Regul R500 is a high-availability real-time programmable logic controller, designed for the use in process industries.

It features high-speed dual ring data bus, allowing fast collection of data for further processing, even with complex algorithms, without compromising on speed.

Its flexibility of communications and a special focus on redundancy, instrument-free replacement of hot-swappable modules, make it controller of choice when processes must go uninterrupted.

Applications

  • High-availability process control systems for
    • Steam and gas turbines (control and emergency protection)
    • Oil pumping stations and gas compressors
    • Main and auxiliary systems at power stations
    • Fire and gas systems
    • Water management systems
  • Fiscal applications (for example, LACT units)
  • Applications with unstable connection to upper level
  • Applications with large number of tags sent to upper level

Features

General

  • Real-time programmable logic controller
  • Modular configuration, allowing flexible extension and change of configuration
  • Supports up to 130,000 channels
  • In-module event archiving

Processing power

  • Minimum application cycle time – 1 ms (5 ms with redundancy)
  • Scan time – 1 ms
  • Switchover in 5 ms
  • Processing of complex algorithms with powerful CPU modules and built-in microprocessors in I/O modules

System configuration

  • Up to 40 modules in a rack, up to 255 racks, up to 10 km (via fiberoptic line) between racks
  • RJ-45, SFP, or mixed connection between racks
  • Star, ring, or mixed network topologies
  • CPU module can be placed into any rack

Programming and visualization

  • Programming with IEC 61131-3 languages + CFC in Epsilon LD software
  • Online application update
  • Remote configuration/maintenance and application updates
  • Special firmware with MySQL database server
  • CPU module with DVI output for connecting a display and using Target-visualization
  • Web visualization option in CPU modules

Redundancy

  • Hot swapping of all modules
  • Hot-standby CPU modules
  • Dual ring high-speed internal data bus
  • Automatic power distribution between power supply modules
  • Redundancy of internal bus, CPU, CPU interconnection, I/O modules, power supply modules, SCADA connection
  • Hybrid counter/digital modules with support of 2oo3 voting at the level of modules

Communications

Supported interfaces

  • RS-232 (9-pin, full duplex, speed 300–115, 200 bps, opto-isolation 500/1500 V, overvoltage protection)
  • RS-422/RS-485 (9-pin, speed 300–115, 200 bps, full-channel opto-isolation 500/1500 V, overvoltage protection): up to 96 ports per controller
  • Ethernet 10/100/1000 RJ-45 (full duplex): up to 4 ports per CPU
  • Ethernet 10/100/1000 fiberoptic (single-mode, multi-mode): up to 2 ports per CPU

Built-in communication protocols*

  • IEC 61870-5-101 (master/slave)
  • IEC 61870-5-104 (master/slave)
  • Modbus RTU (master/slave, with expansion capabilities)
  • Modbus TCP (master/slave, with expansion capabilities)
  • OPC DA, OPC UA
  • EtherCAT

*Additional communication protocols, including non-standard ones, can be implemented according to your requirements.

Design

  • Mid-size dimensions: 40x180x145 mm (WxHxD)
  • Detachable terminal blocks
  • Installation on a 105-mm DIN rail, with a clamp
  • Passive cooling; no mechanical or rotating structural components

Specifications

Minimum application cycle time

1 ms (5 ms in redundant configuration)

Scan time

1 ms

Switchover time from main to standby controller 5 ms
Timing accuracy 50 μs
Processor Intel Atom, ARM Cortex-Axx
RAM 1 Gb
Flash memory (CU 00 021, 031) 1 GB
SSD (CU 00 051, 061, 071) 4 GB (optional up to 64 GB)
Input power
  • 85…264 VAC
  • 18…36 VDC
  • 120…370 VDC
I/O module size (WxHxD) 40×180×145 mm
Operating temperature range 0…+60°С
Approvals CE, EAC, GOST-R, FCC-ready

Examples of Rack Connections

  • Support of a redundant CPU module installed in the same rack or in another rack
  • Connection of up to 255 expansion racks
  • Up to 40 modules in one rack
  • Maximum distance between racks of 10 km (via fiber-optic line)
  • In one system you can combine REGUL controllers from several series. For example, have R500 CPU racks and I/O racks made of R200 racks and R500 racks
  • 100% Mirror Redundancy
  • Shared I/Os, redundant bus, CPUs, CPU interconnection
  • 100% CPU redundancy, shared I/Os

Examples of Rack Connections

REGUL R500 Controller Modules

  1. CPU modules
  2. Power supply modules
  3. Communication modules
  4. I/O modules
  5. Bus modules

CPU modules

Part number Description Latest update of firmware

R500 CU 00 021
R500 CU 00 021(W)

