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2. supply Vaux EP010 L 1 EIARS 485 Modbus interface for the connection to EP010 24V fy ee A B KIT yp K2 wip yp we CB terminal box mb TK wie two or sliding contacts PR120 D M PR122 P PR123 P S33M 1 3 S751 1 7 7 Note W1 W2 terminals for the connection of the Modbus cable K1 K2 terminals for auxiliary power supply Vaux L 1 terminals for the Modbus port S33M 1 3 contacts signaling spring charged 751 1 7 contacts signaling circuit breaker racked in for CBs in with drawable version The Modbus cable which connects EP010 to the trip unit shall have a maximum length of 1 m Bus communication with ABB circuit breakers 93 5 x uuy s jnpow UONBOIUNWILUOD OY s jnpow UOIeBOIUNWIWIOD yL X uuy 94 Technical Application Papers 1 t i N y Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers PR330 D M communication module Protocol Modbus RTU Physical interface RS 485 Baud rate 9600 19200 bit s The communication module is supplied directly through PR332 P or PR333 P trip unit which in its turn is supplied by the auxiliary power supply Vaux The relevant technical data are shown in the following table PR332 PR333 PR330 D M Supply auxiliary power supply from galvanic insulated 24 V dc 20 PR332 PR333 Maximum ripple 5 Inrush current 24
3. ns Technical Application Papers No 9 Bus communication with ABB circuit breakers Technical Application Papers Bus communication with ABB circuit breakers Index 1 Introduction 2 2 Digital communication 3 21 Communication protocols ccceeees 4 2 1 1 Physical layer ccccccccesecssessssssesesseeeteeeseesees 5 2 1 1 1 RS 232 and RS 485 interfaces 6 2 1 2 Data link layer c ccscseesesesessscsseseseseseseeeeeees 8 2 1 3 Application layer scsssssssssesscscsssesssseseees 8 2 1 4 Compatibility between the layers 9 3 Supervision of electrical distribution plants 10 3 1 Supervision with ABB SACE circuit breakers cccceeeeseeeeeeceeeeeeees 12 4 ABB solution for bus communication 14 4 Emax air circuit breakerS ccceee 14 42 Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers 17 43 Moulded case circuit breakers Tmax 14 15 16 19 44 Moulded case circuit breakers SACE Tmax XT2 XT4 wccccccccesssceeeseeeeeees 22 4 5 SD030Dx solution for the circuit breakers without Modbus RTU ceeeeeeeeeeeees 25 46 Front panel interface HMIOS0 29 4 7 Network Modbus RS 485 Rules for a correct Wiring 40 4 7 1 Modbus RTU system functioning 44 4s Ekip Connect software cccceeeee 46 4 8 1 Scanning of t
4. Converter x x y 2 a BERRI TT rasta 71777 atp BRAUB T7 BTPRS aBa 7 x r x x F x 4 r N SA i N N f a AR SAB y 1 1i 1 1 ial it uw 1 j m y f i id 1 i E i I ie I I tt 1 1 11 I I p1 I I a t 1 yn j g ph Ed im i I a x X I 1 1 LI I A Ye A A a Ae ee A ae Cf ee a aa I 4 I I i I i Hn j I gg f i wt 1 1 j Fal Li tt I 1 pe I eee Sane pete Li t E EERE E I Loz l EEEIEE SPERN FENA i L PEER PEREAT ee ee EEA er RS I L N EEE OORE EE i VY Vv a Y Vv Y Y Vv Vv Vv Vv Y A A A A A A A A A A A A M M Q M M M W M M M Q Manufacturing line 1 Bus communication with ABB circuit breakers Manufacturing line 2 Manufacturing line 3 6 3 Management of priority and non priority loads In a shopping mall there are various refrigerating rooms each of them equipped with independent refrigeration system The refrigeration system of each room is pro vided with its own thermostat and starts automatically and independently Moreover each refrigeration system is able to run in normal mode in steady state or in fast mode when the room is filled with new products which need to be cooled as quickly as possible In this last case a power peak occurs The distribution system supplies in addition to the re frigerating rooms also room lightning air conditioning and external emergency lightn
5. Bus communication with ABB circuit breakers RS 232 Ta tL full duplex means that the devices can transmit and receive the data simultaneously Full duplex operation is possible because there are two separated electrical connections for the both directions in which the data can flow The bits are transmitted as voltage values from the transmission terminal Tx of one device to the receiv ing terminal Rx of the other device These voltages are referred to a common ground conductor connected to the corresponding GND pin of the two devices Figure 12 Basic links for the communication between two devices with RS 232 interface Connector of device 2 Connector of device 1 Therefore for the connection minimum three wires Tx Rx and GND are necessary it is possible to use more links to regulate the data flow e g to signal when a device is ready to transmit or to receive These operations which constitute the handshaking and flow control processes are not the subject of this technical paper Each character flowing over the serial cable is constituted by one or more start bits to inform the receiver about the arrival of a new character being RS 232 an asyn chronous interface it is impossible for the receiver to know when a character has been transmitted and therefore it is necessary to signal in advance the start of the frame a cert
6. T E j Bus communication with ABB circuit breakers 3 uonesiunwwod jesd zZ uoleciunwwod jesd z Technical Application Papers These are some examples of process management where a dialogue is required between the devices in a communication network 1 data interchange between the personal computers in a company or a firm linked through a LAN network Figure 5 Example of LAN network 2 data and commands transceiving between a supervi sion system and the field devices sensors and actua tors of an automation system for the management of an industrial process Figure 6 Example of a supervision system for industrial process manage ment Sensor Actuator Sensor Actuator To manage the data traffic over the network and to allow understanding between two communicating devices a communication protocol is necessary The communication protocol is the whole of rules and behaviors which two elements must comply with to in terchange information it is a definite convention associ ated to the data exchanged between the communication partners 2 LAN Local Area Network local network e g Ethernet linking together personal computers and terminal stations physically near for instance located in the same office or in the same building Bus communication with ABB circuit breakers The
7. When the System bus W1 of the trip unit is used the maximum recommended length for the connection between HMI030 and trip unit is 300 m In this case it is necessary to use PR120 D M PR330 D M communication module for the connection between HMI030 and trip unit HMI030 shall be connected to the System bus W1 of the trip unit set HMIO30 unit to Master mode use Modbus RS485 communication interface terminals 3 and 4 set the following communication parameters of the trip unit Address 3 Baud rate 19200 Parity EVEN Stop bit 1 The connection between trip unit and HMI030 shall be achieved through twisted pair cables shielded and with characteristic impedance equal to 120 Q e g Belden 3105 cable type or equivalent The shield shall be connected to earth at one end of the connection With this configuration and with trip unit type PR121 P and PR331 P it is possible to connect only one HMI030 unit to the trip unit on the Local bus W2 With this configuration and with trip units type PR122 P PR123 P PR332 P PR333 P PR122 DC and PR123 DC it is possible to connect up to two HMIO030 to the trip units the first one on the Local bus W2 and the second one on the System bus W1 see Since they are connected to two different buses the two HMIO30 units can be set to the same operating mode 32 Bus communication with ABB circuit breakers Display on panel front with more units HMI030 It is possible to connec
8. PR222DS PD AUX E auxiliary contacts in electronic version X3 connector MOE E motor operator with electronic interface Supervision PR222DS PD AUX E Connector X3 MOE E Bus communication with ABB circuit breakers 19 UOHedIUNWWOD snq 104 uonnjos ggY p UOHeDIUNWIWOD snq 104 uonnjos ggY p i Technical Application Papers 20 PR223EF electronic trip unit PR223EF AUX E auxiliary contacts in electronic version X3 connector MOE E motor operator with electronic interface Supervision PR223EF AUX E Connector X3 MOE E PR223EF AUX E auxiliary contacts in electronic version X3 connector X4 connector VM210 measuring module MOE E motor operator with electronic interface Supervision Connector X3 PR223EF AUX E Connector X4 MOE E Bus communication with ABB circuit breakers UOHedIUNWWOD snq 104 uonnjos ggY p i UOHeDIUNWWOD snq 104 uonnjos ggY p PR223DS electronic trip unit PR223DS AUX E auxiliary contacts in electronic version X3 connector MOE E motor operator with electronic interface Supervision PR223DS AUX E Connector X3 MOE E PR223DS AUX E auxiliary contacts in electronic version X3 connector X4 connector VM210 measuring module MOE E motor operator with electronic interface Supervision Connector X3 Connector X4 MOE E PR223DS NOTE For more detailed information about the dialogue functions and the characteristics of the pr
9. PR332 P PR330 D M communication module accessories for the remote control PR330 R SOR SCR M Supervision PR332 P For remote control with Tmax T7 the motorizable version T7M is needed PR330 D M PR330 R Note together with PR330 D M module also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied Bus communication with ABB circuit breakers 17 UOHedIUNWIWOD snq 104 uonnjos ggY uo esiunwwos snq 10 uonnjos ggY p i 18 Technical Application Papers PR332 P PR330 D M communication module PR330 V measuring module accessories for the remote control PR330 R SOR SCR M Supervision cS R PR332 P PR330 V PR330 D M PR330 R iy M SOR SC For remote control with Tmax T7 the motorizable version T7M is needed Note together with PR330 D M module also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied PR333 P electronic trip unit for Emax X1 PR333 P PR330 D M communication module accessories for the remote control PR330 R SOR SCR M SOR Supervision PR333 P PR330 D M PR330 R The measuring module PR330 V is mounted by default on PR333 P trip unit Note together with PR330 D M module also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied NOTE For more detailed information about the dialogue fu
10. V aima V V 23min V Phase to phase voltages Vizma Voamax ae ea 3 Phase neutral voltages Vinmav V Vinee rie Veet axe 2Nmax Frequency maximum value minimum value Total active power Promax Protmin and phase power Pmae Pomaxr Pamax Paimin Pomin Pomin Total reactive power Qhoinax Quoin aNd phase power Qima Q Q Oe Om Qe 2 max 3max 1min Total apparent power S S totmax and phase power Simac Somar Sama Simm Soin See tamin State information CB state open close tripped CB reset position Mode local remote Protection parameter setting curves times and thresholds Thermal memory activated Maintenance data Total number of operations from closed to open Total number of trips due to protections Number of trip tests Number of operations from closed to open with opening command Number of trips failed Record data of the latest 20 trips Protection alarms Diagnostic alarms Protection trip Protection S timing and trip Protection L timing and trip Protection G timing and trip Protection R rotor blocked and U unbalance and phase current loss timing and trip Pre alarm protection L Undervoltage protection UV timing and trip Overvoltage protection OV timing and trip Trip command failed Trip coil disconnected or failed C
11. trip unit type Ekip E LSIG each unit HMI030 has SW version 3 00 or following ones it is configured in Master mode and communicates via the Internal bus WI terminals 7 and 8 four different operating modes Ammeter Voltmeter Wattmeter and Custom are selected for each HMIO30 Principle scheme Ekip E LSIG gerere pile IO ewes Internal bus WI 24 V DC auxiliary voltage kit HMI030 RS A V W RS Rotative Selector WI Internal bus of the trip unit CAN interface reserved for ABB devices cables W3 and W4 of the 24V DC auxiliary voltage kit Maximum recommended length for the Internal bus WI 15 m For the lengths exceeding 15 m and up to 300 m it is necessary to set each unit type HMI030 in Master mode and use Modbus RS485 communication interface terminals 3 and 4 use the communication module type Ekip Com instead of the 24 V DC auxiliary voltage kit use the System bus WS of the trip unit cables W1 and W2 of Ekip Com module for the connection of the trip unit to HMIO030 units set the following communication parameters of the trip unit Address 247 Baud rate 19200 Parity EVEN Stop bit 1 For the wiring between the trip unit and HMI030 units use twisted pair cables shielded and with characteristic impedance equal to 120 Q e g cable type Belden 3105 or equivalent It is advisable that the shield is connected to earth at the end of the connection towards the trip un
12. Bus communication with ABB circuit breakers 43 uoesiunwwo snq JO uonnjos ggy r UOHedIUNWWOS snq JO uonnjos ggY p 44 echnical Application Papers 4 7 1 Modbus RTU system functioning The traffic of information on the bus is managed through a procedure type Master Slave with a PC or PLC as Master and the circuit breakers as Slaves The Master defines all the traffic on the bus and only it can start the communication It transmits data and or commands to the Slaves and requires them to send the data in their turn The Slaves transmit on the network only when required by the Master The Slaves cannot communicate between them directly for instance in order to transfer a datum from one Slave to another one it is necessary that the Master reads the datum from the first Slave and then transfer it to the second one However in the application context of ABB SACE circuit breakers this operation is never necessary The communication sequence between each circuit breaker Slave and the PC Master occurs as follows 1 the PC sends a command or a query on the bus 2 the queried circuit breaker sends a response by per forming the appropriate action which may be performing the command received 8 The command or the request includes the identification code of the circuit breaker to which the communication has been sent therefore though the transmission is received by all the devices connected to the network onl
13. Figure C 11 Ekip Com module for molded case circuit breakers SACE Tmax XT2 and XT4 in fixed version Ekip Com module Wires W1 W2 K1 K2 Trip unit Cable for the dialogue with the trip unit Figure C 12 Connection to the Modbus network of SACE Tmax XT2 and XT4 circuit breakers in fixed version Ekip Com module Trip unit Bus communication with ABB circuit breakers Modbus RS485 network 5 6 0 eb o Auxiliary terminals It is up to the customer wiring of cables W1 W2 K1 and K2 to the auxiliary terminals choice and wiring of the auxiliary terminals of the auxiliary supply and of Modbus RS485 communication cable Cable for the dialogue with the trip unit Connector for the dialogue with Ekip Com With SACE Tmax XT2 XT4 circuit breakers in plug in version the connection of Ekip electronic trip units with dialogue functions to the Modbus network is carried out through the 6 pin connector XC5 according to the following diagram Plug in circuit breaker 1 i i Auxiliary i terminals W1 a i W2 1 Modbus i 1 2 RS485 cable i K1 3 v 8 i Ekip Com 1K2_ 7 4 5 2av 1 6 i 4 Auxiliary Auxiliary power i 1 6 pin termina s supply Vaux connector Ekip E LSIG Ekip LSIG i i Ekip LSI i Ekip M LRIU i 1
14. TCP IP defines a set of protocols which perform data transport from one device to another passing through one or more interconnected networks But TCP IP does not give information about the transported data or the application using them For example just consider that TCP IP is equally used to transfer files ftp protocol Web pages http protocol electronic mail SMTP protocol and videos to be shown in real time streaming each of these applications has different protocols In an industrial control and supervision system once Ethernet has been chosen as communication medium and TCP IP as transport protocol the following is still to be defined data format e g how many bytes are transmitted at a time how are numbers represented meaning of data e g how can a measure an alarm indication or a control signal be distinguished behavior of the devices transmitting and receiving data e g how often does the transmission of a measure occur what happens if a datum gets lost or arrives late As it is evident the details to be described are numer ous such as the problems which may occur Designing this type of protocol requires an effort out of the reach of most manufacturers of devices and systems Besides if each manufacturer of devices and systems chose his own solution there would be total incompat ibility thus undoing the main advantage of Ethernet and TCP IP that of being the standard technologies
15. 1 if in the character to be sent there is an odd number of 1s ones 0 if in the character to be sent there is an even number of 1s ones so that there is always an even number of 1s ones in the character to be transmitted In compliance with this rule the receiver shall count the number of bits set to 1 and if the counted number is odd it shall understand that there must have been some problem and shall ask to the transmitter to send the character again Vice versa when the parity control is in odd mode the parity bit shall be set to 1 or to 0 so that there is always an odd number of ones in the character to be transmitted Bus communication with ABB circuit breakers Even parity Character to be transmitted Parity bit Transmitted character 00111000 1 001110001 Odd parity Character to be transmitted Parity bit Transmitted character 00111000 0 001110000 Two communicating devices to understand each other must be set to the same control mode of the parity bit Technical Application Papers QTI Low voltage selectivity with ABB circuit breakers ely MV LV trasformer substations theory and exam ples of short circuit calculation SE Distribution systems and protection against indi rect contact and earth fault QT4 ABB circuit breakers inside LV switchboards QIS ABB circuit breakers for direct current applications QT6 Arc proof low voltage switchgear and control
16. Figure 42 Diagram of the auxiliary service of a power plant E Then there is also a system with an emergency generator which supplies the essential services only Each switchboard has got as main circuit breaker an Emax equipped with PR122 P PR123 P trip unit PR123 P is used only for the switchboards relevant to the essential services which can be supplied by the emergency generator because it has the possibility of using the dual setting function it can store the settings of the protections both for the normal condition with power supply from the network as well as for the emergency condition with power supply from the auxiliary generator unit and to switch instantaneously from one to the other in case of need PR122 P and PR123 P trip units are all provided with Modbus communication interface PR120 D M auxiliary module and connected to the supervision system The supervision system interfacing with the circuit breakers over a bus communication network via Modbus protocol displays three types of information relevant to a Supervisor PC 2
17. In both cases the purpose is to allow each node of the network to transmit within an ac ceptable time avoiding that two or more devices transmit at the same time there is a single channel and if the two transmitters operate simultaneously the interferences between the forwarded data will make them unusable Here is a simple description of how Ethernet works when a computer must transfer a data packet first it checks if another computer is already transmitting if this is the case it waits until the data transfer is over when the channel is free the computer starts transmit ting if two computers begin data transfer simultaneously both realize it since they detect an interference then both stop transmitting and wait a variable time ran domly defined between a minimum and a maximum and then try again to transmit after the transmission of a data packet the sender must observe a minimum wait before transmitting the next one This precaution shall prevent that which must transmit a lot of data in sequence from completely oc cupying the network for a long time The fact that the data are split into packets ensures access in sequence to the network to all connected devices The described procedure offers several advantages Ethernet is a peer to peer communication system since all devices are equal as regards communication methods and access to the transmission medium In particular the presence of a central cont
18. System pro M compact ODIN Meter DELTAplus DELTAmax EQ meters A43 EQ meters A44 6 DIN modules 7 DIN modules 7 DIN modules 7 DIN modules 7 DIN modules LCD LCD LCD Backlit Pixel LCD 230 400 V AC 57 100 288 500 V AC 57 100 288 500 V AC 100 173 400 690 V AC 50 60 Hz 65 10A 80 6A CT CTVT CTVT CTVT Bus communication with ABB circuit breakers 65 UOledIUNWIWOD snq 104 uonnjos ggY l UONeDIUNWIWOD snq 104 uonnjos ggY p 66 N ie Y Val j i 7 Technical Application Papers y i fat 4 12 Serial converter RS485 RS232 The multifunction serial converter CUS is used in all cases in which it is necessary to convert or manage the serial lines EIA 232 RS 232 EIA 485 RS 485 and EIA 422 RS 422 The communication links between devices using these types of buses such as for example PLCs measuring and control instruments peripherals and computers run ning specific software applications etc often requires the type of serial line to be converted the signal on the line to be amplified different parts of the communication network to be insulated etc Thus CUS converter is widely used thanks to its config urability and operational flexibility which enable it to be used in the most different applications CUS ensures the galvanically isolated conversion be tween the RS 232 side the RS422 485 side and the supply source Supply voltage V The main applications ar
