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ABB Ability™ enabled switchgear – MNS® Safe, scalable and flexible low voltage switchgear2021-06-08
DISTRIBUTION SOLUTIONS
© Copyright ABB – Any distribution without consent of ABB is prohibited
How to make any switchgear digital?
Switchgear ready to unlock Industry 4.0 customer value
27 May, 2019 Slide 3
• ABBs universal and scalable platform to suit all customer needs – including digital solution
• Any MNS solution can become digital !
• MNS Digital consists connected smart devices to an Edge device that includes the digital application ABB Ability CMES -Condition Monitoring for electrical systems
• Smart device communicate as needed to control systems,and non-intrusively to the CMES
• A complete scalable solution for new projects and system upgrades or migration solution for legacy systems
• No need of PLC or SCADA complexities at switchgear level
• Redundant system configuration supported
MNS low voltage switchgear solution
Power Factor
Incoming and Energy distribution
Sub and Final distribution
Motor control
Customer needs and our response
MNS Low-voltage switchgear, energy distribution and motor control
27 May, 2019
1 MNS UP – UPS critical poser supply with energy distribution attachedSlide 4 2 DOL-Direct On-line starting, RDOL-Reverse direct on-line starting, VSD-Variable speed drive/ Frequency converter
The MNS portfolio provides the highest options to combineindustry standard solutions into a single assembly with itsuniversal design:
– Motor Starting, DOL, RDOL, VSD, Softstarter 2
– MCCB feeder, fused feeder
– Power, Sub and Final distribution options
– Power Factor Correction
– Uninterruptable Power Supply 1
Combine and connect with MNS Digital and ABB Ability™ CMES
integration to increase your asset overview and optimise youroperation procedures to reduce your Opex.
Combine the options optimise your operations and reduce your Opex
Scale and optimise your solution
Technical features
MNS Low-voltage switchgear, energy distribution and motor control
27 May, 2019 Slide 5
- Fully certified to IEC 61439 -1/-2 up to 690V, 6300A, 100kA
- Arc proof certified to IEC TR 61641 Ed.3:2014 criteria 1 to 7
up to 690V, 100kA, 0.3sec
- Segregation up to form 4b
- Modular construction, extendable at both ends
- Single front, back-to-back or duplex (most space saving design)
- Busbar design 100% maintenance free
- Universal panel design for different technologies:withdrawable, plug-in, fixed, Compact
- Highest density, lowest space requirement with MNS Compact design for energy distribution
- Global life-time support through ABB Service.
IEC standards and design
Highest safety, flexibility and lowest operational expenditure
Condition report
ABB Ability™ Condition Monitoring for electrical systems - CMES
September 1, 2021ABB Ability™CMES = ABB Ability-condition-monitoring-for-electrical-systems
Slide 5
Monitoring, analysis and reporting
ABB Ability™ CMES is the switchgear ‘black box’ monitoring solution entirely on-premise
Monitor
Collect the data from every device (with communication interface) without additional cost (no need to send to a control system)
Monitor and supervise the complete electrical system without programming work
Prioritize information to get right action in time
Analyze
Inbuild data analytics, connect data and analyze to
– Separate normal fromabnormal condition
– Enable fast fault finding
– Present only needed information
Expandable for future analytics
Report
One click report creation tool for
– Switchgear and connected load condition (one click information for maintenance planning)
– Energy and power loss reporting and changes versus previous periods (quickly identify high energy consumers)
Predict
Online 24/7 data analysis of devices such as motor starter, circuitbreaker, switchgear modules, etc. to identify maintenance needs and time i.e.
– Contact greasing
– Device maintenance
– Operation checks, etc.
ABB Ability™ Condition Monitoring for electrical systems - CMES
September 1, 2021 Slide 6
The health index provides a fast summary to the condition and leads to further details in case of needs.
While in traditional switchgear fault finding and correction can be time consuming tasks, LVS Digital reduces the time needed by up to 50% through easy identification, spare part selection and repair.
