Motor Protection Relay Manufacturer for Industrial and Power Applications

Motor Protection Relay Manufacturing Capabilities

As a professional Motor Protection Relay Manufacturer, we maintain complete vertical integration from R&D to factory acceptance. Our core manufacturing capabilities include:

Product Development & System Architecture

We define product specifications in-house and develop modular hardware platforms supporting flexible I/O configurations, multiple communication protocols (Modbus, Profibus, IEC 61850), and scalable protection functions for both LV and MV motor applications.

Hardware Design & PCB Engineering

In-house design covers precision analog sensing circuits, high-speed digital signal processing, isolated power supplies, output drivers, and EMC-compliant PCB layout. Rated for -40°C to +85°C industrial environments, verified against surge, burst, and ESD immunity.

Protection Algorithm Development

Proprietary algorithms include thermal overload, phase loss/reversal/unbalance, earth fault, short-circuit/locked rotor, over/under voltage, over/under frequency, and starting supervision. Validated against actual motor waveforms and field data for reliable operation with minimum nuisance tripping.

Embedded Software & Firmware

Deterministic real-time control code delivers <20ms fault response, non-volatile parameter storage, multi-protocol communication, local HMI interaction, time-stamped event logging, and remote firmware upgrade capability.

Assembly & Manufacturing

ESD-safe workstations covering SMT placement, through-hole soldering, CT/PT termination, IP54/IP65 enclosure sealing, and torque-controlled terminal connections. Full barcode traceability with standardized operating procedures.

Functional Testing

100% automated testing simulating motor start, running, and fault conditions. Verifies protection accuracy (±2%), time delay curves, I/O response, communication, and contact performance. All test results electronically stored.

Calibration & Precision Adjustment

Two-stage calibration using traceable 0.05-grade reference sources: gain/offset trimming, system calibration, and temperature compensation. Each unit ships with its own calibration certificate.

Quality Inspection

Covers incoming, in-process, and outgoing inspections, plus batch environmental sampling (thermal cycling/humidity). ISO 9001-compliant with layered process audits conducted regularly.

Factory Acceptance Testing (FAT)

Witnessed testing per customer requirements, including protection function demonstration, communication handshake, trip circuit verification, and visual inspection. Signed FAT report issued to ensure plug-and-play readiness upon delivery.

Traceability & Continuous Improvement

Each relay is assigned a unique serial number linking to batch codes, assembly records, test/calibration data, and firmware version. Field feedback and production metrics (yield rate, defect analysis) drive ongoing improvements.

Types of Motor Protection Relay

Our product portfolio covers four major series: Motor Differential Protection, Motor Comprehensive Protection, Self-Balancing Differential Protection , and Low Voltage Motor Protection — providing complete solutions for motor protection across low voltage to medium/high voltage applications, from simple to complex requirements.

Motor Differential Protection Relay

Employing percentage biased differential protection principle, designed specifically as the primary protection for winding internal faults in large and medium-sized high-voltage motors, delivering fast and sensitive operation.

Attribute	Details
Product Model	ASD-442H
Voltage Level	Medium to high voltage systems (3kV ~ 35kV)
Protection Principle	Percentage biased differential protection + instantaneous differential protection
Key Functions	Phase-to-phase short circuit protection, turn-to-turn short circuit protection, CT saturation suppression (prevents maloperation for external faults), automatic CT ratio matching, adjustable differential pick-up value
Core Features	Dual-slope restraint curve (S1/S2分段), harmonic restraint stabilization, fault recording
Applications	Primary protection for large and medium-sized induction motors and synchronous motors; differential protection for generators and transformers
Applicable Standards	IEC 60255-187-1

Motor Comprehensive Protection Relay

An integrated protection device combining protection, control, measurement, and monitoring functions, offering complete primary and backup protection solutions for various medium to high-voltage motors.

Attribute	Details
Product Model	ASD-441H
Voltage Level	Medium to high voltage systems (3kV ~ 35kV)
Key Functions	Thermal overload protection, instantaneous short-circuit protection, locked rotor protection, starting timeout protection, phase loss/unbalance protection, earth fault protection, underload protection, negative sequence protection, over/under voltage protection, frequency protection
Integrated Capabilities	Protection + Control + Measurement + Energy Metering + Circuit Breaker Wear Monitoring + Event Recording
Communication Protocols	IEC 61850, Modbus RTU/TCP, DNP 3.0
Advanced Features	Programmable logic (CFC graphical editing), 8 sets of fault recording, local/remote control switching
Applications	Primary and backup protection for medium to high-voltage motors in power plants, petrochemical, metallurgical, water treatment, and other industries

Self-Balancing Differential Protection Relay

Utilizes the magnetic balance principle (based on the vector sum of three sets of CT secondary currents) to achieve differential protection without external braking quantity — simple structure with reliable operation.