19. Total active power Active energy positive negative Total active energy Measures history Imax Measures history Vmax Pmax Pmean Data logger CB state open close tripped CB position connected test isolated Spring state charged discharged Mode local remote Protection parameters set load control parameters Maintenance data Total number of operations from close to open Total number of protection trips Total number of trip tests Number of manual operations with opening command Number of trips according to each protection functions Contact wear Data recording of the latest 20 trips Protection alarms Protection L timing and trip L pre alarm Protection S timing and trip Protection trip Protection against overtemperature OT pre alarm and trip Protection G timing and trip Phase unbalance protection U timing and trip Undervoltage protection UV timing and trip Overvoltage protection OV timing and trip Reverse power protection RP timing and trip Diagnostic alarms Failure of opening mechanism TRIP command failed Contact wear 100 Rating Plug disconnected Trip coil TC disconnected or failed Controls CB opening closing command Reset alarms Trip reset Protection curve and threshold settings System time synchronization of each CB Ev
20. it is possible to get to a Modbus TCP telegram by 1 removing the fields Slave Address and CRC from the traditional Modbus telegram 2 adding the MBAP Header Modbus Application Header to the start of the message As explained hereafter the field Slave Address is in serted in the field UnitID of the Modbus TCP telegram when the server is a gateway for the conversion from Modbus TCP to ModbusRTU protocol The MBAP Header contains the following fields Transaction identifier 2 bytes set by the Client in the request and duplicated by the Server in the response used to univocally identify a transaction a specific request sent by the Client to the Server Figure 35 Modbus TCP telegram MBAP Header Protocol identifier 2 bytes to identify the protocol the Modbus protocol is identified by the value 0 Length this field 2 bytes identifies counts the length in bytes of the subsequent fields present in the mes sage Unit Identifier hereafter called Additional Address this field 1 byte length allows the Modbus map to be extended thus permitting a single server to answer as if consisting of different devices virtual units When the server is a gateway which connects a Modbus serial line to an Ethernet TCP IP network this field is used to identify any connected remote slave see Figure 36 For further information see the document MODBUS Messaging on TCP IP Imple
21. the information the alarms available in the trip unit and the circuit breaker state for the supervision of the electrical plant e g con trol the energy consumption and monitor the quality of the electrical network send from remote opening closing and reset comman ds if the circuit breaker is equipped with MOE E motor operator see Annex F set from remote the configuration programming and protection parameters current thresholds and trip times of the protections curves of the protection functions of the trip unit SACE Tmax XT2 XT4 moulded case circuit breakers can be used in the communication systems for a complete and total supervision of the electrical plant starting from load currents of 4 A for example this is possible with a moulded case circuit breaker type SACE Tmax XT2 equipped with Ekip LSI electronic trip unit In 10 A and protection L set at 0 4 In For the communication and dialogue functions the Ekip 22 Bus communication with ABB circuit breakers Com module and the electronic trip unit must be supplied with 24 V DC auxiliary voltage Vaux for the technical characteristics see Annex B To accomplish from remote the opening closing and re set commands the moulded case circuit breakers type SACE Tmax XT2 and XT4 must be equipped with MOE E motor operator with electronic interface see Annex F Measures In addition to the supervision functions described above the trip units with communic
22. the same ones used for the remote control of standard Emax circuit breakers for alternating current applica tions shunt opening release YO shunt closing release YC geared motor for the automatic charging of the closing springs M As regards bus communication please note that the trip units PR122 VF must be supplied with an auxiliary sup ply voltage of 24 V DC for its technical characteristics see Annex B The measures data information and control operations from remote are summarized in Table A 1B of Annex A All the commands from remote control via bus can be blocked by setting the trip unit to local mode As regards the configuration of use of the trip unit PR122 VF with the accessories for the Modbus communication reference must be made to the configuration of use of PR122 P trip unit for alternating current shown on page 14 of this document NOTE For a deeper analysis on variable frequency applications in wind power systems please consult Technical Application Paper No 13 Wind power plants NOTE For more detailed information about the dialogue functions and the characteristics of the products described in this clause reference must be made to the relevant catalogues and product technical manuals For further information on the structure of the Modbus map of the ABB trip units provided with communication interfaces reference must be made to the following documents Modbus system Interfa
23. which can be used also to connect devices of different manufacturers For these reasons in recent years industry has defined various standard protocols for the use of Ethernet in industrial environments At least a dozen protocols are currently widely spread and about as many are used for particular applications Any developer of control and automation systems chooses among the available protocol that which better satisfies his application requirements 5 3 Modbus TCP protocol Developed in 1999 Modbus TCP was one of the first industrial protocols to use Ethernet and TCP IP As the name itself indicates this is an adaptation of the tradi tional Modbus protocol on a serial port to the networks using TCP IP Its main advantages are simplicity which makes it easily implementable both in new devices as well as in adaptations to existing devices similarity to the traditional Modbus protocol already known by many programmers and developers of con trol and supervision systems existence of devices to interconnect through Ethernet networks devices using the traditional Modbus on a serial port as you can see below these devices work by converting the single telegrams The concept is quite easy the master slave architecture is replaced see clause 4 7 1 with a client server archi tecture The sensor or actuator works as server a device providing for other devices the clients which require it data to be re
24. 05 ms 22 mA 20 530 mW Inrush current 24V Rated current 24V 20 mA Rated power 24V 480 mW When the electronic trip unit is used with Ekip Com communication module the power and current data are summed Annex C The communication modules Emax air circuit breakers E1 E6 PR120 D M communication module Modbus RTU RS 485 9600 19200 bit s Protocol Physical interface Baud rate The communication module is supplied directly through PR122 P DC VF PR123 P DC trip unit which in its turn is supplied by the auxiliary power supply Vaux The relevant technical data are shown in the following table PR122 PR123 PR120 D M eee insulated E eag from PR122 PR123 Maximum ripple 5 2 Inrush current 24 V 10 A for 5 ms Rated current 24 V 130 mA 40 mA Rated power 24 V 3 W 1W With PR122 VF trip unit for the connection of the auxiliary supply to the trip unit a shielded twisted pair cables e g cable type BELDEN 3105A 3105B must be used The shield must be earthed at the end of the connection towards the trip unit Connection to the Modbus network PR122 P DC VF PR123 P DC trip units are connected to the Modbus network through the communication module PR120 D M according to the diagram in the figure Figure C 1 Wiring diagram for the connection of PR12X P to the Modbus network through PR120 D M module Auxiliary power
25. 16 Representation of the main flow and of the digital flow amain flow energy flow constituted by the power and the energy which through the line conductors and the switching and protection apparatus is delivered to the users and the loads of a plant adigital flow constituted by all the information the data and the commands useful for the control and manage ment of the plant It is the supervision system which manages the digital flow passing over the communication network Main flow iI UL Digital flow Bus communication with ABB circuit breakers According to the extent and the complexity of the in stallations to be managed it is possible to implement supervision systems with different architectures from the simplest two layer architecture to the most complex ones multi layer architecture In this document for a simple treatment of the subject the systems with two level architecture suitable for the management of low and medium distribution plants are dealt with In this type of architecture two levels are distinguishable 1 the control level constituted by the supervision con trol and data acquisition system SCADA Supervisory Control and Data Acquisition In the most simple applications this level comprises a computer on which the software programmes for data acquisition plant control or supervision are installed It is at this level that the data transmitted by the sen sors are acquired
26. A B supply Vaux EIA RS 485 interface A for Modbus network 24V K14 p K2 wip qT W2 CB terminal box KT 4 tK wie pe or sliding contacts T EIARS 485 Modbus cable PR120 D M PR122 X PR123 Y saat S751 1 7 Note W1 W2 terminals for the connection of the Modbus cable K1 K2 terminals for auxiliary power supply Vaux 33M 1 3 contacts signaling spring charged 751 1 7 contacts signaling circuit breaker racked in for CBs in withdra wable version X P DC VF Y P DC With PR122 VF trip unit for the connection of the auxiliary supply to the trip unit a shielded twisted pair cables must be used e g cable type BELDEN 3105A 3105B The shield must be earthed at the end of the connection towards the trip unit Inside PR120 D M module there are the contacts K51 YO to control directly the shunt opening release YO and K51 YC to control directly the shunt closing release YC to carry out the circuit breaker opening and closing commands from remote With PR120 D M communication module the supply of the shunt opening and closing releases YO and YC must not be derived from the main supply and can have maximum voltage values equal to 110 120 V DC or 240 250 V AC Connection to EP010 unit PR122 P and PR123 P trip units are connected to EP010 unit through the communication module PR120 D M Figure C 2 Wiring diagram for the connection of PR122 P PR123 P to EP010 unit Auxiliary power
27. E m a Protection E a E E E Protection G bl a a a a a fue nay unbalanced phase currents U s Protection against overtemperature of the trip unit OT E a E E B e P unbalanced phase voltages U s Z Protection against undervoltage UV timing and trip a a Protection against overvoltage OV timing and trip a E a a Protection against residual voltage RV timing and trip E E a RE e P reversal of active power RP Z Z Protection against under frequency UF timing and trip a a a E Protection against over frequency OF timing and trip a a a Directional protection D timing and trip E E Diagnostic Trip command failed a a L alarms Contact wear 100 E a E a Rating Plug error m E E a Trip coil TC disconnected or damaged E E E E E Current sensors disconnected a a E E Commands Circuit breaker opening closing a H a a E a Alarm reset trip reset a E E a a a For further information about the electric quantities the data and the alarms available reference must be made to the following document Modbus FBP Interface User and Operator Manual document code 1SDH000510R0001 Test isolated position in which the power contacts are disconnected whereas the auxiliary contacts are connected Bus communication with ABB circuit breakers Supervision with fieldbus Profibus DP and DeviceNet Table A 5 Measures data alarms and commands available with Tmax moulded case circuit breakers type T4
28. ELA RS 232 RS 485 converter Power supply Emergency by network generator 2 x x 2 i yY g g rn L Vv A A A A A A x E x EG x E bd E 2 a O aq a kl FI Vv Vv Vv Vv Vv 4 y A A A A A A x x x x x x x x y SoA A A Ne aye oy a 2 z 2 a 2 a a a 2 a 2 a a a 2 a 2 Outlet Heating system Autoclave Command room Lightning system Circuit breaker and switch disconnector J motors J Non essential services Bus communication with ABB circuit breakers Essential services the auxiliary systems alarms for protection overloads data relevant to the protection trips in case of trip both the values of the interrupted currents as well as the waveforms recorded by the trip unit in the internal data logger are displayed data relevant to the life of each circuit breaker number of operations and percentage of contact wear The supervision system reads cyclically the information contained in each circuit breaker via the communica tion bus The alarm and trip data of the protections are made avail able for the operators in the control room and stored in the history database of the supervision system Thanks to the available data it is possible to 1 monitor in real time the state of the circuits supply ing the auxiliary services 2 carry out a diagnostic and statistic analysis of the occurred anomalies for a preventive study on the fault causes in order to reduce the inefficiencies
29. French data link layer and on the subject matter of the conversation application layer To get a successful communication between two entities all the layers taken into consideration shall correspond to each other for instance when using the telephone we could not talk to whom is using a radio we could not un derstand each other if we use different languages etc Figure 7 Impossibility of communication between transceiver and telephone Without aiming at a thorough description of the existing protocols we wish to point out some of the charac teristics of the communication system through a brief description of the three mentioned layers 2 1 1 The physical layer When taking into consideration the physical layer it is possible to distinguish between wireless systems which use as physical medium radio waves infrared rays or luminous signals propagated in free space wired or cabled systems whose signals are transmitted over cables or optical fibers Among the latter there are point to point cabling systems in which each section of cable links two devices and is used exclusively for the communication between them a typical example is represented by the communication PC printer This communication can be full duplex type when the two devices can transmit simultaneously or half duplex if they can transmit only alternately multipoint called also multidrop cabling systems in which many devices sh
30. Hz 45 65 VA lt 6 Measurement accuracy Voltage 0 5 FS 1 digit in the range Current Active power 0 5 FS 1 digit in the range 1 0 1 FS from cos 0 3 to cos 0 3 Frequency Energy metering Maximum metered value for single phase 0 2 0 1Hz from 40 to 99 9 Hz 0 2 1Hz from 100 to 500 Hz 4294 9 MWh Mvarh with kA KV 1 Maximum metered value for three phase 4294 9 MWh Mvarh with KA KV 1 Communication parameters Protocol Accuracy Class index 1 Modbus RTU Physical interface RS 485 Baud rate 4800 bps 9600 bps 19200 bps Parity Odd Even None Stop bit 0 1 Address 1 247 NOTE For more detailed information see the technical catalogue System pro M compact Bus communication with ABB circuit breakers 61 UONLOIUNWIWOD snq 104 uonnjos ggY p UONPIIUNWIWOD snq 40 uonnjos ggY p Technical Application Papers 4 11 2 ANR network analysers When more advanced analysis functions are required to enrich the range of ABB front panel instruments ANR network analysers allow network parameters alarms and information about other devices state to be measured and recorded it also allows addressing the data to remote supervision and control systems The software SW01 which they are provided with represents a first hand tool for the remote visualization of the measures and for recording of the latter and pre
31. K1 K2 terminals for auxiliary power supply Vaux SOR shunt opening release SCR shunt closing release K51 SOR control contact for the shunt opening release K51 SCR control contact for the shunt closing release Q 5 Q 6 circuit breaker auxiliary contacts 33M 1 3 contacts signaling spring charged 751 1 7 contacts signaling circuit breaker racked in for CBs in withdrawable version The supply of the shunt opening release SOR and of the shunt closing release SCR must not be derived from the main supply and can have maximum voltage values equal to 110 120 V DC or 240 250 V AC Bus communication with ABB circuit breakers 95 5 xeuuy s jnpow UONBOIUNWILUOD OY 5 xeuuy s jnpow UONESIUNWIWOS yL 96 Technical Application Papers Connection to EP010 unit PR332 P and PR333 P trip units are connected to EP010 unit through the communication module PR330 D M Figure C 4 Wiring diagram for the connection of PR33X P to EP010 unit i t Auxiliary power z supply Vaux EP010 L J1 Z 4 e EIA RS 485 interface for Modbus network 24V wap A B K1 1 T K2 w1 1 T w2 C134 pcr2 c3 T 1 c2 CB terminal box KI KR wib we C13 tC C39 02 or sliding con
32. PC tPC that is the time elapsing between the end of the RESPONSE of a circuit breaker and the start of the QUERY sent by the PC to the next circuit breaker is considered negligible To implement a communication network among more slaves in Modbus RTU protocol it does not matter if measuring instruments protection circuit breakers or temperature control units it is fundamental to have the possibility of setting the same communication param eters on all devices present in the network These parameters are speed of data transmission called baud rate e g 19200 bps data bit no of bits 8 parity bit Even Odd None stop bit 1 when parity bit even or odd or 2 when parity bit none address of each slave Once the same baud rate parity bit and stop bit have been set and after having identified each slave device with its own single address it is possible for the master to proceed with the acquisition of the information NOTE A detailed description of the Modbus communication protocol can be found on the website www modbus org Bus communication with ABB circuit breakers 45 uo esrunwwo snq 104 uonnjos ggY p UONPIIUNWIWOD snq 104 uonnjos ggY p 46 Technical Application Papers 4 8 Ekip Connect software Ekip Connect is a software application for personal computers with Microsoft Windows operating system which allows data to be exchanged between one or m
33. PR120 V see Annex D which must be required for PR122 P whereas it is fitted out by default on PR123 P allows the trip units to make available in addition to the current measure also the main electrical quantities of the plant such as e g the power see Annex A The measured values can be sent by means of PR120 D M to the remote supervi sion system For measures data alarms and remote control opera tions please refer to Table A 1 in Annex A All the commands from remote control through the bus can be disabled by setting the trip unit to local mode PR122 P PR120 D M communication module remote control accessories YO YC M Supervision PR122 P PR120 D M N Note together with PR120 D M module also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied Bus communication with ABB circuit breakers PR122 P PR120 D M communication module remote control accessories YO YC M Supervision PR122 P PR120 V PR120 D M Note together with PR120 D M module also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied PR123 P electronic trip unit PR123 P PR 120 D M communication module remote control accessories YO YC M Supervision PR123 P PR120 D M The measuring module PR120 V is mounted by default on PR123 P trip unit Note together with PR120 D M modul
34. Q Zand SY 3 i i 1 Ekip LSIG x J i l f Ekip M LRIU ip svis he x J T i i i i i 1 XF3 1 MOE E 1 i i i i Li i Ekip Com iLL 1 hw o ey 1 It is up to the customer wiring of cables W1 W2 K1 and K2 to the auxiliary terminals choice and wiring of the auxiliary terminals of the auxiliary supply and of the Modbus RS485 communication cable Bus communication with ABB circuit breakers Figure C 9 Ekip Com module for SACE Tmax XT2 and XT4 moulded case circuit breakers in withdrawable version Trip unit JE3 JF3 Connectors for the auxiliary circuits of the circuit breaker in withdrawable version withdrawal of the connectors occurs simultaneously with that of the circuit breaker Cable for the dialogue T with the trip unit RS L Plug of JE3 connector Plug of JF3 connector Trip unit When the moving part of the circuit breaker is inserted in the fixed part the coupling between the socket fixed part of JF3 connector inserted in the fixed part of the circuit breaker and the plug moving part of JF3 con nector inserted in the moving part of the circuit breaker Cable for dialogue with the trip unit Connector for dialogue with Ekip Com Ekip Com module Moving part of JE3 connector Moving part of JF3 connector Auxiliary power supply Vaux Auxiliary terminals It is up to the customer wiring of cables
