTECTION CLASS 1 EQUIPMENT REQUIREMENTS
3.7 PRE-ENERGISATION CHECKLIST
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Caution:
Check integrity of the PCT connection.
Caution:
Check voltage and current rating of external wiring, ensuring it is appropriate for
the application.
3.8 PERIPHERAL CIRCUITRY
Warning:
Do not open the secondary circuit of a live CT since the high voltage produced
may be lethal to personnel and could damage insulation. Short the secondary of
the line CT before opening any connections to it.
Note:
For most General Electric equipment with ring-terminal connections, the threaded terminal block for current
transformer termination is automatically shorted if the module is remov ed. Therefore external shorting of the CTs
may not be required. Check the equip ment documentation and wiring diag r ams first to see if this applies.
Caution:
Where external components such as resistors or voltage dependent resistors
(VDRs) are used, these may present a risk of electric shock or burns if touched.
Warning:
Take extreme care when using external test blocks and test plugs such as the
MMLG, MMLB and P990, as hazardous voltages may be exposed. Ensure that CT
shorting links are in place before removing test plugs, to avoid potentially lethal
voltages.
3.9 UPGRADING/SERVICING
Warning:
Do not insert or withdraw modules, PCBs or expansion boards from the
equipment while energised, as this may result in damage to the equipment.
Hazardous live voltages would also be exposed, endangering personnel.
Caution:
Internal modules and assemblies can be heav y and may have sharp edges. Take
care when inserting or removing modules into or out of the IED.
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4 DECOMMISSIONING AND DISPOSAL
Caution:
Before decommissioning, completely isolate the equipment power supplies
(both poles of any dc supply). The auxiliary supply input may have capacitors in
parallel, which may still be charged. To avo id electric shock, discharge the
capacitors using the external terminals before decommissioning.
Caution:
Avoid incineration or disposal to water courses. Dispose of the equipment in a
safe, responsible and environmentally friendly manner, and if applicable, in
accordance with country-specific regulations.
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5 STANDARDS COMPLIANCE
Compliance with the European Commission Directive on EMC and LVD is demonstrated using a Technical
File.
5.1 EMC COMPLIANCE: 2014/30/EU
Compliance with EN60255-26:2009 was used to establish co nformity.
5.2 PRODUCT SAFETY: 2014/30/EU
Compliance with EN60255-27:2005 was used to establish co nformity.
Protective Class
IEC 60255-27: 2005 Class 1 (unless otherwise specifi ed i n equipment documentation). This equipment
requires a protective conductor (earth) to ensure use r safety.
Installation category
IEC 60255-27: 2005 Overvoltage Category 3. Equipment i n this category is qualification tested at 5kV peak,
1.2/50
m
S,
500 Ohms, 0.5 J, between all supply circuits and earth and also between independent circuits.
Environment
IEC 60255-27: 2005, IEC 60255-26:2009. The equipm ent is intended for indoor use only. If it is required for
use in an outdoor environment, it must be mounted i n a specific cabinet or housing which will enable it to
meet the requirements of IEC 60529 with the classification of degree of protection IP54.
5.3 UL/CUL COMPLIANCE
If marked with this logo, the product is compliant with the requirements of the Canadian and USA
Underwriters Laboratories.
The relevant UL file number and ID is shown on the equipment.
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Equipment with this marking is not itself suitable for operation within a potentially explosive
atmosphere.
Compliance demonstrated by Notified Body Type Ex am i nation Certificate.
ATEX Potentially Explosive Atmospheres directive 94/9/EC for equipment.
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3 Hardware Design
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HARDWARE DESIGN
CHAPTER 3
3 Hardware Design
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P50 Agile P253
3 Hardware Design
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3-3
1 CHAPTER OVERVIEW
This chapter consists of the following sections:
1
Chapter Overview
2 Hardware Design
2.1 Overview of Hardware Design
2.2 Microcontroller with DSP Module
2.2.1 Microcontroller Module (processor board) Features
2.3 Microcontroller and Analog Measurement
2.4 Digital Input/Output Module
2.5 Power Supply Module
2.6 Communication Module
2.7 Human Machine Interface Module
3 Hardware Design
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2 HARDWARE DESIGN
The P253 hardware comprises of the following main components:
• Housing, consisting of a front panel and connections at the rear
• Microcontroller module
• Analogue input module
• Digital input module
• Digital output module
• Communication module
• Power supply unit
• Human machine interface (HMI) module
Figure 1: P253 general assembly
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2.1 Overview of Hardware Design
The P253 hardware design overview is explained with the help of the schematic diagram. The P253
hardware consists of three sets of internal Current Transformers (CTs). These internal CTs are
designed to cater to protection & metering requirements. Dedicated CT is available for the earth fault
protection requirements. The relay also has provision for the built-in SMPS unit which accepts power
supply input of 24-230 V AC/DC from external source and outputs 12 V and 24 V DC for internal
circuitry. The current signals acquired as analogue inputs get pr ocessed through operational amplifier,
filter circuit, multiplexer, ADC (Analog to digital converter) and finally fed to CPU.