Attribute	Details
Product Model	ASD-443H
Voltage Level	Medium to high voltage systems (3kV ~ 35kV)
Protection Principle	Magnetic balance differential protection (Kirchhoff’s current law vector sum)
Key Functions	Winding phase-to-phase short circuit protection, turn-to-turn short circuit protection, CT secondary open circuit detection, CT saturation suppression
Core Features	No external braking voltage/current required; automatic vector comparison of three CT groups; strong anti-CT-saturation capability; simple setting
Differentiation	More compact and reliable than traditional percentage biased differential relays; ideal for applications with limited installation space or wiring complexity
Applications	Differential protection for large and medium-sized high-voltage motors, synchronous motors, and generators; particularly suitable for retrofit projects

Low Voltage Motor Protection Relay

Designed specifically for low-voltage distribution systems, providing comprehensive motor protection and monitoring — the ideal replacement for traditional thermal overload relays.

Attribute	Details
Product Model	ASD-521M3K
Voltage Range	Up to AC 690V (50/60Hz)
Current Range	0.4A ~ 800A (expandable with external CTs)
Key Functions	Thermal overload protection (Class 5~30 adjustable), phase loss/reversal/unbalance protection, locked rotor/stall protection, earth fault protection, short circuit protection, PTC/NTC temperature monitoring
Core Features	Digital three-phase current display, fault cause and value recording, motor load rate graphic display, inverse-time/definite-time selectable, separate mounting of main unit and display module
Communication Protocols	Modbus RTU, CANopen, Profibus, EtherNet/IP (depending on model)
Applications	Direct-on-line and variable frequency drive circuits for low-voltage motors; pumps, fans, compressors, conveyors, and general industrial loads
Certifications	CE, UL, CCC

For detailed specifications or selection support for each series, please contact our technical sales team.

Motor Protection Functions

ANSI	Protection Function	Application

49

Thermal Overload

Motor overload

50/51

Overcurrent

Short circuit

50N/51N

Earth Fault

Ground fault

46

Negative Sequence

Phase unbalance

47

Phase Sequence

Phase reversal

27

Undervoltage

Low voltage

59

Overvoltage

High voltage

48

Incomplete Sequence

Motor starting

66

Starts per Hour

Frequent starting

37

Undercurrent

Loss of load

86

Lockout

Trip logic

Motor Protection Relay for Different Motor Applications

Different motor types and application scenarios face distinct operational characteristics, starting profiles, and fault risks. We provide targeted protection relay solutions tailored to each application’s unique demands — ensuring optimal protection, maximum uptime, and minimized nuisance tripping.

LV Industrial Motors

Low-voltage industrial motors are the workhorses of manufacturing facilities, running pumps, fans, conveyors, and processing equipment across countless production lines.

Aspect	Details
Typical Power Range	0.55kW ~ 500kW
Common Fault Risks	Overload, phase loss, voltage unbalance, stall, frequent starting
Recommended Products	GMP Series / NJBK2 Series / TeSys T (LTMR)
Key Protection Functions	Thermal overload (Class 5-30), phase loss/unbalance protection, locked rotor protection, short circuit protection, PTC temperature monitoring
Application Characteristics	Frequent start-stop cycles, variable load conditions, integration with PLC/MCC systems
Value Proposition	Replace thermal relays with digital accuracy; reduce downtime with fault diagnostics; compact DIN-rail or panel mounting

MV Motors

Medium-voltage motors (3kV ~ 35kV) power critical assets in heavy industries — with higher replacement costs and longer lead times, making reliable protection essential.

Aspect	Details
Typical Power Range	200kW ~ 10MW
Common Fault Risks	Winding insulation failure, stator phase-to-phase/turn-to-turn faults, bearing overheating, unbalanced supply voltage, starting current surge
Recommended Products	MPC3000 Series / 7SJ66 Series / 87M Differential Series
Key Protection Functions	Thermal overload, differential protection, negative sequence/unbalance, earth fault, locked rotor, start supervision, under/over voltage, frequency protection
Application Characteristics	High inrush current (6-8x FLA), long starting time (5-30 seconds), critical process continuity requirements
Value Proposition	Prevent catastrophic winding failures with fast fault clearing; support IEC 61850 for substation integration; comprehensive fault recording for root cause analysis

Pump Motors

Pump motors operate continuously or intermittently across water supply, irrigation, drainage, and industrial fluid transfer applications — often running in remote or unattended locations.

Aspect	Details
Typical Power Range	1kW ~ 2MW
Common Fault Risks	Dry running, cavitation, impeller jamming, phase loss, overload due to viscosity changes
Recommended Products	GMP Series (LV) / MPC3000 Series (MV)
Key Protection Functions	Underload protection (dry run detection), thermal overload, phase loss/unbalance, locked rotor, earth fault
Application Characteristics	Continuous duty, variable flow conditions, outdoor or submerged installation, remote monitoring needs
Value Proposition	Prevent pump damage from dry running with sensitive underload detection; remote alarm and auto-restart capabilities reduce site visits

Fan Motors

Fan and blower motors are found in HVAC systems, cooling towers, ventilation shafts, and industrial exhaust — typically running for extended periods with quadratic torque load characteristics.