35. Reset alarms Trip reset Trip test Run Time events State changes of CB of protections and of all alarms 1 Measurement available with neutral connected with four pole CB or three pole CB CT for external neutral conductor 2 It signals that 90 I1 lt I lt 120 l1 Bus communication with ABB circuit breakers Annex B Electrical characteristics of the auxiliary power supply The auxiliary supply must be provided from the outside using a galvanically isolated power supply Since an auxiliary voltage isolated from the ground is required it is necessary to use galvanically isolated converters com plying with the Std IEC 60950 UL 1950 or its equivalent Stds IEC 60364 41 and CEI 64 8 which guarantee a common mode current or leakage current see Stds IEC 478 1 and CEI 22 3 not exceeding 3 5 mA Air circuit breakers type Emax E1 E6 Emax X1 and moulded case circuit breakers type Tmax T7 T7M As regards the air circuit breakers type Emax Emax X1 and Tmax T7 moulded case circuit breakers the auxiliary power supply is delivered to the terminal box and pre cisely to the terminals K1 for the pole of the power supply and K2 for the pole of the power supply The electrical characteristics of the auxiliary supply for the each circuit breaker type is reported in the following tables Emax E1 E6 PR122 P PR122 DC PR123 P PR123 DC 24V dc 20 24Vdc 20 24Vdc 20 Elec
36. Seven annexes are included in this document Annex A contains the tables with the main information the measures and the alarms put at disposal by the trip units The other Annexes deal in details with the functional and applicative aspects of the products and of the ac cessories communication modules measuring modules auxiliary contacts in electronic version connectors and motor operators necessary for the bus communication functions of ABB automatic circuit breakers In particular Annex C includes the indications to connect the circuit breakers to a Modbus RS 485 network M 2 Digital communication Digital communication is a data exchange in binary form that is represented by a string of bits between intel ligent electronic devices provided with suitable circuits and interfaces The communication usually occurs serially the bits which constitute a message or a data packet are transmitted one after the other over the same transmission channel physical medium 1 A bit is the basic information unit managed by a computer and corresponds to the State of a physical device which is represented either as 0 or as 1 A combination of bits may indicate an alphabetical character a numeral give a signal or carry out switching or another function Figure 1 Bit sequence Receiver
37. System Interface document code 1SDHO00566R0001 Instruction manual PR223DS Modbus System Interface document code 1SDHO00658R0001 Instruction manual PR222DS PD Modbus System Interface document code 1SDH000600R0001 The Modbus map or memory map is defined by the manufacturer who decides what register is to be associated to the data read by the circuit breaker and moreover chooses which of the read parameters and which settings of the circuit breaker can be transmitted via serial communication Bus communication with ABB circuit breakers 2 1 4 Compatibility between the protocol layers In industrial communication the different devices inter changing information must use the same protocols for all the layers involved For instance as illustrated in the following chapters ABB SACE circuit breakers use protocol Modbus RTU over RS 485 However there are also industrial devices which use Modbus RTU over RS 232 or Profibus DP over RS 485 Some of the above mentioned combinations are shown in the table below highlighting which are the functioning and not functioning ones PROTOCOL PROTOCOL OF THE PROTOCOL OF THE LAYERS DEVICE A DEVICE B COMMUNICATION DIALOGUE Logical layer Modbus RTU Modbus RTU YES COMMUNICATION Physical layer RS 485 RS 485 Compatibility on all the layers of the protocol Logical layer Modbus RTU Modbus RTU YES COMMUNICATION Physical layer RS 232 RS 232 Compatibility on all the layers of t
38. T5 and T6 PR223EF PR222DS PD PR223EF VM210 EP010 EP010 EP010 Electric Phase currents IL1 IL2 IL3 neutral current IN quantities ground current lg UW Phase to phase voltages V12 V23 V31 E Phase to neutral voltages V1 V2 V3 E Peak factor L1 L2 L3 N E Frequency E State Circuit breaker state open closed tripped E E information Mode local remote a E E Protection parameters set B E L Maintenance Total number of operations a data Total number of trips a E a Number of trips separated according to the protection function L S I G a z Number of trips separated according to the protection function EF SOS Number of test trips a E Number of manual operations a Protections Protection L timing and trip B w E amis Protection S timing and trip a E E Protection G timing and trip H E Protection E Protection EF SOS E Diagnostic Trip command failed L alarms MOE E overheating a a Trip coil disconnected or damaged a Commands Circuit breaker opening closing with MOE E E Circuit breaker reset with MOE E a E E Alarm reset a Events State changes of CB of protections and of all alarms D a E For further information about the electric quantities the data and the alarms available reference must be made to the following document Modbus FBP Interface User and Operator Manual docume
39. The apparatus which have to exchange data and informa tion are linked together in a communication network A network is usually constituted by nodes interconnected with communication lines the node an intelligent device capable of dialogue with other devices is the point of data transmission and or reception the communication line is the linking element between two nodes and represents the direct path followed by the information to be transferred between the two nodes in practice it is the physical medium coaxial cable twisted pair cable optical fibers infrared rays through which data and information are transmitted The main communication networks can be classified according to the following topologies Ring network Ring networks are constituted by a series of nodes in Figure 2 these are represented by personal computers interconnected to get a closed ring Figure 2 Ring network Star network Star networks are based on a central node to which all the other peripheral nodes are connected Figure 3 Star network E f E 4a Bus network The bus structure is based on a transmitting medium usually a twisted cable or a coaxial cable in common for all the nodes which thus result to be connected in parallel Figure 4 Bus network Cm Sill
40. W1 W2 K1 and K2 to the auxiliary terminals choice and wiring of the auxiliary terminals of the auxiliary supply and of the commu nication cable Modbus RS485 Socket of JE3 connector Socket of JF3 connector accomplishes wiring continuity for the connection of the trip unit to the Modbus network Coupling of the fixed part with the corresponding moving part of JE3 and JF3 con nectors accomplishes also wiring continuity to provide the auxiliary supply to Ekip Com module and to the trip unit Bus communication with ABB circuit breakers 99 s jnpow uopesiunwwo OU 5 xX uuy 5 xeuuy s jnpow UONSIUNWIWOS yL echnical Application Papers With SACE Tmax XT2 XT4 circuit breakers in fixed ver sion the trip unit is connected to the Modbus network through the cables W1 and W2 according to the following diagram Fixed version 7 Circuit breaker i Auxiliary i terminals i q i w1 n Modbus i i W2 a 5 RS485 cable i Ekip Com K1 i i 24V y 4 1 i i K Auxiliary Auxiliary power i i terminais supply Vaux i q i 1 i Ekip E LSIG l i Ekip LSIG i Ekip LSI Ekip M LRIU l 1 i It is up to the customer wiring of cables W1 W2 K1 and K2 to the auxiliary terminals choice and wiring of the auxiliary terminals of the auxiliary supply and of Modbus RS485 cable
41. a be r Aea i mopBus TIV L3 1 Rs485 Ekip E LSIG i TN ap bea ea a Ekip LSI i Ekip LSIG Ekip MLRIU I l Opening closing i I reset commands MOE E E i actuator unit _ gt 7 i UEO EEUE EA E E a EEE YO1 opening solenoid of the microprocessor based overcurrent release Bus communication with ABB circuit breakers Electrical characteristics of MOE E for SACE Tmax XT2 and XT4 Nominal voltage Un AC DC 24 V 48 60 V 110 125 V 110 125 V 220 250 V 220 250 V 380 440 V 480 525 V Operating voltage Umin 85 Un Umax 110 Un Power absorbed on inrush Ps AC DC lt 300 VA lt 300 W Power absorbed during normal operation Pc AC DC lt 150 VA lt 150 W Operating frequency 50 60 Hz Switching time opening lt 1 5 s closing lt 0 1 s reset lt 3 s Mechanical life 25000 operations Minimum duration of electrical opening and closing command 150 ms Total time from transmission of impulse to circuit breaker opening Bus communication with ABB circuit breakers 107 4 xouuy vLX ZLX xXewL AFOVS 104 40 e49d0 10 0W 5 30W yq Ayued aul 5 xouuy 108 echnical Application Papers LE Annex G The parity bit The parity bit is an additional control bit in queue after each transmitted character to avoid communication errors With the parity control in even mode this bit is set to
42. able to restore in the correct order the single packets received thus reconstructing the sent communication In practice through the IP protocol a device is able to make a data packet reach any device whereas the TCP protocol uses the IP protocol to allow transfer of struc tured data systems from a device to another in a reliable and correct way For example when it is necessary to transfer a file or a Web page from a PC to another one various operations must be carried out here is a simplified description of the process alogical connection must be established by sending a series of packets to indicate the intention of transmit ting a file and even indicating the type and dimension of the file a response confirming that the other computer is ready to accept the transmission is sent back Bus communication with ABB circuit breakers 69 SOMU dI dO L PUY U S19yeO1g 1INDIID JAY G SIOMJOU dI dOL PUY U S19yeO1g 1INOIID JAY G 70 Technical Application Papers the transmitting computer through the TCP protocol shall split the file into data packets number them and through the IP protocol send them one after the other Since the transmission is carried out through the IP protocol the packets might arrive with different delays or in a different order with respect to the original one the receiving computer through the TCP protocol shall reorder the packets according to their numeration
43. about the measures data and alarms placed at disposal by the electronic trip units Ekip LSI and Ekip LSIG in the following configurations see Table A 6 of Annex A As regards the remote control operations which can be performed on the circuit breaker see Table A 6 of Annex A under the entry Commands All the commands from remote via bus can be blocked by setting the trip unit to local mode MOE E pze gams li baaie 13 3591 NOTE For more detailed information on the dialogue functions and on the characteristics of the products described in this clause reference has to be made to the relevant catalogues and product technical manuals Bus communication with ABB circuit breakers 4 11 Measuring instruments The measuring instruments for the installation inside MV and LV primary and secondary industrial distribution panels represent an ideal enhancement of the ABB offer through which the panel can be configured as function integrated system ABB offer of digital instruments provided with commu nication function includes DMTME multimeters both in modular version as well as in front panel version ANR network analysers for an accurate control of network quality MID certified energy meters for monitoring of the energy consumption of single loads and of the plant TMD temperature control units for the control of tem peratures on the windings of the power transformers 4 11 1 DMTME multimete
44. circuit breaker switching 78 6 2 Allocation of the energy costs inside a plant eeeeeeeeeeeees 79 6 2 1 Description of the distribution and Communication System ccccccceesetetetees 80 62 2 FUNCONN Eisner e iR 80 6 3 Management of priority and non prioritary loadS eeeeeeene 81 Annex A Measures data and commands for supervision and remote Control 0000000000 82 Annex B Electrical characteristics of the auxiliary POWT SUPDIY ccccceceeeeeeeeeeeeeneeeeeeeeeeeeeeeeeeeeee 91 Annex C The communication modules cceeeeeeeeeeee 93 Annex D The measuring modules sssseesseeseerreeerrresenns 102 Annex E AUX E auxiliary contacts and MOE E motor operator for Tmax T4 T5 T6 sses 104 Annex F MOE E motor operator for SACE Tmax XT2 X74 ccccssscccccceceeeessssssssssseeeeees 106 Annex G The parity Dit vccccccccecee cee ceeeceetecstieee nsec aara 108 uononpou Technical Application Papers 1 Introduction Due to the ever growing use of automation and super vision systems for industrial processes for a better management of the electrical and technological plants circuit breaker manufacturers have been driven to imple ment on the electronic trip units the dialogue interfaces for bus communication with control devices such as PLC PC or SCADA In this way automatic circuit breakers are used not only for switching and protection but also for
45. connected to the Modbus network through W1 and W2 cables coming out from the fixed part the socket of JF3 connector housed in the fixed part of the circuit breaker See Figures C 8 C 9 and C 10 11 SY 3 contact for electrical signaling of circuit breaker open due to tripping of magnetic thermomagnetic trip units microprocessor based trip unit electronic type shunt opening release undervoltage release residual current release Figure C 8 Wiring diagram for the electrical connection to the Modbus network of the trip units type Ekip E LSIG Ekip LSI Ekip LSIG and Ekip M LIRU with Ekip Com module Circuit breaker in withdrawable version t l i I Li i Li i i Li i Li i i 1 Li i Li i i 1 ir ton Cok a i 1 Li TEN Ra ued 1 Q JES 1 XV W4 zii T Le eo Auxiliary power lt E xv 2 W3_xc5W3 1 Auxiliary supply a i if ae I terminais Vaux 24 VDC i 1 XF1 Ve K1 xcs KI K1 _ 3 _ i I i XF2 A eae 2av J _ _ i z l J3 wo K2 1 TI L1 x L 1s e XC5 w2 A 1 l Digital l 4 p XV Wt eg Wa 1 WS i THL2 eae I D e 1 signals i za ae ay ae z ant wi v A Li t 1 i TI L3 Qi7 X Modbus RS485 Auxiliary y cable Ekip E LSIG contacts I 1 p e Epis
46. connected to the same bus must have the same settings in order to intercommunicate In industrial automation and energy distribution the most part of the communication networks are realized with bus technology and the most used physical layer is the interface RS 485 4 In principle in a multidrop connection the devices are linked in parallel to a main cable 5EIA TIA 485 Differential Data Transmission System Basics is the document which descri bes the Standard RS 485 which represents the main reference for all the manufacturers Bus communication with ABB circuit breakers 7 UuOILESIUNWIWIOS je1u161g A uoleolunWwWwod jesd zZ 8 Technical Application Papers 2 1 2 Data link layer As regards the data link layer we speak of master slave protocols when one of the devices the master has the task of controlling and managing the communication with all the others slaves Instead we speak of peer to peer systems when such hierarchy does not exist and the de vices gain access to the communication medium equally in such case the protocol includes the procedures to manage the turns and the access priorities to the com municaton medium a typical example is Ethernet Among the most common communication protocols there are Modbus RTU the most common connection protocol for electronic industrial devices ProfiBus DP used for field communication with intel ligent sensors and actuator
47. device which through a display allows the electrical quantities of the plant and the information available in Ammeter mode A the connected trip unit to be displayed Before completing the installation of HMI030 by acting on the suitable selector positioned on the back of the device it is possible to choose one of the selected operation mode Ammeter mode A In this mode it is possible to display the values of the cur rents in the three phases and in the neutral based on the trip unit connected Moreover it is possible to display the maximum current value and the phase passed through by the maximum current referred to the latest acquisition from the Measure History of the trip unit This information is available if in case of Modbus com munication HMI030 unit is operating in Master mode Voltmeter Mode V In this mode it is possible to display the values of the phase voltages V1N V2N V3N and the values of the line to line voltages V12 V23 V31 In this mode the information of the Measure History of the trip unit cannot be displayed E1 E6 X1 T7 E2 E6 T4 T5 T6 XT2 XT4 PR12x P PR33X P PR12X DC PR222DS PD PR223DS PR223EF Ekip LSIG LSI Ekip E LSIG Ekip M LRIU Phase currents I l E E E E Neutral current lye L E L Measures history currents a Measures available in the presence of the neutral with four pole circuit breaker or three pole circuit breaker
48. displayed and processed and the commands are sent to the actuators In this way from a single work station an operator can monitor the state of the whole plant and carry out the necessary operations to guarantee its efficiency and proper functioning Figure 17 Supervision system with two level architecture Control level Bus network Field level Actuator Sensor Slave Slave More in general in the applications which combine the management of the electrical distribution plant and the process management the control level is constituted by the control processor which supervises the automa tion system of the whole industrial process 2 the field level constituted by the field devices equipped with communication interfaces Sensors actuators and protection circuit breakers fitted out with suitable electronic trip units which are installed in the electrical plant and interact directly with it connecting it with the control level The main functions of the field level are 1 transmitting the plant data e g currents voltages energies state of the circuit breakers etc to the control level 2 actuating the commands e g opening closing of the circuit breakers received by the control level The two levels communicate through a bus network The information e g the measured values transmitted from the field level to the control level and the commands which travel in the opposite direction constitute the informativ
49. energy Total reactive energy Total apparent energy Data of the latest trip a a E E E E E E Measures available in the presence of the neutral with four pole circuit breaker or three pole circuit breaker CT for external neutral conductor Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 and in the presence of the neutral conductor Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 30 Bus communication with ABB circuit breakers On the HMIO30 unit the interface RS485 terminals 3 and 4 and CAN terminals 7 and 8 cannot be used simultaneously As a consequence it is not possible to have simultaneously Modbus communication and the communication on WI internal bus Bus CAN dedicated to ABB devices More than one unit HMI030 set in the same operating mode cannot be connected to the same bus To be able to operate the unit HMI030 must be supplied with an auxiliary voltage Vaux having the following characteristics Supply voltage 24 V dc 20 Maximum ripple 5 1 4 W 24 V dc Rated power Emax E1 E6 Emax X1 Tmax T7 The auxiliary supply shall be provided using a galvanically isolated external power supply Since an auxiliary supply voltage isolated
50. in not motorizable version cannot be control led from remote To perform the remote control i e the mechanical im plementation of the remote opening and closing com mands the circuit breakers type Emax X1 and Tmax T7M with PR3830 D M communication module must be equipped also with the following accessories PR330 R actuation module see Annex C shunt opening release SOR shunt closing release SCR geared motor for the automatic charging of the clos ing springs M As regards bus communication remind that it is neces sary to supply the trip units PR332 P and PR333 P with the auxiliary voltage Vaux for its characteristics see Annex B Measures The measures made available depend on the typology of trip unit used and on the presence of the measuring module PR330 V The voltage measuring module PR330 V see Annex D which must be provided for PR332 P whereas it is fitted out by default on PR333 P allows the trip units to make available in addition to the current measures also the main electrical quantities of the plant such as for example the power see Annex A The measured values can be sent by means of PR330 D M to the remote supervision system For measures data alarms and remote control operations please refer to Table A 1 in Annex A All the commands from remote control through the bus can be disabled by setting the trip unit to local mode PR332 P electronic trip unit for Emax X1 and Tmax T7
51. phase power active P reactive Q apparent A Power factor Peak factor Ip Irms Frequency Total and phase energy active reactive and apparent Harmonic analysis THDi THDv and spectrum up to 40th harmonic up to 35th with f 60 Hz Waveform of phase and neutral currents Waveform of the line to line voltages Data logger Lal Measures history Imax Measures history Vmax Vmin Pmax Pmean Qmax Qmean Amax Amean State Circuit breaker state open closed tripped information ircuit breaker position racked in test isolated Spring state charged discharged Mode local remote Protection parameters set parameters for the load control Maintenance Total number of operations and trips data Number of test trips and manual operations Number of trips separated according to each protection function Contact wear Data records of the last 20 trips Protections Protection L S 1 G alarms Directional protection D timing and trip Protection against unbalanced phase currents U timing and trip Protection against overtemperature of the trip unit OT Protection against unbalanced phase voltages U timing and trip Protection against undervoltage UV timing and trip Protection against overvoltage OV timing and trip Protection against residual voltage RV timing and trip Protection against reversal of active power RP timing and trip Protecti