Central processor unit module

  • Supports redundant operation
  • ARM Cortex-Aхх, 512 Mb RAM, 1Gb Fl

CU 00 0261(W) – additionally includes web server with support of Web visualization

1.6.0.2

R500 CU 00 031
R500 CU 00 031(W)

Central processor unit module

  • Supports redundant operation
  • ARM Cortex-Aхх, 512 Mb RAM, 1Gb Flash
  • RS-232, RS-485, 2x Ethernet SFP
CU 00 031(W) – additionally includes web server with support of Web visualization
1.6.0.2
R500 CU 00 051
R500 CU 00 051(W)
Central processor unit module
  • Redundancy support
  • Intel Atom
  • 1 x 2 GB RAM, 1 x 4 GB SSD
  • 1 x RS-232, 1 x RS-485,
  • 4 x Ethernet RJ-45
  • 2 x USB host
  • GPS/GLONASS receiver
CU 00 051 (W) additionally includes web server with support of Web visualization
1.6.0.2
R500 CU 00 061
R500 CU 00 061(W)
Central processor unit module
  • Redundancy support
  • Intel Atom
  • 1 x 2 GB RAM, 1 x 4 GB SSD
  • 1 x RS-232, 1 x RS-485,
  • 2 x Ethernet RJ-45, 2 x Ethernet SFP
  • 2 x USB host
  • GPS/GLONASS receiver
CU 00 061 (W) additionally includes web server with support of Web visualization
1.6.0.2
R500 CU 00 071
R500 CU 00 071(W)
Central processor unit module
  • Redundancy support
  • Intel Atom
  • 1 x 2 GB RAM, 1 x 4 GB SSD
  • 1 x RS-232, 1 x RS-485,
  • 2 x Ethernet RJ-45, 2 x Ethernet SFP
  • 2 x USB host, 1 x DVI
  • GPS/GLONASS receiver
CU 00 071 (W) additionally includes web server with support of Web visualization
1.6.0.2

Power supply modules

Part number Description
R500 PP 00 011 24 VDC, 75 W power supply module, without galvanic isolation
R500 PP 00 021 24 VDC, 75 W power supply module, with galvanic isolation
R500 PP 00 031 220 VAC/VDC, 75 W power supply module, with galvanic isolation

Communication modules

Part number Description
R500 CP 04 011 Communication processor RS-485 (Modbus RTU), 4 ports
R500 CP 02 021 Communication processor Ethernet (Modbus TCP), 2 ports
R500 CP 06 111 Communication processor for Regul bus segments, EtherCAT, RJ-45, 6 ports
 

I/O modules

Part number Description Latest update of firmware

R500 AI 16 011

Analog input, AI module (current)

  • Current measuring range: 0…20 mA, 4…20 mA
  • Resolution: 14 bits (including overflow)
  • Operating error under normal conditions: ±0.1%
  • Shared ADC for all channels
  • Common galvanic isolation
  • 16 channels
1.0.14.0

R500 AI 16 081

Analog input, AI module (current, HART)

  • Current measuring range: 4…20 mA
  • Resolution: 16 bits (including overflow)
  • Operating error under normal conditions: ± 0.1%
  • Built-in HART protocol
  • 1 ADC and 1 HART-modem per channel group (2 groups of 8 channels)
  • Group galvanic isolation
  • 16 channels
1.0.15.0
R500 AI 08 031

Analog input, AI module (thermal resistances, thermocouples)

  • Thermal resistance measurement range: 1…450 Ohm
  • Supported thermal resistances: Cu50, Cu100, Pt50,Pt100, Ni50, Ni100
  • Supported thermocouples: R, S, B, J, T, E, K, N, A-1, A-2, A-3, L
  • Operating error under normal conditions: ±0.1%
  • Common galvanic isolation
  • 8 channels
1.0.15.3
R500 AI 08 131

Analog input, AI module (thermal resistances, thermocouples)

  • Thermal resistance measurement range: 1…450 Ohm
  • Supported thermal resistances: – 50М, 100М, 50П, 100П, Pt50, Pt100, 50Н, 100Н;
  • Supported thermocouples: R, S, B, J, T, E, K, N, A-1, A-2, A-3, L
  • Operating error under normal conditions: ±0.1%
  • Common galvanic isolation
  • 8 channels
1.0.15.3
R500 AI 08 041 Analog input, AI module (current, voltage; high-accuracy)
  • Current measuring range: 0…20 mA, 4…20 mA
  • Voltage measuring range: 0…+10 V, -10…+10 V
  • Resolution: 14 bits (including overflow)
  • Operating error under normal conditions: ±0.025%
  • Channel galvanic isolation
  • Individual ADC for each channel
  • 8 channels
1.0.15.6
R500 AI 08 051