Aspect	Details
Typical Power Range	0.75kW ~ 1.5MW
Common Fault Risks	Bearing failure, imbalance, belt breakage (for belt-driven fans), overloading due to damper/duct blockage, phase loss
Recommended Products	TeSys T (LTMR) Series / NJBK2 Series / MPC3000 Series
Key Protection Functions	Thermal overload (with slow response suitable for fan inertia), phase loss, unbalanced current, locked rotor, underload (belt failure detection)
Application Characteristics	Long running hours, high inertia, slow thermal response, critical for building climate control
Value Proposition	Detect belt breakage via underload monitoring; prevent motor burnout from prolonged overload; reduce energy waste with load monitoring

Compressor Motors

Compressor motors drive reciprocating, screw, or centrifugal compressors in air compression systems, refrigeration plants, and gas processing — characterized by high starting torque and cyclic loading.

Aspect	Details
Typical Power Range	5kW ~ 5MW
Common Fault Risks	Frequent start-stop cycles, overload due to pressure build-up, locked rotor, phase unbalance, thermal stress
Recommended Products	GMP Series / TeSys T (LTMR) / MPC3000 Series
Key Protection Functions	Thermal overload (Class 10/20/30), locked rotor protection, start supervision, frequent start restriction, phase unbalance, short circuit
Application Characteristics	High inrush current with extended start-up, pressure-dependent load variation, often operating in explosive/hazardous environments
Value Proposition	Restart inhibition prevents compressor motor burnout from rapid cycling; precise thermal modeling accounts for pressure-induced load changes

Conveyor Motors

Conveyor motors drive belt, roller, or screw conveyors in material handling, mining, logistics, and manufacturing — subject to variable loads and sudden jams.

Aspect	Details
Typical Power Range	1kW ~ 800kW
Common Fault Risks	Overload due to material buildup, mechanical jamming, belt slip, motor stall, extended starting time
Recommended Products	NJBK2 Series / MPC3000 Series / GMP Series
Key Protection Functions	Locked rotor protection, thermal overload, start supervision, undercurrent (belt breakage/slip detection), phase unbalance
Application Characteristics	Frequent starts under load, long acceleration time due to belt inertia, dusty or abrasive environments
Value Proposition	Adjustable start supervision prevents thermal damage during extended acceleration; undercurrent detection identifies belt slip or breakage to avoid material spillage

Mining Motors

Mining motors drive crushers, mills, hoists, ventilation fans, conveyors, and slurry pumps in underground and open-pit operations — some of the harshest conditions for electrical equipment.

Aspect	Details
Typical Power Range	50kW ~ 10MW+
Common Fault Risks	Overload from material surges, voltage dips due to weak grid, frequent heavy starts, moisture ingress, mechanical shock
Recommended Products	M60 Differential Series / MPC3000 Series / 87M Series
Key Protection Functions	Differential protection, thermal overload, short circuit, earth fault, negative sequence/unbalance, voltage/frequency protection, start supervision
Application Characteristics	Dusty, humid, or corrosive environments; wide voltage fluctuations; extended starting times; 24/7 continuous operation
Value Proposition	Ruggedized enclosures (IP54/IP65) withstand harsh conditions; differential protection detects winding faults early, preventing costly downtime; comprehensive fault records aid in predictive maintenance

Power Plant Motors

Power plant motors drive critical auxiliary equipment — boiler feed pumps, cooling water pumps, forced draft fans, induced draft fans, coal mills, and condensate pumps — where reliability is paramount for grid stability.

Aspect	Details
Typical Power Range	100kW ~ 20MW
Common Fault Risks	Winding insulation degradation, bearing overheating, phase-to-phase faults, earth faults, voltage sags/swells
Recommended Products	7SJ66 Series / M60 Differential Series / MPC3000 Series
Key Protection Functions	Differential protection, thermal overload, negative sequence, earth fault, over/under voltage, frequency protection, breaker failure protection
Application Characteristics	Continuous critical duty, integration with plant DCS, compliance with utility grid codes, high fault current levels
Value Proposition	High-speed fault clearing protects both motor and upstream transformers; IEC 61850 GOOSE messaging enables fast inter-tripping with switchgear; detailed event logs assist in post-fault analysis for utility reporting

Water Treatment Motors

Water and wastewater treatment facilities rely on motors for pumps, aerators, mixers, clarifiers, and chemical dosing systems — often in damp, chemically aggressive environments with varying process loads.