52. see Table A 5 of Annex A As regards the remote control operations which can be performed on the circuit breaker see Table A 5 of Annex A under the entry Commands All the commands from remote via bus can be blocked by setting the trip unit to local mode MOE E PR222DS PD AUX E AUX E MOE E AUX E Connector X4 VM210 ae ED le Bus communication with ABB circuit breakers 59 UOledIUNWIWOD snq 104 uonnjos ggY p UOledIUNWWOD snq 104 uonnjos ggY p i 60 Technical Application Papers 1 4 10 3 Moulded case circuit breakers SACE Tmax XT2 XT4 Profibus DP and DeviceNet supervision and remote control SACE Tmax XT2 and XT4 moulded case circuit breakers equipped with the electronic trip units type Ekip LSI and Ekip LSIG are connected to EP010 unit through Ekip Com communication module For SACE Tmax XT2 and XT4 moulded case circuit breakers there is only one version of EP010 unit which is compatible with both the trip units Ekip LSI and Ekip LSIG To carry out from remote the opening closing and reset commands SACE Tmax XT2 and XT4 moulded case Ekip LSI and Ekip LSIG electronic trip units wee we ee ee we we ee we ee ee ee ee ee eee J tome Supervision DeviceNet Ekip LSIG Laesa sz Ekip Com 4333307 EP010 Be Profibus DP circuit breakers must be equipped with the motor ope rator with electronic interface MOE E see Annex F For information
53. supervision and remote control Emax air circuit breakers provided with the electronic trip unit type PR122 P or PR123 P to be interfaced with Modbus networks need the suitable communication module PR120 D M for the characteristics of the module see Annex C in order to e transmit the alarm signals of the protections the in formation about the circuit breaker e g state and position and the measures made available by the trip unit to a remote control system thus implementing supervision e receive from a remote supervision system the com PR122 P electronic trip unit mands e g opening and closing of the circuit breaker or the settings of the protection functions thus imple menting remote control To perform the remote control i e the mechanical implementation of the remote opening and closing commands the circuit breakers of Emax series to gether with PR120 D M communication module must be equipped also with the following accessories shunt opening release YO shunt closing release YC geared motor for the automatic charging of the clos ing springs M As regards bus communication remind that the auxil iary supply voltage Vaux is necessary for the trip units PR122 P and PR123 P for its technical characteristics see Annex B Measures The measures made available depend on the typology of the trip unit used and on the presence or not of the measuring module PR120 V The voltage measuring module
54. that moment phase currents IL1 maximum value IL2 maximum value IL3 maximum value IL1 minimum value IL2 minimum value IL3 minimum value current in the neutral INe maximum value INe minimum value in the presence of the neutral line to line voltages V12 maximum value V23 maximum value V31 maximum value V12 minimum value V23 minimum value V31 minimum value line to neutral voltages V1N maximum value V2N maximum value V3N maximum value VIN minimum value V2N minimum value V3N minimum value in the presence of the neutral frequency maximum value minimum value total active power Ptot maximum value Ptot minimum value and in the presence of the neutral the active power on the three lines P1 maximum value P2 maximum value P3 maximum value P1 minimum value P2 minimum value P3 minimum value total reactive power Qtot maximum value Qtot minimum value and in the presence of the neutral the reactive power on the three lines Q1 maximum value Q2 maximum value Q3 maximum value Q1 minimum value Q2 minimum value Q3 minimum value total apparent power Stot maximum value Stot minimum value and in the presence of the neutral the apparent power on the three lines S1 maximum value S2 maximum value S3 maximum value S1 minimum value S2 minimum value S3 minimum value Bus communication with ABB circuit breakers Alarms This window displays the alarm entries of the protect
55. the suitable 24 V DC auxiliary voltage kit to connect the electronic trip units type Ekip E LSIG Ekip LSI Ekip LSIG and Ekip M LRIU to HMI030 unit The 24 V DC auxiliary voltage kit is available in two versions one for the circuit breakers in fixed plug in version and one for the circuit breakers in withdrawable version Figure 22 24 V DC auxiliary voltage kit for circuit breakers in withdrawable version W3 24 V DC auxiliary voltage kit for CBs in withdrawable version UuOledIUNWWOS snq 104 uonnjos ggY p j Fixed part of JH2 connector Fixed part of JL2 connector Moving part of JH2 connector Moving part of JL2 connector Cable for the connection to the trip unit JL2 JH2 connectors for the auxiliary circuits of the circuit breakers in withdrawable versions Bus communication with ABB circuit breakers 35 UONLIIUNWIWOD snq 104 uonnjos ggY p 36 JL2 JH2 connectors of the 24 V E K2 K1 DC auxiliary voltage kit for CB in JH2 W4 TW3 withdrawable version X3 6 pin plug and socket adapter X3 K2 K1 W4 W3 on the back of the panel for the 24 V DC auxiliary voltage kit for CB in plug in version 24 V DC auxiliary voltage kit 24V Cable for the connection to the trip unit gt Ekip E LSIG Ekip LSI Ekip LSIG Ekip M LIRU This configuration can be achieved if HMI030 unit i
56. the supervision and control of electrical distribution plants This Technical Application Paper has the main purpose of introducing the reader to the basic concepts of communication networks and protocols dialogue between microprocessor based intelligent devices and describing the main functions of the electronic trip units which allow ABB circuit breakers to communicate via bus In particular this document is aimed at giving the essential information for the correct choice of the trip units of the communication modules of the acces sories and of the software necessary to integrate ABB circuit breakers in the supervision systems of electrical and technological installations e g manufacturing lines of industrial processes Bus communication with ABB circuit breakers This document is divided into five main parts introduction to digital communication and basic con cepts regarding communication protocols supervision of electrical distribution plants ABB solution for field bus communication Modbus RTU Profibus DP and DeviceNet and the rules for the arrangement of the Modbus RS 485 network front panel interface HMI030 solution to integrate ABB circuit breakers into the Ethernet networks with Modbus TCP protocol some application examples regarding ABB SACE circuit breakers used for the automated management of electrical distribution plants
57. Annex C For the air circuit breakers type Emax E1 E6 and Emax X1 and for Tmax T7 T7M moulded case circuit breakers there is only one version of EP010 unit which is compa tible with all the trip units PR122 P PR123 P PR332 P and PR333 P For information about the measures data and alarms pla ced at disposal by the trip units type PR122 P PR123 P PR332 P and PR333 P in the following configurations see Table A 4 of Annex A As regards the remote control operations which can be performed on the circuit breaker see Table A 4 of Annex A under the entry Commands All the commands from remote via bus can be blocked by setting the trip unit to local mode Bus communication with ABB circuit breakers 57 UONPOIUNWIWOD snq 104 uonnjos ggY p UOHeDIUNWWOD snq 104 uonnjos ggY i 58 Technical Application Papers Emax E1 E6 PR122 P PR123 P electronic trip units Supervision PR122 P E iii EP010 PR120 D M PR120 V PR122 P Profibus DP PR123 P i ma Emax X1 PR332 P PR333 P electronic trip units and Tmax T7 T7M PR332 P electronic trip units Supervision PR332 P SOR EP010 PR330 R SCR M PR330 D M PR330 V PR332 P ea S Profibus DP PR333 P For remote control with Tmax T7 the motorizable version type T7M is needed _ Bus communication with ABB circuit breakers 4 10 2 Moulded case circuit breakers Tmax T4 T5 T6 Profibus DP and DeviceNet supervisio
58. Auelixne 3 XNY 3 xeuuy plLx cLX XewL IOVS 10 10 e1 do 10 0W J JON 4 xouuy 106 Technical Application Papers ay Annex F MOE E motor operator for SACE Tmax XT2 XT4 The moulded case circuit breakers type SACE Tmax XT2 and XT4 can be controlled by a remote supervision system when equipped with MOE E stored energy motor operators The digital signals opening and closing commands are sent from the remote system to the Ekip Com module which transmits them to the electronic actuator unit of the MOE E This unit converts the digital signals into the power signals necessary for operating the motor operator to open and close the circuit breaker The auxiliary contacts Q 7 and SY 3 inform the Ekip Com module about the state open closed tripped of the circuit breaker thus Ekip Com will allow the commands coming from the remote system to be carried out only if they are compatible with the actual state of the circuit breaker for example a closing command will not be permitted if the circuit breaker is tripped Figure F 1 Wiring diagram with MOE E Q E B _ _ 7 7 _ _ 7 7 E _ 7 E 7 p T i NE tive Auxiliary contacts Q7 and SY 3 i a5 a8 ME REL 1 Q s xy wa Yes wa xy ws 32 wal WI i xy Kt kt gn x ke veo A WN f JF3 TI L1 XY w2 X65 sel 5 B k ae A ml 4 ET pee
59. CT for external neutral conductor Voltmeter mode V E1 E6 X1 T7 E2 E6 T4 T5 T6 XT2 XT4 PR122 P PR123 P PR12X DC PR223EF PR223DS Ekip E LSIG PR332 P PR333 P Phase voltages V Voy Vay a a a a a Residual voltage a a E Line to line voltages V V V3 a a a a Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 and in the presence of the neutral Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 Bus communication with ABB circuit breakers 29 UONLOIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers Wattmeter Mode W In this mode according to the trip unit connected it is possible to display the values of active power P reactive according to the trip unit connected also other informa tion such as power factor cos frequency f current peak factor active E P reactive E Q and apparent E S UONLOIUNWIWOD snq 104 uonnjos ggY p energy and the data relevant to the latest trip e g tripped protection and value of tripped current power Q and apparent power S total and phase Custom Mode A V W In this mode it is possible to display the values relevant to Amperometer Voltmeter and Wattmeter modes and Wattmeter mode W E1
60. E6 X1 T7 E2 E6 T4 T5 T6 XT2 XT4 PR122 P PR123 P PR12xX DC PR223DS Ekip E LSIG PR332 P PR333 P Phase active power P1 P2 P3 a a a Phase reactive power Q1 Q2 Q3 m E E Phase apparent power S1 S2 S3 a a a Total active power P E a E Total reactive power Q E a a Total apparent power S a a a Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 and in the presence of the neutral conductor Measures available in the presence of the measuring module PR120 V for Emax E1 E6 PR330 V for Emax X1 and Tmax T7 VM210 for Tmax T4 T5 T6 Custom mode A V W E1 E6 X1 17 PR121 P PR331 P_ PR122 P PR123 P PR332 P PR333 P Phase currents I I I a E a E E E E a a a E2 E6 PR12X DC T4 T5 T6 PR223EF XT2 XT4 Ekip LSIG LSI Ekip M LRIU PR222DS PD PR223DS Ekip E LSIG Neutral current lye a Measures history currents Phase voltages Vin VanVan Residual voltage Line to line voltages V V V Phase active powers P1 P2 P3 Phase reactive powers Q1 Q2 Q3 Phase apparent powers S1 S2 S3 Total active power P Total reactive power Q Total apparent power S Total power factor cos Frequency Phase peak factor Peak factor of the neutral Total active
61. IG or Ekip E LSIG PR120 D M or Ekip LSI Ekip Com L5 4 3 2 1 Figure 40 Reading of the currents on Ethernet TCP IP network Response IP address 5 6 7 8 4 tia IP address 1 2 3 4 1 Ethernet TCP IP network Gateway ee oe SD GEM Response 5 6 7 8 1 04 DATA o4 DATA Modbus serial line gt Tmax T4 Tmax T4 T5 Tmax T4 Emax E1 E6 SACE Tmax XT4 PR223EF PR223DS PD SD030DX PR122 o PR123 Ekip LSIG or Ekip E LSIG PR120 D M or Ekip LSI Ekip Com 5 4 3 2 an 5 6 7 8 IP address of the client which has sent the request and which receives the response 1 2 3 4 IP address of the server SD GEM receiving the request 1 Unit Identifier or Additional Address of the circuit breaker Tmax XT4 connected to a Modbus serial line 04 Function Code instructions for reading of currents run time values 100 number of register from which reading of currents starts 8 number of registers to be read from register 100 to register 107 to get the current values of the three phases and of the neutral DATA this field contains the values of the currents in the phases IL1 IL2 IL3 and in the neutral INe read by the circuit breaker Bus communication with ABB circuit breakers 75 SYIOMIOU _I dOL UYI Ul S49yYBOIG INIIID Gay G SIOMIOU dI dOL PUY U S1ayeO1g YINOWID JAY G 76 Technical Application Papers SD GE
62. M is a gateway which operates the conversion from Modbus TCP protocol to Modbus RTU protocol thus allowing ABB low voltage automatic circuit breakers with Modbus RTU communication interface to be inte grated into the supervision systems on Ethernet TCP IP networks with Modbus TCP protocol SD GEM gateway is equipped with 1 a standard serial port RS 485 for the connection to a Modbus serial line The field devices e g ABB circuit breakers with com munication interface which communicate through Modbus RTU protocol are connected to this serial port Such devices connected in a bus network must be com munication slaves that is to say they are only allowed to reply to the queries of the master and they cannot Bus communication with ABB circuit breakers transmit on their own initiative From the side RS 485 SD GEM operates as a Modbus RTU master see clause 4 7 1 Modbus RTU system functioning Maximum 31 devices can be connected to the serial port RS 485 2 an Ethernet port for the connection to Ethernet TCP IP networks via Modbus TCP protocol Thus SD GEM allows a client which communicates via a Modbus TCP protocol e g a PC or a SCADA connected to an Ethernet TCP IP network to exchange data with the devices connected to a Modbus serial line From a client e g a PC connected on an Ethernet TCP IP network it is possible to communicate with a remote slave on a Modbus serial line by specifying the IP ad
63. Racked in 1 Closed 1 Tripped 1 Local 1 T1 T2 T3 with 5 wire solenoid operating mechanism DI2 contact for the electrical signaling of tripped protection S51 DI3 contact for the electrical signaling of circuit breaker in racked in position 8751 1 DI4 CB auxiliary contacts Q 1 DI1 contact for the electrical signaling of circuit breaker tripped SY T4 T5 T6 T7 X1 E1 E6 DI1 limit contact for spring charging motor S33M 1 DI2 contact for the electrical signaling of tripped protection S51 Dl2 contact for the electrical signaling of circuit breaker open due to the tripping of the overcurrent trip unit S51 DI3 contact for the electrical signaling of circuit breaker in racked in position 8751 1 DI3 contact for the electrical signaling of circuit breaker in racked in position 8751 1 DI4 CB auxiliary contacts Q 1 DI4 CB auxiliary contacts Q 1 DI1 contact for the electrical signaling of circuit breaker tripped SY DI5 switching contact for electrical signaling of local remote selector state 83 1 DI5 switch for setting remote local control 843 Switch discon nector type T1D T3D with 5 wire solenoid operating mechanism DI3 contact for the electrical signaling of circuit breaker in racked in position 8751 1 DI4 CB auxiliary contacts Q 1 T4D T5D T6D DI3 contact for the electrical signa
64. V 2 A for 5 ms gt Rated current 24 V 130 mA 40 mA Rated power 24 V 3 W 1W Bus communication with ABB circuit breakers PR330 R actuator module Emax X1 and Tmax T7 circuit breakers can operate open ing and closing commands from remote control when together with PR330 D M communication module they are equipped with PR330 R actuator module too This device allows such commands to be carried out through the internal contacts K51 SCR to command the shunt closing release SCR and K51 SOR to command the shunt opening release SOR See Figure C 3 Connection to Modbus network PR332 P and PR333 P trip units are connected to the Modbus network through PR3830 D M communication module according to the diagram in the figure C 3 Figure C 3 Wiring diagram for the connection of PR33X P to the Modbus network through PR330 D M module Auxiliary power A B t o Sg te supply Vaux EIA RS 485 interface for Modbus network OS aS SS SSS SS a SSS SS 24V K1 K2 wi 1 W2 C13 1 C12 C3 f C2 CB terminal box Ki K2 Wis We C13 C12 C3 02 or sliding contacts SOR SCR i 4 K51 SOR K51 SCR PR330 R PR330 D M J PR332 P PR333 P Q 1 6 33M 1 3 S751 1 7 7 Note W1 W2 terminals for the connection of the Modbus cable
65. XC5 6 pin plug and socket connector on rear of panel for the auxiliary circuits of the circuit breaker in plug in version It is up to customer wiring of cables W1 W2 K1 and K2 to XC5 connector choice and wiring of the auxiliary terminals of the communication cable Modbus RS485 and of the auxiliary supply The coupling between the socket fixed part of the 6 pin connector and the corresponding plug moving part accomplishes the continuity of wiring for the connection of the trip unit to the Modbus network Connection to EP010 unit SACE Tmax XT2 and XT4 moulded case circuit breakers equipped with electronic trip units type Ekip LSI and Ekip LSIG are connected to EP010 unit through the cables W1 and W2 coming out of Ekip Com module installed in the circuit breaker with circuit breaker in fixed version the cables W1 and W2 coming out of the fixed part the socket of JF3 connector housed in the fixed part of the circuit breaker with circuit breaker in withdrawable version the cables coming from the terminals 1 for W1 and 2 for W2 of the fixed part the socket of the 6 pin plug and socket connector on rear of panel with circuit breaker in plug in version The connection between the communication cables terminals W1 and W2 of Ekip electronic trip units and the terminals Modbus L left and 1 right of EP010 unit must be carried out as shown in the following table Modbus communication c
66. a consequence with each EP010 unit the suitable connector FBP FieldBusPlug must be used in particular for each circuit breaker to be integrated into the fieldbus the following items are needed EP010 unit one PDP22 FBP connector for fieldbus Profibus DP or EP010 unit one DNP21 FBP connector for fieldbus DeviceNet The connection of the circuit breakers to the fieldbus is achieved as shown in the figure Trip unit Note as regards the connection between EP010 and trip unit see Figure C 2 in Annex C Nex HN Lom circuit breaker The same communication system is used with other ABB products such as PLC motor starters universal motor controllers softstarters and position sensors Therefore it is possible to use circuit breakers in industrial automation systems for the most different applications thus combining the control of a process with the control of the electrical distribution plant which supplies it Connections to EP010 unit PE earth terminal Female connector for FBP connector Modbus port terminals L and 1 for the connection with the Modbus communication terminals A and B of the trip unit of the communication module As regards the communication between the electronic trip unit and EP010 unit the connection between the Modbus terminals A and B of the trip unit of the communication module and the Modbus terminals L left
67. ables terminals of the trip unit W1 A W2 B Modbus EP010 terminals L left 1 right It is up to the customer to connect the trip unit with EP010 and to connect the field bus through the suitable connector FBP FieldBusPlug Figure C 13 Connection to the Modbus network of SACE Tmax XT2 and XT4 circuit breakers in plug in version Cable w1 w2 K1 K2 Trip unit Cable for the Connector for dialogue with the dialogue with nto up Ul Ekip Com Terminal Modbus RS485 network Auxiliary power supply Vaux Auxiliary terminals 1 2 3 4 Auxiliary terminals It is up to the customer wiring of the cables W1 W2 K1 and K2 co ming out from the circuit breaker to the 6 pin plug and socket connector XC5 connector wiring of the cables from the 6 pin connector to the auxiliary terminals choice and wiring of the auxiliary terminals of the auxiliary supply and of Modbus RS485 communication cable Fixed part Moving part Bus communication with ABB circuit breakers 101 5 xeuuy s jnpow UONBOIUNWILOD OY s jnpow Bunnse w y q xouuy 102 Technical Application Papers Annex D The measuring modules Emax air circuit breakers E1 to E6 with PR120 V measuring module and X1 air circuit breaker and Tmax T7 moulded case circuit breaker with PR330 V measuring module The measuring module has the main function of measur ing and proce
68. ad or memory spaces in which to write This representative model is the same as in the traditional Modbus protocol whose data are registers which can be either read or written The client is the device wishing to read or write the data to do it it sends a request telegram to which the server replies with a response telegram The structure of the telegram is the same as in the tra ditional Modbus both as regards length and codifica tion the request of reading consists of a command indi cated in the Function Code specifying the type of action to be performed e g reading of the data fol lowed by the address of the register or registers to be read the information are included in the field Data of the telegram the request of writing comprises command indicated in the Function Code address and data to be written included in the field Data the response telegrams to indicate that the command has been successfully completed repeat the command if necessary followed by the required data instead if the command cannot be carried out they include an error code exception response The data format is the same as in traditional Modbus and also the codes Function Code used to indicate the reading and or writing functions and the errors exception response code are the same This allows system devel opers to reuse a large part of the code already written in order to implement traditiona