Analog input, AI module (current, voltage)

  • Current measuring range: 0…20 mA, 4…20 mA
  • Voltage measuring range: 0…+10 V, -10…+10 V
  • Resolution: 14 bits (including overflow)
  • Operating error under normal conditions: ±0.1%
  • Channel galvanic isolation
  • Shared ADC for all channels
  • 8 channels
1.0.15.0
R500 AO 08 011

Analog output module (current)

  • Output range, current: 0…20 mA, 4…20 mA
  • Resolution: 16 bits
  • Operating error under normal conditions: ±0.1%
  • Channel galvanic isolation
  • 8 channels
1.0.14.5
R500 AO 08 021

Analog output module (current, voltage)

  • Output range, current: 0...20 mA, 4…20 mA
  • Output range, voltage: 0…+10 V, -10…+10 V
  • Resolution: 16 bits
  • Operating error under normal conditions: ±0.1%
  • Channel galvanic isolation
  • 8 channels
1.0.14.5
R500 AS 08 011 Hybrid analog module (current, voltage)
  • Current measuring range / output current: 0…20 mA, 4…20 mA
  • Voltage measuring range / output voltage: 0…+10 V, -10…+10 V
  • 6 x AI channels, shared ADC for all channels
  • 2 x AO channels, individual ADC for each channel
  • Resolution: 14 bits (including overflow)
  • Operating error under normal conditions: ±0.1%
  • Channel galvanic isolation
1.0.14.0
R500 DI 32 011
  • Digital input, DI module
  • Input voltage: 24 VDC
  • 32 channels (4 groups by 8 channels)
  • Group galvanic isolation
1.0.14.0
R500 DI 32 111
  • Digital input, DI module
  • Input voltage: 24 VDC
  • 32 channels (4 groups by 8 channels)
  • Galvanic isolation with bus and power supply – 1,500 V
  • Group galvanic isolation
1.0.15.0
R500 DI 16 021
  • Digital input, DI module
  • Input voltage: 220 VAC/VDC
  • Channel galvanic isolation
  • 16 channels
1.0.14.0
R500 DO 32 011
  • Digital output, DO module
  • Output current: 24 VDC / 0.5 A
  • 32 channels (4 groups by 8 channels)
  • Group galvanic isolation
1.0.14.0
R500 DS 32 011
  • Hybrid digital module
  • 24 x DI (3 groups by 8 channels), 24 VDC
  • 8 x DO, 24 VDC/0.5 A
  • Group galvanic isolation
1.0.14.0
R500 DA 03 011
  • Counter/digital module
  • Channel supply voltage: 4…24 V
  • Frequency measurement ranges: 1…10 kHz (enhanced accuracy), 1…500 kHz
  • Pulse measurement range: from 1…264 (with overflow)
  • Operating error under normal conditions, frequency:
  • less than ± 0.01%
  • Pulse-counting error: ±1 pulse
  • 3 x counter channels
  • 6 x DI channels, 24 V
  • 6 x DO channels, 24 V / 0.5 A
  • Channel galvanic isolation of the counter channels
1.0.15.2
R500 DA 03 021
  • Counter/digital module
  • Channel supply voltage: 5, 12, 24 V
  • Frequency measurement range: 1 Hz…500 kHz
  • Pulse measurement range: 1…264 (with overflow)
  • Operating error under normal conditions, frequency: less than ± 0.01%
  • Pulse-counting error: ±1 pulse
  • 3 x counter channels
  • 1 x generator channel
  • 6 x DI channels, 24 V
  • 6 x DO channels, 24 V / 0.5 A
  • Channel galvanic isolation of the counter channels
  • Electronic overspeed trip software
1.0.15.2

Bus modules

Part number Description
R500 ST 00 001 Termination module without bus extension function
R500 ST 01 011 Bus extension module (IN), RJ-45, non-redundant bus, 1 port
R500 ST 01 021 Bus extension module (OUT), RJ-45, non-redundant bus, 1 port
R500 ST 02 011 Bus extension module (IN), RJ-45, redundant bus, 2 ports
R500 ST 02 021 Bus extension module (OUT), RJ-45, redundant bus, 2 ports
R500 ST 02 111 Bus extension module (IN), SFP, redundant bus, 2 ports
R500 ST 02 121 Bus extension module (OUT), SFP, redundant bus, 2 ports
Система Orphus