Two examples
Early identification ensures continuous operation, shortest time to repair and safe switchgear condition
Conventionalswitchgears
LVS Digital ~50% Reduction
20
5
40
10
20
5
40
40
—Connected switchgear, device integration
Low-voltage switchgear - MNS Digital
September 1, 2021 Slide 8
Automation & Control
Local panel (WebHMI)
MView on switchgear level
(alternative remote on-premise using web browser)
Smart relay for
protection and control
either part of circuit breaker (Emax2 with Ekip Touch/ Hi-Touch)
or utilizing external relay (Emax2 MS with REF615)
Motor starter and feeder modules
MCCB / fuse / power monitoring through
– Smart motor controller (M10x, UMC100.3 etc.)
– Smart feeder controller (Ekip Touch, FC610 etc.)
– Power or energy meter (M4M, FC610 etc.)
Digital Gateway
- Central communication interface for process
control communication
(Modbus RTU/ TCP; Profibus
- Web server for MView or remote viewing
- Data concentrator for ABB Ability™ CMES
Internal communication
- Modbus RTU and Modbus TCP
SCADA & Electrical control
- ACB direct interface IEC61850
or Modbus TCP
SCADA
Low-voltage switchgear - MNS Digital
September 1, 2021
ABB Ability™CMES = ABB Ability-condition-monitoring-for-electrical-systems
LVS Digital = Digital solution for all LV switchgear ABB low-voltage-switchgear-digitalSlide 9
Monitoring and Diagnostic
Condition monitoring utilizes data from smart relays and few sensors to identify switchgear and device health condition
Power contact sensor in drawer module
– Plug-in or withdrawable design
– Monitoring connection to incoming and outgoing power contacts
IR Sensor at breaker connection
– Monitoring incoming / outgoing cable or bus duct connection
Local panel option on switchgear or remote on-premise using web browser Temperature Monitoring
at critical joints
Switchgear black box ABB Ability™CMEScollects, stores and analyses condition data on-premise
Smart relay for protection and controleither part of circuit breaker (i.e. Emax2 w/ Ekip) orutilizing external relay to (i.e. Emax2 w/ REF)
Feeder or motor starter module
– ACB / MCCB / fuse switch monitoring
– Feeder / motor controller i.e. monitoring energy, power loss, utilization, other condition
– Monitoring connection quality of incoming and outgoing power contacts and termination
Switchgear and section
– Next maintenance interval
– Total power loss, utilization, space for addition/ extension
IR Sensor at breaker connection
– Monitoring incoming / outgoing cable or bus duct connection
Low-voltage switchgear - MNS Digital
* ABB Ability™CMES - Condition monitoring for electrical systems** TMS - Temperature monitoring system (busbar joints, circuit breaker cable/busway connection, outgoing module power contacts)*** For integration of devices using other protocols contact ABBSeptember 1, 2021 Slide 11
Connectivity and architecture
- Utilizes a network architecture for fast installation, connectivity and troubleshooting, non-intrusive with other control communication
- Collects and stores all data incl. those usually not send to a control system (reducing PLC costs)
- Collects data from multiple LV (and MV) switchgear in same location or same site
- Provides a web-based user interfaceto access the data anywhere on site and remote (through customer network)
- Optionally connects to cloud application for further diagnostic application and future solution
Turning data into information on-premise
TMS **
ACBEmax 2
Modbus RTU/TCP network ***
MCCBTmax XT,
SlimLine etc.
Expandable to MV i.e. REF615
Electrical and process control
Expandable to 3rd party devices
ABB Ability™CMES*On-premiseaccess through web browser
Customer
Switchgear
MCC’s(M10x Motor controller, VSD and Softstarter)
Switch Disconnector, Power MeterFC610
Optional connectable ABB Ability™Energy and Asset management
Up to 512 devices/CMES Edge
Utilizing the breakers full functionality
Low-voltage switchgear - MNS Digital
27 May, 2019 Slide 9
Smart Device Integration
ACB Emax 2 with Ekip Touch/Hi Touch with Ekip COM
• Measurement function including current /voltage/power/power factor/energy etc.