69. ain number of data bits e g 8 3 Flow control method of controlling the flow of information Handshaking exchange of pre established signals between two devices so that a correct communication is achieved Thanks to this signal exchange the devices inform that they have some data to transmit or that they are ready to receive data an optional parity bit used to detect whether among the transmitted bits there is a wrong one in positive case the whole character is considered not valid and discarded The parity bit if used can be configured in even or odd mode one or more stop bits to signal the end of the transmission All the listed bits have the same length the configuration of the serial interface is such as to transmit a definite number of bits per second bps or baud The transmission speeds are standardized and by tradition multiples of 300 bits per second are used For instance a device could transmit at 9600 19200 or 38400 bauds that is bits per second For a correct communication it is necessary that the two devices use the same settings baud rate data transmis sion speed number of data bits start bits and stop bits presence or not of the parity bit and if used the mode even or odd If this does not occur no character is recognized correctly and consequently the transmission of data is impos si
70. all carry out or not the opening closing and reset commands it receives by the supervision system In this way the trip unit consents only to the actuation of the commands which are compatible with the real state of the circuit breaker for instance it shall not consent to a closing command when the circuit breaker is in the tripped state Tmax T4 T5 Tmax T6 Nominal voltage Un AC DC AC DC 24 M 24 M 48 60 V 48 60 V 110 125 V 110 125 M 110 125 M 110 125 V 220 250 V 220 250 V 220 250 V 220250 V 380 V 380 V Operating voltage Umin 85 Un Umin 85 Un Umax 110 Un Umax 110 Un Power absorbed on inrush Ps AC DC AC DC lt 300 VA lt 300 W lt 400 VA lt 400 W Power absorbed during normal operation Pc AC DC AC DC lt 150 VA lt 150 W lt 150 VA lt 150 W Operating frequency 50 60 Hz 50 60 Hz Switching time opening 1 5 s opening 3 s closing lt 0 1 s closing lt 0 1 s reset 3 s reset 5 s Mechanical life 20000 operations 10000 operations Minimum duration of electrical command 150 ms 150 ms Total time from transmission of impulse to circuit breaker opening Figure E 3 Operating principle of MOE E and AUX E modules Circuit breaker AUX E Trip unit Bus communication with ABB circuit breakers 105 MOE E 91 GL pL Xew 10 10 2e13do 10 0W 3 JOWN pue sppey uoo
71. allocating the energy costs associated to the industrial process under control Besides thanks to the information included in the circuit breakers it is possible for example to keep under control the electrical energy distribution system and guarantee the optimum operation of the industrial process it supplies to verify that the main electrical quantities are in the range of the relevant rated values and that the plant works properly In this way it is possible to control that the electrical supply has a good quality level to control the alarm signals of the circuit breakers in order to prevent situations of anomalous operation faults and the consequent tripping of the protections with the aim of reducing to a minimum inefficiencies and down times to have dedicated information about the fault causes in a definite section of the electrical plants For instance such causes can be determined by storing and ana lyzing the phase currents e g trip due to a 12356 A short circuit on the phase L2 on 04 28 2006 at 12 25 With this type of information a statistical survey of the occurred abnormal conditions is possible thus allowing a statistical study on the fault causes to know the diagnostics data of the protection devices e g percentage of contact wear in order to schedule preventive maintenance compatible with the working cycle of the supplied process so as to limit to a mini mum the downtimes and guarantee service con
72. am a E wt 4d 4 4 N I 6543214 a 5 VM210 sai 7 8 9 10 The output signals on terminals 3 4 5 and 6 of VM210 associated with the system voltages are brought as yoy Connection tabl input to the trip unit through the terminals 5 6 7 and 8 Terminal Signal Terminal Signal of the dedicated X4 connector according to the wiring Input 1 Vaux Output 3 COMM i H 2 Vaux 4 Vout1 diagram of Figure D 4 Sa N 5 Veut In order to operate VM210 shall be supplied through z 6 Vout3 the terminals 1 and 2 with an auxiliary power supply of o B3 24V dc having the following characteristics Connections between VM210 and circuit breaker trip unit terminals 3 to 6 maximum length of cable 15m twisted multicore cable Supply voltage 24 Vdc 20 shielded with shield earthed on one side of the connection cross sec Maximum ripple 5 tional area 0 2 2 5 mm2 22 14 AWG terminals 1 2 and 7 to 10 maximum length of cable 15m cross sectional Rated power 24 V 3 5W area 0 2 2 5 mm2 22 14 AWG Maximum number of PR223DS PR223EF which can be connected to a single VM210 5 Figure D 5 Connection of VM210 module to X4 connector Modbus Cable gt Auxiliary power supply Vaux Bus communication with ABB circuit breakers 103 d xeuuy sojnpow Bulunseow yL J xouuy 91 GL yL XBW 10 10 e19d0 10 0W 3 JOW pue s pezuoo Aselixne 4 xnyv 104 H Technical Application Papers ry Annex E AUX E auxilia
73. and check that all the packets have arrived in case some packet has got lost the recipient shall ask the sender to transmit it again once the correct and complete reception has been verified the two computers exchange some packets indicating that the operation has been completed and the logical connection closed As it can be seen whereas the IP protocol relates to routing and delivery of a single data packet the TCP pro tocol is intended for the use of data packets to transmit the quantities of data required and restore the received data These two protocols are commonly used together and as a matter of fact TCP IP is often referred to as a single protocol The possibility of using TCP IP based protocols is one of the factors which contributed to the spreading of industrial Ethernet technology for example for the automation of production systems or for the control of electrical systems for the generation distribution and management of electrical energy Bus communication with ABB circuit breakers 5 2 Ethernet industrial protocols When wishing to use Ethernet as communication medium for industrial control it is necessary to specify in details what protocols are employed In fact Ethernet can be used for many different applications each of them having a well defined set of protocols Indicating that TCP IP is used which actually occurs in the most cases does not complete the picture In fact as previously mentioned
74. and 1 right of EP010 must be made as shown in the following table Modbus communication terminals of the Modbus terminals EP010 trip unit of the communication module L left A W1 1 right B W2 The Modbus cable which connects EP010 to the trip unit shall have the maximum length of 1 m The PE terminal of EP010 unit must be earthed The power supply at 24 V dc for EP010 unit is delivered through the FBP connector which provides also bus communication The trip unit connected to EP010 shall be supplied by an auxiliary voltage Vaux at 24 V dc for the electrical characteristics see Annex B NOTE For further information see the following documents Modbus FBP Interface User and Operator Manual document code 1SDH000510R0001 Modbus FBP interface Annex for PR223EF User and Operator Manual document code 1SDH000663R0001 4 10 1 Emax air circuit breakers E1 E6 Emax X1 air circuit breakers and Tmax T7 T7M moulded case circuit breakers Profibus DP and DeviceNet supervision and remote control Emax air circuit breakers equipped with the electronic trip units PR122 P or PR123 P are connected to EP010 unit through PR120 D M communication module as shown in Annex C Emax X1 air circuit breakers equipped with PR332 P or PR333 P electronic trip units and Tmax T7 or T7M moulded case circuit breakers equipped with PR332 P trip unit are connected to EP010 through PR330 D M communication module as shown in
75. and phase power active P reactive Q apparent S Total power factor Total energy active reactive apparent State information Circuit breaker state open closed tripped Mode local remote Protection parameters set Maintenance data Total number of operations Total number of trips Number of test trips Number of manual operations Number of trips separated according to the protection functions L S I G Number of trips separated according to the protection functions EF SOS Data records of the last n trips DS O De Oo Protections alarms Protection trip Protection L S G timing and trip Protection EF SOS trip Diagnostic alarms Trip command failed MOE E overheating Trip coil disconnected or damaged Commands Circuit breaker opening closing with MOE E Alarms reset Circuit breaker reset with MOE E Setting of protection curves and thresholds Events State changes of CB of protections and of all alarms For further information about the electric quantities the data and the alarms available re Instruction manual PR223EF Modbus System Interface document code 1SDHO00566R0001 Instruction manual PR223DS Modbus System Interface document code 1SDH000658R0001 Instruction manual PR222DS PD Modbus System Interface document code 1SDHOO00600R0001 Bus communica
76. ansmitted through the serial output RS845 with Modbus RTU protocol The figure below shows the front panel temperature control unit TMD T4 96 The main technical characteristics of TMD T4 96 tem perature control units are summarized in the following table Auxiliary supply V 20 250 15 Power consumption VA 4 Measuring inputs PT100 RTD Measuring range C 0 4220 2 C Trip delay hysteresis 5 2 s C Measurement display 7 segments LED Outputs 1 to 12 V d c 3 NO CO NC relays 8 A resistive load Outlet functions alarm trip ventilation self diagnosis Programmable functions ALARM TRIP HOLD FAN T MAX Communication parameters Protocol Modbus RTU Physical interface RS 485 Baud rate 2400 bps 4800 bps 9600 bps 19200 bps Parity Odd Even None Address Standards 1 247 IEC EN 50081 2 IEC EN 50082 2 IEC 14 1 IEC EN 60255 NOTE For more detailed information see the technical catalogue System pro M compact Bus communication with ABB circuit breakers 63 UONPOIUNWIWOD snq 104 uonnjos ggY p UOHeDIUNWWOS snq 104 uonnjos ggY p 64 echnical Application Papers ry 4 11 4 Electronic energy meters The wide range of ABB modular energy meters for measuring energy is shown in the table below For a description of the specific technical characteristics of every single device reference has to be mad
77. are in parallel the same communication cable Among multipoint systems particular importance have those with bus connection where a main cable backbone without stubs or with very short stubs connects in parallel all the concerned devices Backbone The physical layer interfaces mostly used in industrial networks are RS 232 for point to point connections and RS 485 for multipoint connections Bus communication with ABB circuit breakers 5 UuO ILESIUNWIWIODS je1big A uo esviunwwo jebad Z 6 2 1 1 1 RS 232 and RS 485 interface When speaking of physical layer we have The RS 232 interface which is so common in personal computers to be known as serial port is an asynchro nous point to point serial communication system allow ing full duplex operation Figure 9 RS 232 9 pin serial connector Here is an easy description of its features serial means that the bits are transmitted one after the other asynchronous means that each device can send only one character or byte separated by long or short intervals of time as needed point to point means that only two devices can be interconnected according to this mode When using the RS 232 interface to connect more than two devices each pair shall have at its disposal an independent channel with two dedicated ports Figure 11 Point to point connection between two PCs
78. ation interface allow the elec trical quantities of the plant to be monitored by sending to the supervision and control system the measures they make available In particular the electronic trip units Ekip LSI Ekip LSIG and Ekip M LRIU are able to measure the current values currents in the three phases in the neutral and to earth Ekip E LSIG electronic trip units for SACE Tmax XT4 circuit breakers put at disposal in addition to the current values also the main electrical parameters of the plant such as voltages line to line and line to neutral power energy to optimize consumption as well as their alloca tion frequency and harmonic distortion rate THD and spectrum to control the quality of the energy All the electrical quantities are measured by the Ekip E LSIG without any help from external measuring modu les The measured electrical quantities are stored in the trip unit with the possibility of being transmitted to the control system for the supervision of the electrical plant The main data alarms and measures put to disposal by each trip unit are summarized in Table A 3 of Annex A All the commands from remote control via bus can be blocked by setting the trip unit to local mode Electronic trip units Ekip E LSIG Ekip LSIG Ekip LSI and Ekip M LRIU Ekip E LSIG LSIG LSI M LRIU Ekip Com communication module MOE E motor operator iL Nee G4 Srar Geter i EdpeLsi0 D TestPro SSF hittin etti n
79. ble For instance in the bit frame of Figure 13 it is possible to identify 1 start bit 8 bits 60 67 constituting the character the trans mitted data 1 stop bit Figure 13 8 bit character 1 acct I Start Stop 0 e bO bi b2 b3 b4 b5 b6 b7 The RS 485 interface differs from RS 232 in the electri cal and connection characteristics Its main advantages are the possibility of implementing multidrop commu nication links that is between more than two devices see Figure 14 and the best immunity from electrical disturbances Figure 14 Multidrop system with bus connection on RS 485 Terminal resistor Data Data These features make of RS 485 the most used interface in industrial environment from the first versions of Mod bus in the Sixties to the more modern Modbus RTU Profibus DP DeviceNet CANopen and As Interface With RS 485 all the devices are connected in parallel on a single bus constituted by two connections called Data and Data or A and B or also Data1 and Data2 according to the different manufacturers of devices The used signals are differential that is the bits are re presented by the voltage difference between Data and Data The conductors are twisted and kept near one to the other so that the electrical disturbances affect them with equal intensity and the voltage difference is altered as less as possible When a device is not transmitting it prepares for re
80. ble to connect up to two HMI030 units on which two different ope rating modes have been selected Ammeter A and Custom A V W In this configuration to manage the information exchange between the trip unit and HMI030 interface devices MMO030 unit must be used MMO030 is a microprocessor based device provided with two different communication buses one Local bus W2 for the connection and communication with the trip unit via the System bus W1 of the trip unit one Accessory bus W3 for the connection and communication with HMIO30 units In this way MMO30 receives the data from the trip unit via the bus W2 and sends it to the visualization units HMIO030 connected to it via the bus W3 so that it is possible to display on the panel front the measured electrical quantities For more detailed information see the product technical manual Flex interfaces for accessory Bus document code 1SDH000622R0001 Bus communication with ABB circuit breakers 33 UOledIUNWIWOD snq 104 uonnjos ggY p UONLOIUNWIWOD snq 104 uonnjos ggY p 34 Technical Application Papers Moulded case circuit breakers type SACE Tmax XT2 XT4 With the moulded case circuit breakers series SACE Tmax XT2 and XT4 equipped with Ekip E LSIG Ekip LSI Ekip LSIG and Ekip M LIRU electronic trip units are possible with the two following configurations Remote supervision and display on panel front Remote supervision s
81. bus RTU on RS 485 can be connected to SD GEM gateway In particular regarding ABB automatic circuit breakers the following devices can be connected Device Trip unit Circuit breakers Ekip E LSIG Ekip Com communication SACE Tmax XT2 XT4 module Ekip LSIG Ekip Com communication module Ekip LSI Ekip Com communication module Ekip M LRIU Ekip Com communica tion module Circuit breakers PR222DS PD Tmax T4 T5 and T6 PR223DS PR223EF Circuit breakers PR332 P communication module Tmax T7 Emax X1 PR330 D M PR333 P communication module PR330 D M Circuit breakers PR122 P communication module Emax E1 E6 PR120 D M PR123 P communication module PR120 D M Circuit breakers PR122 DC communication module Emax DC PR120 D M PR123 DC communication module PR120 D M Circuit breakers PR122 VF communication module Emax E2 VF E3 VF PR120 D M Flex interface SDO30DX Thermomagnetic or basic electronic trip unit for details see clause 4 5 Since SD GEM carries out a generic protocol conversion in addition to automatic circuit breakers it is possible to connect to RS 485 port also any other device which implements Modbus RTU protocol provided that it ope rates with the same parameters of the serial port baud rate number of bits parity bit stop bit see clause 4 7 1 and Annex G For the communication on Ethernet TCP IP networks please remember that it is necessary to supply the trip units with 24 V DC auxiliary vol
82. ce for Protection relays PR122 P and PR123 P communication module PR120 D M mounted on CB New Emax Protection relays PR332 P and PR333 P communication module PR330 D M mounted on CB Emax X1 Tmax T7 and Tmax T8 document code 1SDH000556R0001 Emax DC PR122DC PR123DC PR120 D M Modbus System Interface document code 1SDH000841R0001 Emax VF PR122 VF PR120 D M Modbus System Interface document code 1SDH000922R0001 Bus communication with ABB circuit breakers 42 Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers Modbus communication supervision and remote control To be interfaced with Modbus networks Emax X1 air circuit breakers equipped with the electronic trip unit type PR332 P or PR333 P and Tmax T7 moulded case circuit breakers provided with PR332 P electronic trip unit need the suitable communication module PR330 D M for the characteristics of the module see Annex C in order to e transmit the alarm signals of the protections the information about the circuit breaker e g state and position and the measures made available by the trip unit to a remote control system thus implementing supervision e receive from a remote supervision system the set tings of the protection functions or the commands e g opening and closing of the circuit breaker thus implementing remote control The circuit breakers Emax X1 and Tmax T7 in motoriz able version T7M can be controlled from remote Tmax T7
83. cep tion showing a high impedance on the communication port The Standard RS 485 EIA TIA 485 sets some limits on the input impedance and defines some requi rements for the current power that each device shall be able to transfer on the line when it conveys data In particular in compliance with the prescriptions of the reference Standard a correct data transmission is pos sible if at the most 31 devices in reception mode are connected on the line As a consequence in compliance with the Standard prescriptions RS 485 guarantees that the communication can be carried out correctly with maximum 32 devices linked to the bus and that in each communication cycle one device is in transmission mode and the other 31 are in reception mode In fact since all the devices are connected in parallel ona single bus only one of them can transmit at a time other wise the signals overlap thus becoming unrecognizable The interface RS 485 does not include any mechanism aimed at defining which device has the permission to transmit this task is demanded to the higher layers of the protocol used The structure of each transmitted character its duration and the possibility of transmission configuration are the same as previously seen for the serial interface RS 232 for instance there can be a data transfer set at a speed of 19200 baud with 1 start bit 1 stop bit and 1 parity bit used e g in even mode All the devices
84. communicate with the supervision system PC PLC or SCAD A Characteristics of the auxilary voltage SDO30DX the Vaux auxiliary supply Supply voltage 24 V dc 20 Maximum ripple 5 Rated power 24 V 2W Figure 21 Wiring diagram of SDO30DX for a CB type Emax E6 EIA RS485 AUXILIARY CHARGED PROTECTION cB cB REMOTE LOCAL cB cB cB SPRING CHARGING INTERFACE SUPPLY SPRINGS TRIPPED RACKED IN CLOSED MODE OPENING CLOSING RESET MOTOR fav n A fg 8 ee A10 ae ma E iaa H x37 x Pos T xfs 1 Xxve37 Xv 698 XF 104 xwe o i ieg x 1 S33M 2 s51 sii an saa PBS 3 1 F w y 1 xvess Xv 95 i oh i fa i X38 X 995 xh i pro t 9 9 Lae XV C11 wio wim XV U1 SD030DX 2 28 Bus communication with ABB circuit breakers 4 6 Front panel interface HMI030 HMI030 is the visualization unit to be installed on the panel front for air circuit breakers series Emax and Emax X1 for moulded case circuit breakers Tmax T and SACE Tmax XT equipped with the following electronic trip units Circuit breakers Trip units Emax E1 E6 PR121 P PR122 P PR123 P PR122 DC0 PR123 DC Emax X1 PR331 P PR332 P PR333 P Tmax T7 PR331 P PR332 P Tmax T4 T5 T6 PR222DS PD PR223DS PR223EF Ekip LSI Ekip LSIG Ekip E LSIG Ekip M LRIU SACE Tmax XT2 XT40 use HMI030 with 3 00 or following SW version It is a