Aspect	Details
Typical Power Range	0.75kW ~ 500kW
Common Fault Risks	Overload due to sludge buildup, phase loss, bearing failure, moisture ingress, frequent starts
Recommended Products	GMP Series / TeSys T (LTMR) / NJBK2 Series
Key Protection Functions	Thermal overload, phase loss/unbalance, underload (loss of prime/dry running), earth fault, PTC temperature monitoring
Application Characteristics	High humidity, outdoor installations, variable flow conditions, integration with SCADA/RTU for remote monitoring
Value Proposition	Sensitive earth fault detection prevents equipment damage from moisture-related insulation degradation; underload protection shuts down pumps in dry-run conditions; Modbus/Profibus connectivity supports centralized plant management

For tailored protection solutions specific to your motor application, please contact our application engineering team for a detailed selection and configuration recommendation.

Motor Protection Relay Manufacturing Process

Our manufacturing process follows a strictly controlled, step-by-step workflow — from engineering design to final shipment — ensuring every relay meets our rigorous quality standards before leaving our facility.

Engineering Design – Each product begins with system architecture definition, schematic capture, PCB layout, and protection algorithm development, with design reviews conducted at every milestone to validate performance targets.

Component Selection – We source only industrial-grade components from qualified suppliers, with 100% incoming quality inspection (IQC) and traceability records maintained for every batch.

PCB / Hardware Assembly – Assembly takes place in ESD-safe workstations using automated SMT placement, precision through-hole soldering, CT/PT termination, and IP-rated enclosure sealing, with torque-controlled terminal connections.

Firmware Loading – The latest verified firmware is flashed into each microcontroller, followed by configuration parameter initialization and checksum validation to ensure code integrity.

Relay Calibration – Using traceable 0.05-grade reference sources, we perform two-stage calibration: gain/offset trimming and full-system accuracy adjustment, with temperature compensation to maintain precision across the entire operating range.

Functional Testing – Automated test benches verify basic operations: power supply, digital I/O, HMI display, LED indicators, and communication port readiness.

Protection Function Testing – Each relay undergoes 100% protection function verification against simulated fault conditions — injecting precise current/voltage signals to validate trip accuracy, time delay curves, and coordination with customer-defined settings.

Communication Testing – We confirm seamless integration with industrial networks by testing all supported protocols — Modbus RTU/TCP, Profibus, IEC 61850, EtherNet/IP, and others — including register mapping and data exchange integrity.

Factory Acceptance Testing (FAT) – For project-based orders, we conduct witnessed testing with customer representatives, demonstrating protection functions, communication handshake, and end-to-end trip verification against approved test procedures.

Final Inspection – A comprehensive outgoing quality check covers electrical performance, mechanical integrity, cosmetic appearance, labeling, and documentation completeness, ensuring every unit is ready for panel installation.

Packaging & Shipment – Each relay is securely packaged with anti-static and shock-proof materials, accompanied by calibration certificates, test reports, and user documentation, then dispatched with full traceability records.

This end-to-end manufacturing process ensures that every motor protection relay we deliver is reliable, accurate, and ready for immediate commissioning in your application.

Motor Protection Relay Testing and Quality Control

Quality is not an afterthought in our production — it is embedded at every stage of manufacturing. Our comprehensive testing and quality control regime ensures that every motor protection relay delivered to our customers performs with precision, reliability, and consistency, even under the most demanding industrial conditions.

Functional Testing

Functional testing serves as the first gate in our verification process, confirming that every relay operates as intended at a basic level before proceeding to more specialized tests.

Item	Details
Test Scope	Power-on verification, LCD/LED display functionality, keypad and HMI response, digital I/O status, analog acquisition channels, alarm and trip dry contact switching
Test Standard	100% verification of all basic functions; any anomalous unit automatically enters the rework process
Test Equipment	Automated functional test bench + custom test fixtures
Pass Criteria	Normal power startup; no missing segments or flickering on display; correct key response; I/O status feedback consistent with control commands
Recording	Each unit generates an independent test log containing test steps and comparison between measured and expected values

Protection Function Testing

Each protection element is individually verified against simulated fault conditions to guarantee accurate and timely operation when real faults occur.

Item	Details
Test Scope	Individual verification of all protection elements: thermal overload (all Class curves), instantaneous short-circuit, locked rotor, phase loss/reversal/unbalance, earth fault, over/under voltage, over/under frequency, start supervision, underload, differential protection, etc.
Test Method	Precision current/voltage sources inject simulated fault signals, covering multiple points across the protection setting range and boundary values
Test Standard	Trip accuracy: within ±2% of setpoint; trip time delay error: ≤±3% or ≤±40ms (whichever is greater); inverse-time curve matching verification
Test Equipment	High-precision three-phase current/voltage source (accuracy 0.05 class), digital oscilloscope, high-precision timer
Pass Criteria	Trip values and time delays for all protection elements meet accuracy requirements; no maloperation or failure to operate
Differentiated Testing	For differential protection series, additional verification of dual-slope restraint curves and operating boundaries across all restraint zones

Accuracy Testing

Measurement accuracy is the foundation upon which all protection decisions are built. We verify accuracy across the full dynamic range of current and voltage inputs.