The CPU design is a hybrid of the digital signal process or (DSP) and high speed microcontroller which
runs complex algorithm for deriving the fundamental & harmonic component from the input current
signals. The digital inputs and outputs modules are designed to interface the monitoring, control and
protection signals through optically isolated circuit as per the field requirements. The other peripherals
modules like 16x2 LCD display, feather touch keys, USB and RS485 communication interfaces,
battery backup for RTC and built in memory circuits are int egrated as per the schematic diagram and
enclosed in the IP-52 enclosure.
3 Hardware Design
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E00276
Figure 2: Hardware design overview
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2.2 Microcontroller with DSP Module
The hardware is designed around 32 bit controller housed in small 100 pin SMD package. It is a high
speed fix point controller having MIPS’s M4K® 32-bit core with 5-stage pipeline capable of operating
up to 80 MHz.This controller is referred to as MCU (Microcontroller unit).
2.2.1 Microcontroller Module (processor board) Features
• 512K Flash memory (plus an additional 12 KB of Boot Flash)
• 128K on chip SRAM memory
• Multiple interrupt vectors with individually programmable priority
• Fail-Safe Clock Monitor mode
• Configurable Watchdog Timer with on-chip Low-Po wer RC oscillator for reliable operation
• Internal 8 MHz and 32 kHz oscillators
• Six UART modules with:
• RS-232, RS-485, USB and LIN support
• Four SPI modules
• Five I2C™ modules
• Hardware Real-Time Clock and Calendar (RTCC)
• Five 16-bit Timers/Counters
2.3 Microcontroller and Analog Measurement
P253 hardware supports 4 analog inputs. The relay hardware uses an external 16 bit ADC converter
with capability to sample 8 signals simultaneously to avoid any phase angle error and achieve higher
accuracy. In P253, only 4 channels of ADC converter are used. This external ADC can measure input
in a range of – 10 V to +10 V. The ADC interface uses a SPI serial interface to avoid any software
delays. The MCU continuously monitors different analog signals like line and E/F currents through
CTs, multiplexer and ADC.
The relay is designed for 5 amp and 1 amp CT secondary cu rr ent signal. These inputs are further
scaled down to low voltage signal by using an internal cur rent and transformer. The internal current
transformer converts nominal current signal to 3.3 mA. These analog signals are then passed through
protection circuit, anti aliasing filter and amplifier which scales analogue signal to required ADC range.
This anti aliasing filter blocks all high frequency components and surges to avoid measurement error.
The sample and hold (S/H) circuit and multiplexer sample all analog signals at same instant to avoid
and phase angle error and give maximum accuracy.
V00277
Figure 3: Analog signal processing
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The MCU acquires analog values at the rate of 16 sam pl es per cycle. Digital signal processing (DSP)
performs powerful numerical algorithms which converts this signal in to equivalent vectors. Once the
signal is converted into vectors, number of parameters are derived from it such as phase currents (Ia,
Ib, Ic), positive sequence current (I1) and negative sequence current (I2). The MCU also calculates
harmonic contents of the current signals (actual harmonics depend upon type of relay). All
measurements are tuned to fundamental frequency i.e. 50 Hz or 60 Hz, so that the relay will remain
stable during distorted waveform generated by modern electronics load.
The typical frequency response of tuned filter for 50 Hz is shown in figure 4.
V00278
Figure 4: Frequency response of tuned filter for 50 Hz
The measurement is totally immune to all higher harm onics which makes relay operation reliable. All
these measured values are then used for different prot ect i on functions such as over current/Earth
Fault and negative phase sequences. The actual prot ection function depends on type of relay and
described in the rest of the document.
2.4 Digital Input/Output Module
This module supports 6 numbers of Digital input DI and 6 number s of Digital output DO channels for
acquiring filed signals or controlling field devices respectively. The DIs are isolated f rom other circuits
by using Opto isolators. The threshold voltage at which Opt o coupler turns ON is controlled by
comparator based on the voltage range selected duri ng device ordering.
2.5 Power Supply Module
The power supply module is a designed using modern PWM based switching mode technique. It
converts input supply to the 12 V and 24 Vdc low voltage su ppl y for relay electronics and control
circuit. It also provides necessary isolation from input power supply. The normal operating voltage
range is 24 V – 230 VAC/DC.
2.6 Communication Module
The P253 supports 2 numbers of isolated ports for communication.
• (a) USB port provided on front of the relay
• (b) RS 485 (2 wired) port provided on the rear side of relay.
The relay can be accessed using the P50 Agile Configurator. Rear port supports open protocols like
IEC60870-5-103/MODBUS or DNP3.0 (ordering option) and is used for external communication.
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