85. cur rent values it sends to the circuit breaker a message containing the numbers of the registers where the requested data shall be read the measured quantities are associated to the register number in the example the registers from no 30101 to 30104 are given which contain the current values the type of operation to be performed e g reading the values contained in the register The slave unit in this specific case the circuit breaker an swers by sending the requested values to the master Then such values are shown to the operator in a format which can be understood through the user interfaces of the software and of the supervision application programs which facilitate the presentation of the information and of the data from the controlled process For further information about the structure of the Modbus logical map of the ABB trip units equipped with communication interface reference must be made to the following docu ments Modbus System Interface for protection relays PR122 P and PR123 P communication module PR120 D M mounted on CB New Emax Protection relays PR332 P and PR333 P communication module PR330 D M mounted on CB Emax X1 Tmax T7 and Tmax T8 document code 1SDH000556R0001 Emax DC PR122DC PR123DC PR120 D M Modbus System Interface document code 1SDH000841R0001 Emax VF PR122 VF PR120 D M Modbus System Interface document code 1SDH000922R0001 Instruction manual PR223EF Modbus
86. dress assigned to SD GEM and the address Unit Identifier or Additional Address of the remote slave to be queried As described in clause 5 4 SD GEM converts the Mod bus TCP messages coming from a client into Modbus RTU messages and deliver them through its serial port RS 485 to the devices connected to the Modbus net work in particular to the device which has received the query by the PC The queried device sends a response to SD GEM through a Modbus RTU message once the response has been received SD GEM converts it from Modbus RTU to Modbus TCP and sends it via Ethernet to the client which has sent the query 10 Gateways are appliances used to connect different devices over a network They have their own microprocessor and process memory to manage the conversions of different communication protocols A gateway is an interface able to couple data transmission systems of different type e g an Ethernet TCP IP Network with a Modbus RS485 serial Line A gateway usually needs hardware support for the connection to both systems and a software for the conversion of the messages Figure 41 SD GEM in Ethernet TCP IP network Ethernet TCP IP network Modbus RS 485 SD GEM Ethernet port a es RS 485 port Tmax T4 Tmax T4 T5 Tmax T4 Emax E1 E6 SACE Tmax XT4 PR223EF PR223DS PD SD030DX PR122 0 PR123 Ekip LSIG or Ekip E LSIG PR120 D M or Ekip LSI Ekip Com The devices equipped with interface Mod
87. e multipoint data transmission networks long distance serial links galvanic separation of peripherals extension of RS 485 lines The main technical characteristics of CUS converters are summarized in the following table 230 V a c 20 Frequency Hz 50 60 Power consumption VA 7 max Power loss W 3 5 RS232 Connection Sub D 9 female poles DB9 Max RS232 line length m 15 Max RS485 422 line length m 1200 Connection of multidrop units Max 32 NOTE For more detailed information see the technical catalogue System pro M compact Bus communication with ABB circuit breakers 5 ABB circuit breakers in Ethernet TCP IP networks 5 1 Ethernet Nowadays Ethernet is the dominant technology in local networks for example those used in offices to intercon nect personal computers However Ethernet applications are extending to other areas such as telephony and industrial control The name Ethernet was used for the first time in 1970 to indicate a communication protocol via radio among different computers All the connected devices shared the same transmission and reception channel Then a very simple mechanism was devised which allowed each device to transmit whenever necessary without the presence of an arbi trator master or central controller Then the same mechanism was used to implement Ethernet networks like the present ones which connect computers via cable
88. e S z o of j Lenses Sor Ait Ta Limas Sr BAREA a ddddd Pere eretes ald be OOs eaa ed ait Amr jU iza Through Ekip Com communication module it is possible to integrate the following equipment into the supervision systems SACE Tmax XT2 and XT4 circuit breakers with electro nic trip units Ekip LS I Ekip I Ekip M LIU Ekip G LS I and Ekip N LS I without Modbus communication and the circuit breakers with thermomagnetic trip units TMA TMD TMG which can be used also for applica tions in continuous current SACE Tmax XT4D switch disconnectors With this configuration it is possible to Ekip Com MOE E acquire from remote the circuit breaker state open closed tripped or the switch disconnector state open closed send from remote opening closing commands to the circuit breaker switch disconnector and reset com mands to the circuit breaker only if the circuit breaker switch disconnector are equipped with MOE E motor operator with electronic interface see Annex F Also in this configuration the module Ekip Com must be supplied with 24 V DC auxiliary supply Vaux for the technical characteristics see Annex B Bus communication with ABB circuit breakers 23 UOledIUNWIWOD snq 104 uonnjos ggY p j UONeDIUNWWOD snq 104 uonnjos ggY H 24 r att Technical Application Papers Circuit breakers with TMA TMD thermomagnetic trip units Ekip electronic trip units wit
89. e also the contact signaling spring charged and the contact signaling CB in racked in out position are supplied Bus communication with ABB circuit breakers 15 UOHedIUNWWOS snq 104 uonnjos ggY p p UONPIIUNWIWOD snq 104 uonnjos ggY p 16 Technical Application Papers PR122 DC and PR123 DC electronic trip units for direct current applications LV circuit breakers type E2 E3 E4 and E6 of SACE series Emax DC for direct current applications equipped with electronic trip unit type PR122 DC or PR123 DC can be integrated into the communication systems with the Mod bus RTU field bus for the supervision and control of direct current installations with voltages up to 1000Vd c PR120 D M communication module must be used for the connection to the Modbus network see Annex PR120 V measuring module is installed by default inside PR122 DC and PR123 DC trip units To implement from a remote supervision system open ing and closing commands on the circuit breakers series SACE Emax DC the following accessories are necessary the same ones used for the remote control of standard Emax circuit breakers for alternating current applica tions shunt opening release YO shunt closing release YC geared motor for the automatic charging of the closing springs M As regards bus communication please note that the trip units PR122 DC and PR123 DC must be supplied with an auxiliary supply voltage of 24 V DC for it
90. e communication network Modbus RS 485 in order to identify all connected devices and to detect any possible error of connection or of setting of the com munication parameters e g address baud rate parity check 2 interact in real time with the following devices Device Circuit breaker SACE Tmax XT2 XT4 Trip unit Ekip LSI Ekip Com communication module Ekip LSIG Ekip Com communication module Ekip M LRIU Ekip Com communication module Ekip E LSIG Ekip Com communication module PR222DS PD PR223DS PR223EF PR332 P PR330 D M communication module PR333 P PR330 D M communication module PR122 P PR120 D M communication module PR123 P PR120 D M communication module PR122 DC PR120 D M communication module PR123 DC PR120 D M communication module PR122 VF PR120 D M communication module Thermal magnetic or basic electronic trip units for further details see clause 4 5 Tmax T4 T6 Tmax T7 Emax X1 New Emax E1 E6 Emax DC Emax E2 VF E3 VF Flex interface SDO030DX with the purpose of reading the information alarms measures parameters and state present in the circuit breakers modifying the configuration and protection parameters thresholds and trip times of the protections set sending commands e g opening and closing to the circuit breakers Ekip Connect is particularly useful for the commissioning configuration monitoring maintenance and test
91. e 24 shows some examples of wrong bus connection Oca Figure 24 Examples of wrong bus connection kK X Bus communication with ABB circuit breakers 41 UOHPOIUNWWOD snq 104 uonnjos ggY p UOleDIUNWWOD Snq 104 uonnjos ggY Technical Application Papers mY 3 Maximum distance and maximum number of devices The main bus shall have a total maximum length of 700 m This distance does not include the stubs which however must be short The maximum number of devices which can be con nected to the main bus is 32 Master included 4 Use of repeaters In order to increase the extension of the Modbus net work repeaters can be used They are devices which amplify and regenerate the signals and have two com munication ports transferring signals from one port to the other one When using a repeater the main cable is divided into different segments each of which can reach a length of 700 m and connect up to 32 devices this number includes the repeaters The maximum number of repeaters which is advisable to connect in series is 3 A larger number may cause excessive delays in the communication system 5 Type of cable to be used The cable to be used is a shielded twisted pair cable type for telephone ABB SACE recommends a cable type Belden 3105A but it is possible to use also other cables with equivalent characteristics The pair cable is formed by two insulated conductors twisted together This h
92. e flow which runs on the bus Master i xe is E fe O ACB ACB Slave Slave Slave Bus communication with ABB circuit breakers 11 s uejd uonnquys p 2911 99 2 JO UOISIAJOdNS s uejd UO NL SIP BO1 D9 9 JO UOISIAJOdNS Technical Application Papers 3 1 Supervision with ABB SACE circuit breakers In the field of energy distribution communication and dialogue between protection devices are made possible by the microprocessor based trip units equipped with the Modbus communication interface The use of these trip units allows ABB SACE circuit breakers to exchange data with other electronic devices through a communication bus and to interact with the supervision systems for the computer based management of low voltage electrical installations integrate the management of the electrical distribution plant with the automation systems of a whole factory or industrial process for instance integrate the informa tion currents voltages and powers coming from the circuit breakers which protect the motors the auxiliary circuits and the supply line of the electrical furnaces of a steelworks with the information and the data relevant to the physical quantities e g pressure and temperature involved in the management of the whole process In this way the circuit breaker equipped with Modbus interface besides carrying out the classic function of protecting the plant agains
93. e network a server which automatically assigns a free IP address to each device which is connecting to the network in which case we speak of dynamic IP address The mechanism of such automatic assignment is described in the DHCP protocol Dynamic Host Configuration Protocol of ad dresses which we do not need to analyze thoroughly now and which is not the subject of this document The main difference between the two types of address is that in case of static IP the address is usually stored in a permanent memory and therefore it does not change if the device is switched off and then switched on or disconnected from and then reconnected to the network But in case of dynamic assignment a new device or a device which reconnects after a disconnection may be assigned any of the free available IP addresses As a consequence after any shutdown or disconnection the IP address of a device may change Industrial control systems usually require that each device has a defined address consequently static assignment of the IP address is largely the most used system 5 1 2 TCP protocol The TCP protocol Transmission Control Protocol has the task to control data transmission each communication e g sets of data files or Web pages exchanged be tween two devices is divided into parts of similar length named packets and each packet is separately sent over the network to the destination device Thanks to the TCP protocol the recipient is
94. e to the catalogue System pro M compact The energy meters can be profitably used in both resi dential tertiary and industrial environments ABB meters are approved and certified in compliance with MID European Directive Measuring Instruments Directive and can be installed in environments where energy must be measured for fiscal purposes A typical example of the first case is offered by shop ping centers where local energy consumption can be measured a record of the history of consumption can be created the building can be managed remotely and integrated in a supervision system provided with Modbus RTU protocol Meters are offered with inbuilt communication EQ meters Ax range or with a separate communication adapter via the IR interface A rey EQ meters C11 ODINsingle DELTAsingle EQ meters A41 EQ meters A42 Overall dimensions 1 DIN module 2 DIN modules 4 DIN modules 4 DIN modules 4 DIN modules Display LCD Backlit LCD LCD Backlit Pixel LCD Operating voltage 230 V AC 230 V AC 230 V AC 57 288 V AC Frequency 50 60 Hz 50 60 16 7 Hz Max current 40A 65A 80A 80A CTVT connected CTVT NOTE For more detailed information see the technical catalogue System pro M compact Bus communication with ABB circuit breakers The figure below shows the coupling between energy meter and Modbus adapter Energy meter Modbus adapter NOTE For more detailed information see the technical catalogue
95. e trip unit display the history data relevant to the last trips of the trip unit display the event history and measures stored by the trip unit Moreover through the graphic displays it is possible send opening and closing commands to the circuit breaker send CB reset command this command which is avai lable for the moulded case circuit breakers with motor operator switches the circuit breaker from tripped to open position send trip unit reset commands to reset the signals associated with the latest trip of the trip unit set the thresholds and trip times of the protections associated with the trip unit display the time current curves of the protection devi ces send the wink commands which activate the winking of the display or the blinking of a LED of the trip unit this to make easier the identification of the circuit breaker installed in the plant The quantity and type of information which can be viewed through the graphic displays vary according to the type of trip unit involved Here are shown some of the available windows Bus communication with ABB circuit breakers Information In this window it is possible to read the general information about the device e g standard of reference rated current of the circuit breaker software version type of circuit breaker information on the circuit breaker state and to send opening closing trip unit reset commands and
96. econd Level Detailed information can be viewed in the Main area and in particular by selecting the node at the first level a summary of all the detected devices connected to the Modbus net work and of their relevant communication parameters is displayed by selecting one of the node at the second level it is possible to view a summary of the main communica tion parameters e g COM port slave address baud rate of the selected device e g a trip unit and of any possible problem which has occurred during scanning operations by selecting the nodes of the third level it is possible to view detailed information and data of the trip unit to modify the communication parameters and the settings of the protections and to send commands to the circuit breaker see clause 4 8 2 Figure 30 Screen shot of the Ekip Connect with the Navigation area and the Main area generated at the end of one scanning operation Navigation area Figure 31 Tree structure of the Navigation area 1st Level Bus 2nd Level GY PR123 P 3 Information Event log 3rd Level Alarms Trip History Signaling status Measures Main area Nodes of the 3rd level Bus communication with ABB circuit breakers 47 UONLOIUNWWOD snq 104 uonnjos ggY p UOleDIUNWIWOS snq 104 uonnjos ggY p 48 Technical Application Papers i During the testing of a switchboard equipped with devi ces which communicate via Modbus and desi
97. een trip unit and HMI030 shall be achieved through twisted pair cables shielded and with characteristic impedance equal to 120 Q e g Belden 3105 cable type or equivalent The shield shall be connected to earth at one end of the connection Maximum recommended length for the connection between HMI030 and trip unit 15 m In this configuration it is possible to connect to the trip unit one HMIO30 unit only on the bus W2 Bus communication with ABB circuit breakers 31 uo esiunwwo snq 104 uonnjos ggY p UONPOIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers Display on panel front HMI030 HMI030 RS485 Bus RS485 Bus A B CAN_L CAN_H A B CAN_L CAN_H 2 1 4 3 5 6 7 8 9 10 2 1 4 3 5 6 7 8 9 10 Vaux Vaux 24V 24v gI P po P A w2 B A w1 B Ki J y Ke w3 1 1 W4 Wit W2 CB terminal box or Ki K2 w3 w4 wi w2 sliding contacts PR120 D M PR330 D M PR122 P PR123 P PR122 DC PR123 DC PR332 P PR333 P PR121 P PR331 P HMIO30 unit configured in Master mode and Modbus communication W1 System bus of the trip unit terminals W1 and W2 W2 Local bus of the trip unit terminals W3 and W4 K1 K2 auxiliary supply Vaux Maximum recommended length for the connection between HMIO030 and the trip unit on the bus W2 15 m
98. elps to improve the immunity against electromagnetic disturbances because the cable forms a series of coils each of them turned in the op posite direction with respect to the following one thus a possible magnetic field in the environment passes through each pair of coils in the opposite direction and consequently its effect is very reduced theoretically the effect on each coil is exactly contrary to that on the following one and therefore the resulting effect is cancelled The shielding can be braided formed by a mesh of fine conducting wires or foil consisting in a metal foil wrapped around the conductors the two types are equivalent Figure 25 Detail of a shielded twisted pair cable Sheath Shield foil type Twisted pair Shield grounding 42 Bus communication with ABB circuit breakers 6 Connection to the terminals In some countries it is allowed to insert two cables into the same screw terminal In such case it is possible to connect the main cable directly to the terminals of the circuit breaker without a stub as shown in Figure 26 Figure 26 Connection of the main cable directly to the terminals of the circuit breakers Instead if each terminal can hold a single wire only it is necessary to create a real stub by using three auxiliary terminals for each circuit breaker to be connected as shown in Figure 27 Figure 27 Connection to the circuit breaker through auxiliary term
99. ents State changes of CB protections and alarms the latest 80 For further information about the electric quantities the data and the alarms available reference must be made to the following document Emax DC PR122DC PR123DC PR120 D M Modbus System Interface document code 1SDH000841R0001 Test isolated position in which the power contacts are disconnected whereas the auxiliary contacts are connected Bus communication with ABB circuit breakers 83 y xouuy J01 U09 0w 1 pue UOISIAJOdNS 10 SPUBLULUOD pue e ep soinseoyy y xouuy J01 U09 8 0W9d4 pue UOISIAJOdNS 40 SPULWWOI pue e ep seinses 84 Supervision with fieldbus Modbus RTU Table A 1B Measures data alarms and commands available with air circuit breakers type Emax VF Emax VF PR122 VF PR120 D M Electrical Phase currents IL1 IL2 IL3 quantities Measures history phase at maximum current Imax Data logger State CB state open close tripped information CB position connected test isolated Spring state charged discharged Mode local remote Protection parameters set load control parameters Maintenance data Total number of operations from close to open Total number of protection trips Total number of trip tests Number of manual operations with opening command Number of trips according to each protection functions Contact wear Data recording of
100. equipped with the following electronic microprocessor based trip units respectively Ekip E LSIG QF4 QF5 PR223DS QF6 and QF7 PR123 P QF2 and QF3 Bus communication with ABB circuit breakers Choice of products and accessories for supervision For the supervision of the plant the following devices are needed e Emax E1 air circuit breakers QF2 and QF3 equipped with 1 PR123 P electronic trip unit 2 PR120 D M communcation module 3 PR120 V measuring module mounted by default on PR123 P trip unit 4 auxiliary power supply Vaux see Annex B e SACE Tmax XT4 moulded case circuit breakers QF4 QF5 equipped with 1 Ekip E LSIG electronic trip unit 2 Ekip Com communication module see Annex C 3 auxiliary supply voltage Vaux see Annex B As it can be noticed with Ekip E LSIG trip unit for SACE Tmax XT4 it is possible to measure voltages and energy without having to use external measuring modules e Tmax T4 moulded case circuit breakers QF6 and QF7 equipped with 1 PR223DS electronic trip unit 2 X3 rear connector see Annexes B and C 3 VM210 measuring module see Annex D 4 X4 rear connector see Annex D 5 auxiliary contacts in electronic version AUX E see Annex E 6 auxiliary supply voltage Vaux see Annex B Figure 32 Supervision and control system of a LV distribution plant Choice of products and accessories for remote control To perform circuit breaker remote control the