Item	Details
Test Scope	Current measurement accuracy, voltage measurement accuracy, power/energy metering accuracy (applicable models), frequency measurement accuracy
Test Method	Standard source outputs multiple calibration points (covering 10%, 20%, 50%, 80%, 100%, and 120% of range), recording deviation between measured values and standard values point by point
Test Standard	Current/voltage measurement accuracy: ±0.5% FS (typical); frequency accuracy: ±0.01Hz; power accuracy: ±1.0% (applicable models)
Test Equipment	0.05-class three-phase standard power source, 0.02-class standard meter, high-precision digital multimeter
Pass Criteria	All test point deviations within declared accuracy specifications; linearity qualified; repeatability verification passed
Additional Verification	PTC/NTC thermistor input circuit equivalent resistance injection accuracy verification (temperature measurement accuracy ≤±2°C)

Communication Testing

Modern motor protection relays must seamlessly integrate with plant automation and SCADA systems. We verify every communication interface under real-network conditions.

Item	Details
Test Scope	Physical layer testing (RS-485 level, fiber optic power, Ethernet connectivity); protocol layer testing (Modbus RTU/TCP, Profibus DP, IEC 61850 MMS/GOOSE, EtherNet/IP, DNP 3.0, etc.); register mapping read/write verification; communication response time testing
Test Method	Relay connected to an actual communication network; master station simulation software performs full register scan read/write to verify communication stability and data consistency
Test Standard	Packet loss rate <0.1%; response time compliant with protocol specifications; register mapping 100% correct; GOOSE message transmission/reception normal (applicable models)
Test Equipment	Communication protocol analyzer, network switch, master station simulation software, fiber optic power meter
Pass Criteria	All configured communication ports and protocols pass verification; data read/write error-free; alarms and events actively reported correctly

Environmental Testing

Industrial environments are harsh — temperature extremes, humidity, vibration, and electromagnetic interference are daily realities. We subject our relays to environmental stress testing to ensure they withstand real-world conditions.

Item	Details
Test Scope	High-temperature operation test (+85°C/72h), low-temperature startup test (-40°C/48h), temperature/humidity cycling test (-40°C~+85°C, RH 93%), vibration test (10Hz~150Hz, 2g), shock test (15g/11ms)
Test Method	Environmental chamber with programmed temperature/humidity cycling; vibration table per IEC 60068-2-6; shock per IEC 60255-21-1
Test Standard	Complies with IEC 60255 series (environmental requirements for measuring relays and protection equipment); EMC immunity per IEC 61000-4 series (ESD, burst, surge, RF radiation, etc.)
Test Equipment	Temperature/humidity chamber, electrodynamic vibration test system, shock test system, EMC test system (ESD gun, surge generator, burst generator, etc.)
Pass Criteria	No electrical parameter drift beyond tolerance after environmental testing; no mechanical damage (cracks, deformation, loosening); communication normal; protection functions intact
Execution Method	Batch sampling on regular production (minimum 2 units per batch); 100% environmental screening available upon customer request for special projects

Insulation Testing

Dielectric strength and insulation integrity are critical for personnel safety and equipment protection in high-voltage installations.

Item	Details
Test Scope	Insulation resistance test (main circuit to enclosure, main circuit to auxiliary circuit, auxiliary circuit to enclosure); dielectric strength test (hipot test); impulse voltage test
Test Method	Insulation resistance: 500V/1000V megohmmeter test, insulation resistance ≥100MΩ (at room temperature); hipot test: apply 2kV (or per standard requirements) power frequency voltage for 1 minute, no breakdown or flashover; impulse voltage: apply 5kV (1.2/50μs waveform) positive and negative 3 times each
Test Standard	IEC 60255-5 (insulation coordination requirements), IEC 60947-4-1 (low-voltage switchgear and controlgear)
Test Equipment	Insulation resistance tester, hipot tester, impulse voltage generator
Pass Criteria	Insulation resistance qualified; no breakdown or flashover during hipot test; no damage from impulse test
Execution Method	100% insulation resistance test and hipot test on every relay; impulse voltage test performed on batch sampling basis

FAT Before Shipment

For project-based and customer-specific orders, Factory Acceptance Testing provides documented, witnessed proof that each relay meets contract specifications before it leaves our factory.

Item	Details
Test Scope	Per customer-approved FAT procedure, covering: visual and mechanical inspection; electrical parameter verification; step-by-step protection function demonstration (with actual fault signal injection); communication handshake (with customer SCADA/PLC simulator or actual system); end-to-end trip circuit verification; special function confirmation
Execution Method	Witnessed by customer representative on-site (or remote video witnessing); our test engineer performs operations while customer confirms each step result
Test Standard	Based on contract technical specifications, approved test procedure, and mutually signed acceptance criteria
Output Documentation	FAT report (with step-by-step test records, test curves/screenshots, witness signatures, test engineer signature, date); calibration certificate (with traceability information); factory certificate of conformity
Post-Pass Actions	Relays can proceed to final packaging and shipment only after customer signs the FAT report; any non-conforming items are immediately rectified and re-tested
Additional Services	Photos/video recordings of test process available upon request; remote real-time screen sharing of test displays available

This comprehensive testing and quality control system ensures that every motor protection relay not only achieves optimal performance at the time of shipment, but also maintains stable and reliable operation throughout its long-term service life. Our commitment to quality spans every stage from design to delivery.