• Network analyzer feature including voltage sags and swells, harmonic etc.
• Energy management feature including minimum, maximum consumption etc.
• Protection setting/tripping /alarms/event logs
• Breaker status and maintenance information.
MCCB Tmax XT (2,4,5,7) with Ekip Dip LSI/LSIG with Ekip COM
• Current measurement
• Protection setting/tripping /alarms/event logs
• Breaker status and maintenance information
• Option to enhance with more function later without need to change the breaker
Low-voltage switchgear - MNS Digital
Connected Air Circuit Breaker
Same control function, same communication interface for simple implementation
Slide 10
Breaker device and application
i.e. Emax 2 ACB
(incomer and large feeder)
i.e. Tmax XT2,4,5,7 MCCB (feeder)
i.e. Ekip UP (circuit breaker retrofit module)
Standardized communication interface
Ethernet
IEC61850 to SCADAModbus TCP CMES condition monitoring
EthernetModbus TCP CMES condition monitoring
EthernetIEC61850 to SCADAModbus TCP CMES condition monitoring
27 May, 2019
Digital Motor Control Center
MNS Digital and ABB AbilityTM
27 May, 2019 Slide 11
Smart Device Integration
Universal motor controller - M10x
• Deployed in each motor starter• Built-in motor protection/motor control/monitoring and reporting features
• Scalable platform with a common form factor and IO assignment• M101 with basic protection and control functions• M102 with advanced protection and control function incl. energy metering
• Parameterizable remotely or through optional panel on switchgear module
• Motor life cycle management functions
• Flexible communication interface (redundant Modbus RTU, Modbus TCP(*), Profibus) • Modbus TCP is used in LVS Digital, optional Modbus RTU is supported
• ATEX certification available for M10x motor controller
(*) M10x-TCP provides communication interface EM01 outside of withdrawable module to ensure intact communication with ring or line structure even if multiple modules are removed. MRP protocol supported for ring structure.
MNS Digital and ABB Ability™
Simplified and standardized schematic – also the platform for switchgear upgrades
M10x product variants: M101 – Basic functionM102 – Advanced functionM10x-TCP – Modbus TCP communication
Slide 15February 8, 2017
Standardization of modules allows :• Reduction of module variants to simplify design• Resulting in lower stock required at customer site
Simplification by:• Reduction of components inside a module• Ready made control and protection functions• Parameterization instead of programming
M10x motor or feeder protection relay, programmable based on application• Single type with current range 0.08 to 63 A (higher with sec. CT up to 800A)• Direct monitoring of residual current, motor thermistor value• Direct connection of field control through configurable input (15) / output (5)
Optional:• Residual current detection (if higher sensitivity is required) by ZCT• Power contact temperature monitoring add-on for condition
monitoring and maintenance support
MCU: M10x-TCP
*
Connected motor starter and load feeder
* Temperature monitoring function may require add-on module for communication
Digital Motor Control Center
MNS Digital and ABB AbilityTM
27 May, 2019 Slide 11
Smart Device Integration
Universal motor controller - UMC100.3
• Deployed in each motor starter
• Built-in motor protection/motor control/monitoring and reporting features
• Logic program editor available for customer specific options
(reduces the need for PLC’s)
• Parameterizeable remotely or through optional panel on switchgear module
• Scalable device, base unit for basic function, extension units for addition options (voltage, temperature, digital and analogue I/O etc.)
• Motor life cycle management functions,
• Flexible communication interface (Modbus RTU, Modbus TCP, Profibus, Profinet)(only Modbus TCP/MTQ22 is used in LVS Digital)
ABB LV digital switchgear
Feeder controller FC610
Slide 18February 8, 2017
Standardization of modules allows :
• Reduction of module variants to simplify design
• Resulting in lower stock required at customer site
Simplification by:
• Built in power metering, energy monitoring and management, network analyzer
features in one unit;
• Reduction of components and cabling inside a module
• Separation of electrical cabling from display
• Easy installation and replacement on site
FC610 feeder controller is a multifunctional feeder management device
• Measuring electrical parameters including current, voltage, power and energy
• Power quality analyzing on harmonics, voltage dips, current and voltage
unbalance, phase sequence etc.