101. following accessories are necessary e For Emax E1 air circuit breakers QF2 and QF3 1 shunt opening release YO 2 shunt closing release YC 3 geared motor for the automatic charging of the closing springs M e Mouldea case circuit breakers SACE Tmax XT4 QF4 and QF5 1 motor operator with MOE E module see Annex F e Moulded case circuit breakers Tmax T4 QF6 and QF7 1 motor operator with MOE E module see Annex E 2 AUX E auxiliary contacts in electronic version pro vided by default with MOE E SS Control level RS 232 RS 485 y converter QF2 Field level QF4 l QF5 E3 QF6 QF7 Bus communication with ABB circuit breakers 55 uoesaiunwwo snq JO uonnjos ggY p UONedIUNWWOS snq 104 uonnjos ggY i 56 4 10 ABB circuit breakers in Profibus DP and DeviceNet fieldbus EP010 fieldbus interface unit allows the integration of ABB SACE circuit breakers into communication systems with Profibus DP or DeviceNet protocol EP010 establishes together with the ABB intelligent connector type FBP FieldBusPlug the connection between a fieldbus and the trip unit connected to its Modbus port In particular EP010 unit operates as gateway for the communication between the FBP connector and the electronic trip unit LAN network lI sa E The connection to the fieldbus is up to the customer FBP connector Bus communication with ABB circuit breakers As
102. from earth is required it is necessary to use galvanically isolated converters complying with the Stds IEC 60950 UL 1950 or its equivalent IEC 60364 41 and CEI 64 8 which guarantee a common mode current or leakage current see IEC 478 1 and CEI 22 3 not higher than 3 5 mA Here are some examples of wiring diagrams for the use of the unit HMIO30 For more detailed information on the use and charac teristics of this device reference must be made to the product technical manual HMI030 Remote visualization unit document code 1SDH000573R0001 With air circuit breakers type Emax E1 E6 Emax X1 and moulded case circuit breakers Tmax T7 the following configurations are available Remote supervision and display on panel front HMI030 RS485 Bus A B CAN_L CAN_H 2 1 4 3 5 6 7 8 9 Remote supervision system 10 Vaux 24V to Modbus cable B A w1 B K1 1 Terminal box of the pwa wia aLe circuit breaker or RIS K1 W4 Wi w2 sliding contacts PR122 P PR123 P PR122 DC PR123 DC PR332 P PR333 P PR120 D M PR330 D M HMIO30 unit configured in Master mode and Modbus communication W1 System bus of the trip unit terminals W1 and W2 W2 Local bus of the trip unit terminals W3 and W4 K1 K2 auxiliary supply Vaux The connection betw
103. gear assemblies TZ Three phase asynchronous motors Generalities and ABB proposals for the coordina tion of protective devices QT8 Power factor correction and harmonic filtering in electrical plants QT9 Bus communication with ABB circuit breakers QT10 Photovoltaic plants QT11 Guidelines to the construction of a low voltage assembly complying with the Standards IEC 61439 Part 1 and Part 2 Generalities on naval systems and installations on board QT13 Wind power plants Contact us ABB SACE A division of ABB S p A L V Breakers Via Baioni 35 24123 Bergamo Italy Phone 39 035 395 111 Fax 39 035 395 306 433 www abb com The data and illustrations are not binding We reserve the right to make changes in the course of technical development of the product Copyright 2012 ABB All rights reserved 1SDC007108G0202 02 2012 3 000
104. gnals open closed tripped Terminals 1 and 2 ll Of X3 rear connector Note SQ Contact for the electrical signaling of circuit breaker open closed SY Contact for the electrical signaling of circuit breaker open tripped position Electrical characteristics of SQ and SY contacts Rated voltage 24 350 V Rated current 0 100 mAmps Max voltage 400 V Max continuous current 120 mAmps Max current for 100 msecs 300 mAmps Bus communication with ABB circuit breakers E 2 Stored energy motor operator MOE E Tmax moulded case circuit breakers series T4 T5 and T6 can carry out opening and closing commands from remote control when they are equipped with MOE E motor operator and AUX E auxiliary contacts in elec tronic version provided by default together with MOE E MOE E motor operator is constituted besides the real motor operating mechanism by an electronic actuation unit which converts the digital signals coming from the remote supervision system into their equivalent power signals necessary to perform the mechanical opening and closing operations of the circuit breaker The digital Electrical characteristics of MOE E signals coming from the supervision system are acquired by the trip unit and sent to the motor operator according to the scheme of Figure E 3 AUX E auxiliary contacts communicate to the trip unit the circuit breaker state open closed tripped and according to this information the trip unit sh
105. gned to be installed in a plant provided with a supervision system the scanning of the system bus is particularly useful In fact this control operation allows wiring anomalies of the devices connected to the Modbus network setting errors of the communication parameters e g baud rate parity number of stop bits etc or configuration errors of the connected devices e g logical address to be detected thus there is the possibility of correcting them at a stage when the switchboard is not in service yet Thanks to these verifications in case of communication anomalies of the supervision systems of the plant du ring commissioning of the switchboard such problems cannot be put down to the circuit breakers installed in the switchboard 4 8 2 Communication with a single device Ekip connect offers some graphic displays through which it is possible to interact with the electronic trip units The windows are displayed in the Main area when a node of the 3rd level is selected from the Navigation area Some windows are associated with each trip unit and they enable you to read the measurements on the circuit breaker and on the protection trip unit know the circuit breaker state e g open closed connected insulated display the protection alarms read the electrical quantities measured in real time e g currents voltages power energy display the parameters of the protection functions associated with th
106. he protocol Logical layer Profibus DP Profibus DP YES COMMUNICATION Physical layer RS 485 RS 485 Compatibility on all the layers of the protocol Logical layer Profibus DP Modbus RTU NO COMMUNICATION Physical layer RS 485 RS 485 Incompatibility on the logical layer of the protocol Logical layer Modbus RTU Modbus RTU NO COMMUNICATION Incompatibility on the physical layer of the Physical layer RS 485 RS 232 protocol Logical layer Profibus DP Modbus RTU NO COMMUNICATION Physical layer RS 485 RS 232 Incompatibility on all the layers of the protocol Note With logical layer the combination of link layer application layer is meant Bus communication with ABB circuit breakers 9 uoedlunwWoo je1161g A s uejd UO NLYSIP je911 9919 JO UOISIAIOdNS 10 Fedlinical Application Papers Ea 3 Supervision of electrical distribution plants A low voltage electrical distribution plant can be consid ered as an industrial process oriented towards the dis tribution of electrical energy and therefore it also needs a supervision and control system to increase reliability and improve managing of the installation From a point of view aimed at the integration between traditional installation technology and control systems with the aim of centrally and automatically managing controlling and monitoring civil and industrial plants it is possible to consider the electrical installation as influenced by two flows Figure
107. he system buUS eee 47 4 8 2 Communication with a single device 48 49 Example of product selection for supervision and remote control 54 410 ABB circuit breakers in Profibus DP and DeviceNet fieldbus 56 4 10 1 Emax air circuit breakers E1 E6 Emax X1 air circuit breakers and Tmax T7 T7M moulded case circuit breakers cccecceeeeeeeeeeeeeeneee 57 4 10 2 Moulded case circuit breakers Tmax 14 15 16 eececscsesesessetetseseseseseeeaes 59 4 10 3 Moulded case circuit breakers SACE Tmax XT2 XT4 uccccsscsescseseessessssseeees 60 4 11 Measuring instruments s e 61 4 11 1 DMTME multimeters cccccssessseeeeeees 61 4 11 2 ANR network analyzers n 62 4 11 3 Temperature control units 0 eee 64 4 11 4 Electronic energy meters 0 cseeeee 65 4 12 Serial converter RS485 RS232 66 5 ABB circuit breakers in Ethernet TCP IP networks 67 54 Ethernet 2 lt csccsscascisccnscegehecsdeaccccsedscssdadsss 67 Ba AIP protocol ic jislecssie lta dias 69 5 1 2 TCP protocol cscscssescsssssssseseseseseseseeseneeeseaees 69 5 2 Ethernet industrial protocols 70 5 3 Modbus TCP PLOLOCOI cceeeesseeeeeeeeeees 71 5 4 Serial Modbus Modbus TCP CONVEISION siciccdieideccseeSievs aadssesestesieccece 74 5 5 SD GEM QatOWay eseeceeeeesseeeeeeeeeseees 76 6 Application examples 78 6 1 Supervision of protections and
108. hout Modbus communication and SACE Tmax XT4D switch disconnectors TMA TMD Ekip without Modbus communication Ekip Com communication module MOE E motor operator Ekip Com MOE E SACE Tmax XT4D switch disconnector Ekip Com communication module MOE E motor operator SS me m T m OOOO ee Og ma creel real eg en me ont rel ce red el malt me mat Switch disconnector state Ekip Com MOE E NOTE For more detailed information about the dialogue functions and the characteristics of the products described in this clause reference must be made to the relevant catalogues and product technical manuals Bus communication with ABB circuit breakers 4 5 SD030DX solution for the circuit breakers without Modbus RTU interface SDO30DX are electronic devices which allow the inter face of air and moulded case circuit breakers equipped with thermomagnetic or basic electronic trip unit air or moulded case switch disconnectors to a Modbus network The circuit breakers and the switch disconnectors con nected in this way appear on the Modbus network as slave units and can communicate with whatever masters PC PLC SCADA This makes it possible for the supervision systems to manage also these apparatus In particular the supervision system can 1 read the circuit breaker state open closed tripped racked in out charged discharged springs 2 command opening closing and reset of the devices Reading of the
109. ical Application Papers SACE Tmax XT2 XT4 moulded case circuit breakers Ekip Com communication module Protocol Modbus RTU Physical interface RS 485 Baud Rate 9600 19200 bit s Ekip Com is the communication interface which allows you to connect Ekip electronic trip units with dialogue fun ction into the field bus Modbus RTU control via remote MOE E motor operator with elec tronic interface detect the state open closed tripped of the circuit breaker Ekip Com is available in two versions one for fixed plug in circuit breakers and one for withdrawable circuit breakers For the communication on the Modbus network an auxi liary voltage Vaux up to 24 V DC is necessary to supply the communication module and the electronic trip unit As regards the electrical characteristics of the auxiliary supply voltage see Annex B Connection to the Modbus network The electronic trip units type Ekip E LSIG Ekip LSI Ekip LSIG and Ekip M LRIU are connected to the Modbus network through Ekip Com communication module There are also the auxiliary contacts Q 7 and SY 3 built in inside Ekip Com for electrical signaling of circuit breaker in open closed position and for circuit breaker in tripped position see Figure C 8 respectively These contacts make the information about the circuit breaker state available for the remote supervision system With the circuit breaker in withdrawable version the trip unit is
110. inals Main cable Main cable Emax terminal box Terminal box of the X3 connector 7 Grounding of shielding The shield of the cable must be connected to ground at a single point Usually grounding is at one end of the main cable Figure 28 shows some correct and incorrect examples of grounding Figure 28 Examples of correct and incorrect grounding of shielding ass ee O A 8 Terminating resistors In order to avoid reflections of the signal a 120 Ohm terminating resistor must be mounted at both ends of the main cable An internal terminating resistance is not provided for ABB SACE devices type new Emax Emax X1 air circuit breakers and Tmax moulded case circuit breakers If other devices are connected in addition to ABB SACE circuit breakers it is necessary to verify whether they are equipped or not with terminating resistors in this case it is usually possible to activate or deactivate it Terminating resistors must be used only at both ends of the main cable If the total length of the main cable is lower than 50 m the terminating resistors at both ends of the main cable can be avoided 9 Connection to a personal computer If the master used is a personal computer the connection to the bus generally occurs through a serial converter RS 232 RS 485 as shown in the following Figure Figure 29 Connection of a PC to the bus through a serial converter RS 232 RS 485 ILPH RS 232 RS 485 TLETT
111. ing The last is considered anon priority load and when necessary can be discon nected to reduce energy consumption The main circuit breakers QBT1 and QBT2 of the sub distribution switchboards are Tmax T5 with PR222DS PD electronic trip unit equipped with Modbus com munication interface mounting the auxiliary contacts with electronic interface AUX E and motor operator with electronic interface MOE E The main circuit breakers Pl 2 3 1880 Pai PLC AC500 L i Ot Che QBTI ot feta O iat ies a E i A i nt A i A A o O HO V p Refrigeration system Air conditioning system QBT3 and QBT4 of the sub distribution switchboards are SACE Tmax XT4 with Ekip LSI electronic trip unit Ekip Com communication module Modbus communication interface and motor operator with electronic interface MOE E The circuit breakers are all connected to the same Mod bus communication bus type RTU whose master is a PLC AC500 with RS 485 interface The PLC implements an application software for the control of loads it reads cyclically the current values from the main circuit breakers and commands opening of those of the non priority loads whenever the sum of the currents exceed a set threshold or under other programmed working conditions These conditions vary according t
112. ing of the circuit breakers equipped with Modbus communication interface 4 8 1 Scanning of the system bus Thanks to this function the software carries out the au tomatic scanning of the Modbus RS 485 network and identifies all the devices connected to the bus At the end of the scanning operation the devices found are displayed both in the Navigation area through a node tree structure as well as in the Main area The devices connected to the network can be viewed in the Main area see Figure 30 with their main commu nication parameters and any warning about potential problems or configuration errors detected in the scanning process e g two devices with different baud rate or two devices with the same Slave Address for a complete diagnosis of the communication network Ekip Connect signals in the Main area also the presence of non ABB devices able to communicate via Modbus RTU protocol and their relevant communication para meters Figure 31 shows an example of the node tree structure of the Navigation area generated after a scanning of the communication network The main node at the first level shows the Modbus network to which the different devices are connected the nodes at the second level indicate the devices e g the trip units connected to the communication network the nodes at the third level indicate the information the data and the alarms put at disposal by the selected trip unit one node of the s
113. ions associated with the trip unit and the diagnostic alarms associated with the circuit breaker e g trip coil disconnected or failed current sensors disconnected The quantity and type of alarms which can be displayed vary according to the type of trip unit with which interaction occurs CRC ECR CRC RT RRR Trip This window offers the possibility of obtaining more information about the cause of tripping e g type of protection tripped values of the interrupted currents time and date of tripping contact wear Some trip units allow access also to the information associated with the previous trips The quantity and type of information which can be displayed vary according to the type of trip unit with which interaction occurs TETIERE T Bus communication with ABB circuit breakers 51 UONLIIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers Settings Through this window it is possible to view and set the values thresholds and trip times of the protection functions of the trip unit The protection functions which can be viewed vary according to the type of trip unit with which interaction occurs Time current curves Thanks to this function it is possible to view the trend of the time current curves set for the main protection functions L S and G 52 Bus communication with ABB circuit breakers Statistics of the operations performed by the circuit breaker In th
114. is window it is possible to display the percentage of contact wear the total number of operations the number of manual operations the number of protection tripping the number of failed trips and the number of test trips carried out by the circuit breaker The data which can be viewed vary according to the type of trip unit with which interaction occurs NOTE For further information about the use of the software Ekip Connect and about the functions put at disposal see the User Manual Instructions for use for communication software EKIP Connect compatible with low voltage circuit breakers by ABB SACE document code 1SDH000891R0002 Bus communication with ABB circuit breakers 53 UOHLOIUNWIWOD snq 104 uonnjos ggY p UOHLIIUNWIWODS snq 104 uonnjos ggY p 54 Technical Application Papers 49 Example of product selection for supervision and remote control Consider a LV distribution plant with supervision of the type shown in Figure 32 the supervision system uses a bus network with Modbus protocol RTU on RS 485 At the control level there is a PC on which a supervision system is installed for the connection of the PC to the bus a serial converter RS 232 RS 485 is used The personal computer operates as SCADA acquiring processing and storing the data sent from all the circuit breakers The field level consists of the protection circuit breakers type SACE Tmax XT4 Tmax T4 and Emax E1
115. isolated inputs A 0 01 5 Minimum current value mA 10 Consumption VA 0 2 Max overcurrent A 10 100 A for 1 second Ratio transformer range kCT 0 01 5000 00 THD Voltage and current Up to the 31st harmonic Frequency Hz 30 500 Accuracy class Current lt 0 5 EN 61036 Voltage lt 05 Power lt 1 Power factor al Active energy lt 1 IEC 62052 11 Reactive energy 2 IEC 62053 23 Communication parameters Protocol Modbus RTU Physical interface RS 485 Baud rate 4800 bps 9600 bps 19200 bps Parity Odd Even None Stop bit 0 1 Address 1 247 NOTE For more detailed information see the technical catalogue System pro M compact 62 Bus communication with ABB circuit breakers 4 11 3 Temperature control units They are used to monitor the temperature levels and the ventilation functions of electric machines transformers motors etc Preventive control of temperature enables malfunctions and overloading to be avoided Four PT100 type sensors are used to measure tempera tures For each measurement channel two alarm levels alarm trip can be set they switch two output relays for remote signaling if a critical temperature level has been reached In addition the units enable the maximum values to be stored each intervention to be stored and ventilation inside the panel to be controlled The temperature values and the alarm state can be remotely tr
116. it With Ekip LSI Ekip LSIG or Ekip M LRIU trip units it is possible to connect on the same bus WI up to two HMIO030 units on which two different operating mode have been selected Ammeter A and Custom A V W Bus communication with ABB circuit breakers 37 UOHedIUNWWOS snq 104 uonnjos ggY r UONLOIUNWIWOD snq 104 uonnjos ggY p 38 Technical Application Papers Moulded case circuit breakers type Tmax T4 T5 T6 With moulded case circuit breakers type Tmax T4 T5 T6 equipped with electronic trip units PR222DS PD PR223DS and PR223EF the following configurations are possible Display on front panel ape eay Re Ga mee ay i x x HMI030 1 Q RS485 Bus I B A CAN_L CAN_H i i 1 2 4 3 5 6 7 8 9 10 T L d apeze TI L2 Tt i TI L3 EOE E E E TUN Auxiliary H voltage Vaux n B Z i 1 i7 Modbus cable A Terminals 1 and 2 i of X3 rear connector gee I E aa hen lew al teeetdaaentese marl HMI030 in Master mode and Modbus communication W1 System bus of the trip unit Maximum recommended length for the System bus W1 300 m The connection between trip unit and HMI030 shall be achieved through twisted pair cables shielded and with characteristic impedance equal to 120 Q e g cable type Belden 3105 or equivalent The shield shall be connected to earth at one end of the connection For the use i
117. ivered Ethernet is said to be the transmission system with non deterministic delays since it is impossible to set a maximum time within which a packet shall be transmit ted with absolute certainty What is possible to do is to set the likelihood that the packet is transmitted within a definite time Due to this lack of determinism Ethernet cannot be used in some applications where time control must be extremely strict for example real time position control of electric drives In all other cases Ethernet can be used without problems provided that the control or supervision system adop ted takes into account the uncertainty of the transfer times Figure 33 Star network with Switch Ethernet Even if Ethernet has been originally developed as a bus with all devices connected in parallel to the same cable current Ethernet systems are usually wired in a star topology In the center of this type of networks there is a Switch which may be either passive that is a device which simply connects the cables or active when it is equipped with an electronic card Active Switches can store the addresses of the devices connected to their ports and can store the data packets in order to direct them from the sender to a specific reci pient without involving the other connected devices and with the result of improving the network performances Switches are used for routing within local area networks LAN namely networks which connect compute