Motor Protection Relay Customization

Every motor application presents unique requirements. We offer extensive customization capabilities to tailor our motor protection relays precisely to your project needs.

Protection Function Customization

Customization Item	Description
Function Enable/Disable	Selectively enable or disable specific protection elements (differential, underload, negative sequence, etc.)
Curve Customization	Custom thermal overload curves beyond standard Classes; inverse-time curves per customer formulas
Setting Range Adjustment	Expand or narrow protection setting ranges to match motor parameters
Dual Settings	Two sets of protection settings switchable via external DI or communication
Custom Logic	Interlock protection, process interlocking, sequence control via programmable logic

CT/PT Input Configuration

Customization Item	Description
CT Ratio Configuration	Support 1A/5A standard CT inputs with configurable primary/secondary ratios
Special CT Types	Support Rogowski coils, zero-sequence CTs, and slip-on CTs for retrofit projects
PT Ratio Configuration	Support 100V/110V/400V PT secondary voltages with configurable ratios
Input Channel Customization	Custom combinations of 3-phase current, 3-phase voltage, zero-sequence current/voltage
Input Range Extension	Adjust analog input ranges for special sensors or CT specifications

Rated Current & Voltage Customization

Customization Item	Description
Rated Current Setting	Configure per motor nameplate FLA, covering 0.1A to thousands of amps (with external CTs)
Rated Voltage Setting	Configure per system voltage, covering AC 110V ~ 35kV
Frequency Configuration	50Hz / 60Hz switchable or locked to a specific frequency
CT Primary Current	Match field CT ratios for direct primary-side display and protection settings
Zero-Sequence Threshold	Configure sensitive earth fault detection thresholds per grounding system type

Communication Protocol Customization

Customization Item	Description
Standard Protocol Support	Modbus RTU/TCP, Profibus DP, Profinet, IEC 61850 (MMS/GOOSE), EtherNet/IP, DNP 3.0
Protocol Customization	Custom Modbus address mapping, data format, byte order, baud rate, etc.
Dual-Network Redundancy	Dual Ethernet ports for ring network redundancy or dual-network backup
Fiber Optic Communication	Multi-mode/single-mode fiber interfaces (ST/SC connectors) for high-EMI environments
Proprietary Protocols	Custom development per customer protocol specifications

Digital Input / Output Configuration

Customization Item	Description
DI Quantity	Standard 4~8 DI, expandable up to 16 channels
DI Function Assignment	Each DI customizable for start/stop, reset, remote/local switching, setting group switching, external interlock, etc.
DO Quantity	Standard 4~6 DO, expandable as required
DO Function Assignment	Each DO customizable for trip output, alarm output, running indication, fault indication, remote control, etc.
Contact Type	NO/NC combinations optional; relay output or transistor output
Signal Logic	Positive or negative logic selectable per customer control requirements

Trip Logic & Alarm Logic Customization

Customization Item	Description
Trip Matrix Configuration	Define actions per protection element: trip, alarm, log only, close lockout, etc.
Trip Delay Customization	Independent adjustable delays per element; definite-time and inverse-time options
Alarm Threshold Setting	Independent alarm thresholds (e.g., overload alarm below trip value) for pre-warning
Alarm Output Mode	Customize alarm output: local LED flashing, LCD display, communication upload, DO output, buzzer, etc.
Trip Lockout Logic	Configure auto/manual reset logic, external lockout conditions, and safety interlock strategies
Event Classification	Custom event classification and storage priority to ensure critical faults are not overwritten

Display Configuration

Customization Item	Description
Display Language	Multi-language support (Chinese, English, and others upon request)
Layout Customization	Customize main screen display priorities (phase currents, voltages, power, load rate, etc.)
Fault Display Format	Customize fault pop-up format: fault type, fault value, timestamp
Waveform Display	Real-time waveform or fault recording summary on LCD (applicable models)
Custom Screens	Add customer logo on startup screen; display company name and project information
LED Indicator Customization	Customize LED function definitions (power, communication, trip, alarm indicators)

Housing & Enclosure Customization

Customization Item	Description
Mounting Type	Panel cutout mounting, DIN-rail mounting, 19-inch rack mounting (optional)
Protection Rating	Standard IP42 (front) / IP20 (body); optional IP54, IP65 (fully sealed)
Enclosure Color	Standard RAL 7032 / RAL 9005; custom colors available upon request
Enclosure Material	ABS engineering plastic (standard), flame-retardant PC, metal housing (high protection or hazardous areas)
Nameplate Customization	Customer logo, model, technical parameters, barcode per requirements
Terminal Type	Plug-in terminals, screw clamp terminals, spring terminals, or quick-connect terminals
Dimensions	Custom dimensions per panel cutout requirements (subject to minimum electrical clearance)