• Main switching device status monitoring and switching cycle monitoring
• Events log and reporting
Simplification and standardization via digital device
*
FC610
Digital Switchgear- Smart Device Integration
September 1, 2021 Slide 19
Motor and feeder control and supervision
• Feeder and motor control easily connected in one Ethernet network
• ABB MS572 allows easy integration of Modbus RTU field devices like feeder controller, temperature sensors, etc. into Modbus TCP network.
• Up to 31 Modbus RTU devices can be connected to one MS572
• Digital Gateway allows data mapping tailored connectivity to DCS systems utilizing different protocols. At the same time it is the interface to the CMES condition monitoring system.
Ethernet connectivity for field devicesProcess ControlSystem
M10x- TCPMotor controller
Digital Gateway
Modbus TCP
Mo
db
us
TC
P
Profibus DP, Modbus RTU/TCP
ABB Ability™ cloud-based solutions, e.g.
ABB Ability Asset Health for electrical systems
CMES Edge device withABB Ability CMES
TMSTemperature
Monitoring System
MS572Modbus RTU to TCP converter
Modbus RTU
FC610Feeder controller
27 May, 2019 Slide 13
MNS low voltage switchgear assembly is designed to provide highest safety with lowest operation and maintenance costs
• Fully type tested acc. IEC 61439 and
IEC TR 61641:2014 Ed.3 crit. 1 to 7
• Maintenance free bus bars
Critical connections :
• ACB cable termination and shipping split connections, executed during commissioning where quality control might not be 100% ensured if executed by non-authorized personal
• Withdrawable module power contacts,critical performance if not maintained as per vendors maintenance guideline
Sensor in drawer module
– Plug-in or withdrawable design
– Monitoring connection to incoming and
outgoing power contacts
IR Sensor at breaker connection
– Monitoring incoming /
outgoing cable or bus duct connection
IR Sensor at shipping splits
– Monitoring bus bar
joints between shipping splits
MNS Digital and ABB Ability™Temperature monitoring in a switchgear
Online temperature monitoring 24/7
MNS Digital and ABB Ability™
27 May, 2019 Slide 14
Smart Device Integration
MNS Temperature Monitoring System (TMS)
Drawer sensors for power contacts
• Deployed in each MNS withdrawable modules;
• 6 sensors to monitor incoming and outgoing cable temperature
• Communicated through Modbus in MNS Digital
IR sensors for critical busbar joints
• Only connections that are made on site:Shipping split busbar joint and ACB cable or busduct joint;
• Up to 8 sensors per interface (i.e. dual bus bar system plus
ambient temperature)
Temperature sensor atpower contacts
LED at module front
IR sensors
4P breakers = 4 sensors
3P breakers = 3 sensors
Fully scalable solutions for your application
MNS Digital and ABB Ability™
27 May, 2019 Slide 15
Smart Devices Integration
TVOC2- Arc Guard – on the roadmap
• In cases where IEC61641:2014 crit. 1 to 7 is not applicable, the Arc Guard System can be used as extension. It uses light as the main condition to instantaneously trip the incoming circuit-breaker, responding in milliseconds and overriding slower protection elements. The system acts in three phases:
• ABB Arc Guard TVOC2 fibre optic light sensors detects the arc in less than 1 ms, a trip signal is then sent to the circuit breaker.
• Emax2 circuit breakers clears the fault in less than 50 ms.
ABB Drives ACS880
• Design for easy cabinet installation;
• Monitor drive parameters, load levels, runtime, energy consumption,
• I/O data, bearing temperatures of the motor connected to the drive if any etc.
Fully scalable solutions for your application
MNS Digital and ABB Ability™
27 May, 2019 Slide 16
Smart Devices Integration
REF615 Feeder Protection and Control
• Circuit breaker protection, control and monitoring
• Measurement function including current /voltage/power/power factor/energy etc.