Panel Integration

Customization Item	Description
Cutout Size	Standard sizes (96×96mm, 144×144mm) or custom per customer drawings
Depth Adjustment	Adjust housing depth to accommodate limited back-panel space
Terminal Location	Top/bottom/rear terminal placement per panel layout
Accessories	Mounting brackets, dust covers, wiring harnesses, wiring diagram stickers
Complete Solutions	Full motor protection panel solutions including relays, CTs, PTs, and operator panels

Firmware Customization

Customization Item	Description
Custom Algorithm Development	Develop new protection algorithms per customer specifications (with technical documentation)
Custom Logic Programming	Customer-defined automation logic via CFC/Ladder editor
Special Feature Development	Custom motor starting strategies, energy-saving control, predictive maintenance algorithms, etc.
Firmware Version Locking	Lock specific firmware versions for project consistency and long-term stability
Firmware Naming	Custom firmware version numbers and device name display per customer request
Source Code Licensing	Source code licensing and joint development for strategic partners (with agreement)

OEM / ODM Services

Service Type	Description
OEM (Private Label)	Custom nameplates, packaging, manuals, colors, and logos; core hardware and firmware provided by us with full manufacturing and testing
ODM (Custom Design)	Full custom development from concept or based on existing platforms — industrial design, hardware, firmware, protection algorithms, communication protocols, etc.
Enclosure Moulding	Custom enclosure shapes and colors with proprietary moulds (MOQ applies)
Deep Customization	Joint product definition; we handle R&D and manufacturing, you handle market and sales; IP ownership negotiable
Long-Term Supply	Long-term supply agreements ensuring component availability and stable delivery; no product obsolescence risk
Certification Support	Support for product certifications in target markets (UL, CSA, CE, CCC, GOST, ABS, etc.)
Service Process	Requirements gathering → Technical proposal → Sample development → Prototype testing → Customer validation → Mass production → Ongoing support

Why Customize with Us?

Core Advantage	Description
Vertical Integration	Full in-house control from hardware to firmware, algorithms to testing — no technical barriers
Flexible MOQ	Low minimum order quantities for OEM/ODM projects; small batches supported for pilot projects
Quick Response	Standard customization: 4~8 weeks; simple configuration adjustments: 1~2 weeks
Strict Confidentiality	NDA signed to protect your design solutions and business information
Quality Assurance	Custom products share the same quality system and testing standards as standard products
Ongoing Support	Firmware upgrades, spare parts supply, and technical consultation throughout product lifecycle

For customization inquiries, please contact our technical sales team with your project specifications — we will provide a tailored solution proposal within 48 hours.

Motor Protection Relay Engineering Support

We don’t just sell relays — we deliver complete engineering solutions. From project conception through to commissioning and ongoing operation, our engineering team works alongside you to ensure your motors are protected with the right scheme, correctly configured, and reliably integrated into your control infrastructure.

Motor Protection Selection

Selecting the right protection relay requires comprehensive analysis of motor parameters, starting methods, load characteristics, and system configurations.

Service Item	Details
Application Analysis	Evaluate motor type, starting method, load characteristics, and duty cycle
Protection Requirements Definition	Define protection function list based on motor criticality and fault risks
Product Selection Recommendation	Recommend best-fit relay series and models with technical comparison tables
System Compatibility Assessment	Verify compatibility with existing CT/PT, communication networks, SCADA/PLC, and installation space
Selection Report Output	Issue formal selection report including recommended model, configuration list, and technical justification

Protection Scheme Design

For MV systems, critical processes, or special environments, we design coordinated primary and backup protection schemes.

Service Item	Details
Protection Coordination Study	Analyze coordination between upstream and downstream protection devices for selectivity
Protection Configuration Scheme	Determine primary and backup protection combination strategies
Setting Strategy Development	Develop complete setting strategies including start blocking and running activation
Single-Line Diagram Markup	Mark relay locations, CT/PT connection points, and protection zones
Solution Documentation	Deliver complete documentation including configuration diagrams, setting lists, and logic descriptions

Relay Setting Support

Incorrect settings can cause maloperation or failure to trip. We provide expert setting support throughout the project lifecycle.

Service Item	Details
Setting Calculation Service	Calculate protection settings based on motor parameters and system data
Setting Table Preparation	Provide standardized setting tables with set values, delays, enable status, and logic
Setting Verification	Verify setting behavior and selectivity using fault simulation software
On-Site Setting Tuning	Assist with fine-tuning and optimization during trial operation
Setting Management	Provide backup tools and change record management for traceability
Emergency Support	24/7 setting review and adjustment recommendations for maloperation/failure-to-trip events

Wiring Guidance

Correct wiring is fundamental to reliable protection system operation. We provide detailed wiring support.

Service Item	Details
Terminal Wiring Diagrams	Provide detailed terminal wiring diagrams for each relay
Typical Wiring Schemes	Cover DOL, star-delta, soft starter, VFD, and other starting circuits
CT/PT Wiring Guidance	Specify polarity connections, phase assignments, and common terminal handling
Shielding & Grounding Recommendations	Provide grounding strategies for communication cables, signal cables, and enclosure
Wire Gauge & Color Recommendations	Recommend wire gauges and color codes per current levels and standards
Wiring Checklist	Provide pre-energization self-check checklist

Communication Configuration

Configure all communication interfaces to ensure seamless data exchange with SCADA/PLC systems.

Service Item	Details
Communication Protocol Configuration	Configure baud rate, IP address, station address, and other protocol parameters
Register Mapping Definition	Provide complete mapping tables, customizable per customer point lists
SCADA/PLC Integration	Assist with data integration with mainstream SCADA and PLC systems
GOOSE Configuration	Configure IEC 61850 GOOSE subscribe/publish and redundancy settings
Communication Testing	Verify data read/write, event uploads, and remote control functions
Communication Troubleshooting	Provide systematic troubleshooting for interruptions and data anomalies

Factory Acceptance Testing (FAT)

Before shipment, we offer witnessed FAT to provide documented proof of product performance and functionality.

Service Item	Details
FAT Procedure Preparation	Prepare detailed test procedures per contract specifications
Customer Witness Testing	Customer on-site or remote video witness of complete test process
Protection Function Demonstration	Step-by-step demonstration with fault signal injection to verify trip values
Communication Integration Verification	Connect to customer SCADA/PLC simulators for protocol verification
Custom Feature Confirmation	Dedicated verification of customer-customized functions or logic
FAT Report Signing	Issue formal report with customer signature for acceptance
Test Video Recording	Provide video recordings of key test items upon request

Site Acceptance Testing (SAT)

After delivery and installation, we support customers with SAT to validate system performance under actual site conditions.

Service Item	Details
SAT Procedure Preparation	Prepare test procedures based on actual site conditions
On-Site Test Execution	Deploy engineers on-site or remote guidance for primary/secondary injection testing
System Integration Testing	Coordinate with upstream/downstream protection and control systems
On-Site Setting Verification	Verify setting suitability under actual load conditions; fine-tune as needed
SAT Report Preparation	Issue test report for customer acceptance and archiving
Open Issue Resolution	Track and resolve any issues identified during SAT until closure

Commissioning Support

The commissioning phase is where the protection system is proven under live conditions. We ensure smooth start-up.

Service Item	Details
Pre-Commissioning Inspection	Provide checklists for wiring verification, insulation testing, parameter checking, and communication
On-Site Commissioning Guidance	Deploy engineers on-site or provide remote support
Start-Up Monitoring	Real-time monitoring during first start and trial operation to prevent maloperation
Load Test Verification	Verify measurement accuracy and protection functions under loaded conditions
Commissioning Report	Provide summary report documenting process, parameters, and acceptance results
Operator Training	Provide training on relay operation and basic fault diagnosis for O&M personnel

Troubleshooting

Field issues can arise. We respond quickly to minimize downtime.

Service Item	Details
Fault Diagnosis Process	Systematic process: symptom confirmation → data collection → cause analysis → solution → verification
Remote Diagnostic Support	Quick response via phone/email/remote desktop to guide on-site handling
On-Site Emergency Support	Dispatch engineers to site within 24 hours for major faults
Fault Record Analysis	Read event records and waveform data for in-depth root cause analysis
Report & Recommendations	Provide analysis report with causes, corrective actions, and preventive recommendations
Emergency Spare Support	Rapid spare relay shipment for critical applications to minimize downtime

Our Engineering Support Commitment

Commitment	Details
Full Lifecycle Support	Continuous technical support from selection to replacement
Quick Response	Technical inquiries within 2 working hours; emergency on-site dispatch within 24 hours
Professional Team	Application engineers with power protection backgrounds; average 10+ years experience
Comprehensive Documentation	Complete documentation output for all services (schemes, reports, records)
Multi-Language Capability	Bilingual technical communication in Chinese and English for international projects
Ongoing Training	Regular technical seminars and online training for customer team development

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For engineering support inquiries, please contact our application engineering team — we are ready to assist from concept to commissioning and beyond.

Contact Beijing Autony Power for Your Motor Protection Relay Project

Looking for a reliable motor protection relay manufacturer with strong technical strength, stable product quality, and professional overseas service? Beijing Autony Power provides one-stop motor protection solutions from scheme design, product customization, factory production to global after-sales service.

Whether you are an EPC contractor, power station operator, or industrial project owner, we can provide low cost motor protection relay products and professional technical support matching your project standards. Contact our professional international sales and engineering team now to get a customized technical proposal and exclusive quotation!