• Protection setting/tripping /alarms/event logs
• Breaker status and maintenance information
Open to more devices and future additions
• Condition is Modbus communication
• Modbus is easy to handle and safe in electrical environments
—Condition monitoringOn-site data collection and assessment in electrical systems
24/7 condition monitoring – field condition assessment
ABB Ability™ CMES
27 May, 2019
Thermal monitoring of motor
• To identify e.g. incorrect TOL protection settings
• Changing loads that affect installed motor
• Potential mechanical defects
Current monitoring
• Phase unbalance due to load issues
• Residual current because of winding ages
• Winding temperatures
Motor starting time supervision
• Supervision of motor starting time to detect change in process load, mechanical defects, aging etc.
Monitoring of motors and connected assets Motor real starting time vs nominal
Nominal
MeasuredSp
ee
d
24/7 condition monitoring – switchgear device assessment
ABB Ability™ CMES
27 May, 2019
Device operation to ensure availability
• Can detect if a device, e.g. motor, has not been used for longer time (e.g. emergency pumps etc.) and reminds fortesting of availability
Module insertion cycle supervision (mech. operations)
• Required for proper maintenance of module contacts
(e.g. greasing of contacts)
Power contact temperature
• as a last measure to detect lack of maintenance
Module and breaker supervision
• Predict next required maintenance based on loads and operations
• Prediction of breaker life status
Maintenance and process related supervision of assets Module mechanical operations
Maintenancerequired
Time
Op
era
tio
ns
Example temperature monitoring
ABB Ability™ CMES
27 May, 2019 Slide 22
• The temperature supervision in the condition monitoring includes the supervision of absolute temperature threshold values specified by the switchgear
• In addition specific optional maintenance algorithms correlate the temperature and the current for dynamic adaption of the sensitivity and to secure early failure detection.
• This ensures an earliest warning of the maintenance personal to prevent a damage of the switchgear for such usually slow developing temperature issues based on a resistance increase of a connection
Intelligent temperature supervision
Current
!
Screen grab from condition monitoring indicating temperature warning
Condition Monitoring for electrical systems
ABB Ability™ CMES
27 May, 2019 Slide 23
• Switchgear ‚black box‘ data collector; fully embedded solution
• No PLC, no programming required
• Web based full graphical user interface,
secure access, password protected
• Online log for alarm, trip and status information
• Switchgear overview and single line diagram for diagnosis purpose
• Condition and Energy consumption report to optimize the assets
• Thermal condition of switchgear
• Assessments i.e. maintenance date calculation
• Option for remote monitoring or assistance and
cloud services for predictive maintenance
Features and Functions Dashboards Reports
Condition report
Dashboard
ABB Ability™ CMES
Switchgear overview including:– Total number of item– General temperature status– Mechanical components– Time related trend
SWGR health condition
Detailed list including per each event– Description– Possible cause– Suggested actions
Event list
Single line showing– Feeder name– Feeder status– Single devices status– Main electrical parameters
SWGR Single line diagram–
Single monitoring point:
Position inside the switchgear– Traffic light status
Temperature monitoring
27 May, 2019 Slide 24
Example: On-Premise switchgear monitoring with distributed substations and remote monitoring options
ABB Ability™ CMES
27 May, 2019 Slide 24
Substation 1
incl.
Switchgear 1..n
Substation 2
incl.
Switchgear 1..n
Remote Substation n
incl.
Switchgear 1..n
Customer Ethernet LAN/WAN(*)
WiFi/
GSM 4G/5G
CMES Edge device
Up to 512 field
devices/ Edge
HTTPS
Web Browser
Web Browser
CMES monitoring
Firewall(*)
Remote monitoring
option, e.g. via VPN
accessHTTPS
HTTPS
Office Control Room
* LAN/ WAN / Firewall / remote access through VPN managed by customer
Substation 3
incl.
Switchgear 1..n
Substation 4
incl.
Switchgear 1..n