118. l Modbus Besides this allows single telegrams to be converted with no need to store additional data and without loss of information Figure 34 Traditional Modbus telegram Modbus RTU Slave Address this field contains the address Mod bus of the slave device connected to the traditional Modbus serial line Function Code this field contains the code used to indicate the actions to be carried out e g functions of reading and or writing in the registers of the slaves Data this field may contain additional information useful to carry out the actions defined in the Function Code for example when a master sends a request of data reading to a slave the field Data of the tel egram shall contain the address of the register from which data reading must be started and the number of registers data to be read If no errors occur the response telegram from the slave shall include in the field Data the data requested by the master CRC field used to monitor and manage the commu nication errors Function Code Slave Address NOTE For further information see the document MODBUS Protocol Specification available on http www modbus org specs php Bus communication with ABB circuit breakers 71 SY OM U dI dOL PUY U S19yeAIG 1INOIID JAY G SOMU dI dOL PUY U S1ayeO1g YINOWID JAY G Technical Application Papers From the traditional Modbus telegram e g Modbus RTU
119. lications the clients and the ser vers communicating via Modbus TCP IP protocol send and receive data on port 502 Figure 37 Request response sequence Client 1 IP address 5 6 7 8 b V 4 V 4 V 4 V y s V aw V y st V oor I pat Le Client 2 Internet TCP IP Modbus TCP communication occurs always through single telegrams to each request only one single re sponse telegram corresponds which satisfies the server processing This mechanism allows a device to serve simultaneously more applications by responding alternatively to different clients For example a control application can read the data once per second whereas a supervision application installed on another computer reads other data always from the same server once per minute Any collision in the transmission of telegrams is proc essed by the mechanism already present in Ethernet transparently for the applications When the server receives request telegrams faster than it can reply it stores them in queue and answers in se quence each response shall be correctly addressed to the client which has sent the request Server IP address 1 2 3 4 Bus communication with ABB circuit breakers 73 SIOMJOU dI dOL PUY U S19yeO1G 1INDIID JAY G SIOMIOU dI dOL PUY U S19 e01g 1INOWID JAY G 74 Technical Application Papers 5 4 Serial Modbus Modbus TCP conversion There is often the require
120. ling of circuit breaker in racked in position 8751 1 DI4 CB auxiliary contacts Q 1 DI5 switching contact for electrical signaling of local remote selector state 63 1 T7D X1B MS E1 MS E6 MS DI1 limit contact for spring charging motor S33M 1 DI3 contact for the electrical signaling of circuit breaker in racked in position S751 1 DI4 CB auxiliary contacts Q 1 DI5 switch for setting remote local control S43 Bus communication with ABB circuit breakers Remote control The SDO30DX units carry out the commands opening closing and reset sent by the supervision system to the circuit breaker switch disconnector The following table shows 1 the circuit breakers and the switch disconnectors which can be remote operated 2 the accessories to be mounted on the circuit breaker through which it is possible to actuate the com mands 3 the type of command which can be performed M geared motor for the automatic charging of the closing springs Circuit breaker type Accessories for the command actuation Commands 11 12 13 Solenoid operator MOS Opening Closing T4 T5 T6 Stored energy motor operator MOE Opening Closing T7M X1 SOR shunt opening release Opening SCR shunt closing release Closing YR reset coil Reset M geared motor for the automatic charging of the closing springs E1 E6 YO shunt opening relea
121. ment to upgrade or modify an industrial control and supervision system by adding new devices or by replacing the existing ones In these cases the protocols and systems which allow these operations to be performed with the least modifications to the exist ing devices and software are preferred The structure of the Modbus TCP telegram is particularly suitable for this purpose because toallintents and purposes the content of the Modbus TCP telegram when excluding what is necessary to the delivery on TCP IP is a traditional Modbus telegram the telegrams are always treated separately every re quest telegram corresponds to one response telegram only Therefore it is possible to interface the existing traditional devices with Modbus TCP systems by using SD GEM converter Such device allows a traditional Modbus se rial line to be connected to an Ethernet system since it Figure 38 Slave Address and Unit ID works as a server on the TCP IP side and as a master on the serial side From the point of view of the Modbus TCP the converter is seen as a single device with its own register map divided into sections each of them identified by an Ad ditional Address or Unit ID Each section represents the traditional device the slave Modbus RTU which has the slave address correspond ing to the additional address According to this representative model the conversion is operated through a quite simple mechanism when
122. mentation Guide V1 0b available on http www modbus org specs php Traditional Modbus telegram Modbus RTU V Transaction ID Protocol ID Length Function Code al Modbus TCP telegram Figure 36 Ethernet TCP IP network Modbus serial line Modbus Client TCP IP Modbus Client TCP IP Ethernet TCP IP network Remote Slave 2 Modbus Server Remote Modbus Server TCP IP CP IP Slave 1 Modbus serial line Modbus Server TCP IP Gateway 72 Bus communication with ABB circuit breakers The Modbus TCP telegrams contain a field named Addi tional Address which allows a single device for example a gateway to have a register map divided into sections the section 1 2 3 of the register map corresponds to the additional address 1 2 3 this is used for the con version between traditional Modbus and Modbus TCP as explained hereafter Both the client and the server have an IP address The server accepts Modbus TCP telegrams indicated with registered port 502 from any client for each telegram a response telegram is built which is sent to the IP ad dress of the sender that is the client The TCP IP protocol ensures that the request telegram is transferred from the client to the server and vice versa each response telegram is transmitted to the unit device which has sent the request and is delivered to destination The port TCP 502 is specifically intended for Modbus app
123. munication with ABB circuit breakers 87 y xouuy J01 U09 8 0W9d4 pue UOISIAJOdNS 40 SPUBLULUOD pue e ep seinsee y 88 Technical Application Papers Supervision with fieldbus Profibus DP and DeviceNet Table A 4 Measures data alarms and commands available with Emax air circuit breakers X1 air circuit breakers and Tmax T7 moulded case circuit breakers E1 E6 T7 X1 X1 PR122 P PR332 P PR332 P PR122 P PR120 D M PR123 P PR330 D M PR330 D M PR333 P PR120 D M PR120 V PR120 D M EP010 PR330 V PR330 D M EP010 EP010 EP010 EP010 EP010 Bees eee IL1 IL2 IL3 neutral current IN E m E E E n Voltages phase to phase phase to neutral residual E a E E Total power active P reactive Q apparent A E E Total power factor B E E E Frequency a a Total energy active reactive apparent a Harmonic analysis THDi THDv and spectrum m m up to 25th harmonic odd order harmonics State Circuit breaker state open closed tripped E i E E fenmen Circuit breaker position racked in test isolated a a a a E a Spring state charged discharged a B B E E Mode local remote a Li a E L Protection parameters set B E m E Maintenance Total number of operations a E data Total number of trips B B B E E a Protections Protection L alarme Protection S J E A
124. n and remote control The moulded case circuit breakers type Tmax T4 T5 and T6 with PR222DS PD and PR223EF electronic trip units are connected to EP010 unit through X3 rear connector as shown in Annex C For Tmax T moulded case circuit breakers there are two different versions of the unit EP010 each of them compatible with the suitable trip unit In particular with PR222DS PD trip unit the EP010 identified by the product code 1SDA059469R1 is used see the Technical Catalogue Tmax T Generation Low voltage moulded case circuit breakers up to 1600 A with PR223EF trip unit the EP010 identified by the product code 1SDA064515R1 is used see the Tech PR222DS PD electronic trip unit DeviceNet i Supervision EP010 Connector X3 PR223EF electronic trip unit Supervision DeviceNet PR223EF EP01 2 5 Connector X3 f y G3 ap PR223EF Profibus DP 5 iy C j Profibus DP E E nical Catalogue Tmax T Generation Low voltage moulded case circuit breakers up to 1600 A To perform the remote control and the mechanical imple mentation of the remote opening and closing commands Tmax T4 T5 and T6 moulded case circuit breakers must be fitted with MOE E motor operator with electronic interface and AUX E auxiliary contacts in electronic version For information about the measures data and alarms placed at disposal by the trip units type PR222DS PD and PR223EF in the following configurations
125. n this configuration the following communication parameters of the trip unit must be set address 247 Baud rate 19200 bit s parity EVEN stop bit 1 In this configuration only one HMIO30 can be connected to the trip unit on the System bus W1 Bus communication with ABB circuit breakers Display on panel front with more units HMI030 It is possible to connect up to four HMI030 units to the same trip unit on the same bus if the following conditions are complied with PR223DS trip unit the following communication parameters of the trip unit are set Address 247 Baud rate 19200 bit s Parity EVEN stop bit 1 four different operating modes Ammeter Voltmeter Wattmeter and Custom are selected for each HMIO30 each unit HMI030 has SW version 2 00 or following ones and is configured in Slave mode Modbus RS485 communication interface is used terminals 3 and 4 MMO030 unit is present supply with auxiliary supply voltage at 24 V d c Pn 2 5 W 24V Principle scheme System bus W1 Accessory bus W3 RS Rotative selector W1 System bus of the trip unit communicating with the Local bus W2 of MMO30 unit terminals 10 and 11 W3 Accessory bus of MMO030 unit terminals 13 and 14 Maximum recommended length for the connection between trip unit and MM030 System bus W1 200 m maximum recommended length for the Accessory bus W3 300 m For the connections use twisted pair cables shielded a
126. nctions and the characteristics of the products described in this clause reference must be made to the relevant catalogues and product technical manuals For further information on the structure of the Modbus map of the ABB trip units provided with communication interfaces reference must be made to the following documents Modbus system Interface for Protection relays PR122 P and PR123 P communication module PR120 D M mounted on CB New Emax Protection relays PR332 P and PR333 P communication module PR330 D M mounted on CB Emax X1 Tmax T7 and Tmax T8 document code 1SDH000556R0001 Bus communication with ABB circuit breakers 4 3 Moulded case circuit breakers Tmax T4 T5 T6 Modbus communication supervision and remote control The trip units type PR222DS PD PR223EF and PR223DS for the circuit breakers type Tmax T4 T5 and T6 can be interfaced to Modbus networks through the suitable X3 rear connector see Annex C Communication and dialogue are implemented in order to e transmit the alarm signals of the protections the in formation about the circuit breaker e g state and position and the measures made available by the trip unit to a remote supervision system thus implement ing supervision To make available for the remote supervision system the information about the circuit breaker state open closed tripped the circuit breakers Tmax T4 T5 and T6 must be equipped with the AUX E auxiliary contacts in electronic
127. nd 2 of the X3 connector Bus communication with ABB circuit breakers Terminal box of the X3 connector Emax terminal box In order to avoid errors when many devices are con nected it is advisable to use the same color for all the wires connected respectively to the terminals A and B of the different devices e g white for A and blue for B this makes easier the identification of reversed wiring Also on the Master device whatever it is the communi cation port has two connections which correspond to A and B Some manufactures indicate them with Tx and Tx or with Data and Data or simply with RS 485 and RS 485 2 Device connection Unlike what happens in many energy distribution sys tems the modality of connection in parallel of the devices must be taken into account The system RS 485 used for Modbus communication of ABB SACE circuit breakers requires a main cable bus or backbone with length not exceeding 700 m to which all the devices must be connected through branches called also stubs as short as possible For ABB SACE circuit breakers the stubs shall not exceed the maximum length of 1 m The presence of longer stubs could cause reflections of the signals with the possible induction of disturbances and consequent errors in the data reception Figure 23a shows the example of a correct bus connec tion Figure 23a Network with bus structure Backbone 4 gt be m On the contrary Figur
128. nd with characteristic impedance equal to a 120 Q e g cable type Belden 3105 or equivalent In the connection between trip unit and MMO030 device System bus W1 it is advisable that the shield is earthed at the end of the connection towards the trip unit When wiring Accessory bus W3 it is advisable that the shield is connected to earth at the end of the connection towards MM030 unit As for wiring the instructions of the product technical manual Flex Interfaces for Accessory Bus should be followed With PR223EF trip units up to three units HMIO30 can be connected on which three different operating modes have been selected Ammeter A Voltmeter V and Custom A V W With PR222DS PD trip units up to two units HMIO30 can be connected on which two different operating modes have been selected Ammeter A and Custom A V W In this configuration to manage the information exchange between the trip unit and HMI030 interface devices MMO030 unit must be used MMO030 is a microprocessor based device provided with two different communication buses one Local bus W2 for the connection and communication with the trip unit via the System bus W1 of the trip unit one Accessory bus W3 for the connection and communication with HMI030 units Thus MM030 receives the data from the trip unit via the bus W2 and sends it to the visualization units HMI030 con nected to it via the bus W3 so that it is possible to displa
129. not of our interest and are not dealt with in this document It is enough to know that the address of the recipient and the address of the sender as well as those of each device connected to the network consist of 4 numbers byte in sequence for example 10 39 1 156 These numbers form the IP address in the future versions of this protocol the IP address shall be extended to 6 numbers On asystem of interconnected networks both an Internet network as well as an Intranet company network having the same IP based architecture there cannot be two devices having the same IP address at the same mo ment This is to guarantee that an address corresponds to a single device Before a device being able to exchange data on a net work it is necessary that it is assigned a distinct IP ad dress This operation can be done by the user operator panel builder who assigns the desired address and veri 8 A router is a device which determines the optimum route communication path of some information through a network routing that is the suitable path to route the data packets from a network to another one As a matter of fact routers applying IP protocol do not have at their disposal all the information about the route of the data packets but only a local piece of information on which path to route a packet intended for a defined address fies that there are no overlaps then we speak of static IP address Otherwise it is possible to have on th
130. nt code 1SDH000510R0001 Bus communication with ABB circuit breakers 89 y xouuy J01 U09 0w 1 pue UOISIAJOdNs 10 SPOUBLULUOD pue e ep seinseoyy y xouuy J01 U0D 8 0W9d4 pue UOISIAJOdNS 40 SPULWWOI pue e ep seinsee 90 Technical Application Papers Supervision with fieldbus Profibus DP and DeviceNet Table A 6 Measures data alarms and commands available with moulded case circuit breakers type SACE Tmax XT2 XT4 Electrical quantities Phase currents IL1 IL2 IL3 Ekip LSI Ekip Com EP010 Ekip LSIG Ekip Com EP010 Neutral current INe Ground current Ig State information CB state open closed CB state tripped CB state reset Mode local remote Protection parameters set curves and thresholds of protections Thermal memory activated Maintenance data Total number of operations Total numbers of trips due to protections Number of trip test Number of manual operations with opening command Number of trips failed Record data of the latest 15 trips Protection alarms Protection trip Protection S timing and trip Protection L timing and trip Protection G timing and trip Pre alarm protection L Diagnostic alarms Commands Trip command failes Trip coil disconnected or failed CB open close with MOE E motor operator CB reset with MOE E motor operator
131. o the time schedule since the kWh peak can be differentiated for time bands more expensive by day and in the consumption peak hours less expensive by night The load control acts mainly pursuing two aims to prevent the main protection of each sub distri bution switchboard from overload tripping in addition if possible to keep the load curve as low as possible in the hours when the kWh cost is higher i QBT3 memm IQBTA mm 1 1 x i 1 X 1 foe aa 14 Bi o N i dS WwW Q I WwW Q Room lightning Emergency lightning system system Bus communication with ABB circuit breakers 81 s jdwex uonesiddy 9 y xouuy J01 U09D 0W931 pue UOISIAJOdNS 10 SPUBLULUOD pue e ep seinsesj Technical Application Papers hee A Measures data and commands for supervision and remote control Supervision with fieldbus Modbus RTU Table A 1 Measures data alarms and commands available with Emax air circuit breakers X1 air circuit breakers and Tmax T7 moulded case circuit breakers E1 E6 T7 X1 X1 PR122 P PR332 P PR122 P PR120 D M PR123 P PR332 P PR330 D M PR333 P PR120 D M PR120 V PR120 D M PR330 D M PR330 V PR330 D M Electric Phase currents IL1 IL2 IL3 neutral current IN quantities ground current Voltages phase to phase phase to neutral residual Total and
132. ocol three levels can be distinguished a physical layer a data link layer and an application layer Each layer refers to a functional aspect of communications and in particular the physical layer specifies the connection between the different devices from the point of view of the hardware and describes the electrical signals used to transmit the bits from one device to the other for instance it describes the electrical connections and the wiring systems the voltages and the currents used to represent the bits 1 and 0 and their duration In the industrial protocols the physical layer is generally one of the standard interfaces type RS 232 RS 485 RS 422 etc the data link layer describes how the bits are grouped into characters and these into packets and how any error is detected and possibly corrected If necessary it defines also the priorities to comply with to gain ac cess to the transmission medium the application layer describes what are the transmitted data and what is their meaning with reference to the process under control It is the layer in which it is speci fied which data shall be contained in the data packets transmitted and received and how they are used Generally speaking these layers are independent one from the other by applying this concept of layers to the communication between people it is possible to agree on talking either on the phone or on transceivers physical layer on speaking English or
133. oducts described in this clause reference must be made to the relevant catalogues and product technical manuals For further information on the structure of the Modbus map of the ABB trip units provided with communication interfaces reference must be made to the following documents Instruction manual PR223EF Modbus System Interface document code 1SDHO00566R0001 Instruction manual PR223DS Modbus System Interface document code 1SDH000658R0001 Instruction manual PR222DS PD Modbus System Interface document code 1SDHO00600R0001 Bus communication with ABB circuit breakers 21 UOledIUNWIWOD snq 104 uonnjos ggY p f UONLIIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers 4 4 Moulded case circuit breakers SACE Tmax XT2 XT4 Modbus communication supervision and remote control The electronic trip units type Ekip LSI Ekip LSIG Ekip M LRIU and Ekip E LSIG the last one for SACE Tmax XT4 circuit breakers only can be integrated into the communication systems with Modbus RTU fieldbus for the supervision and remote control of low voltage elec trical plants The connection to the Modbus network is carried out through Ekip Com module for information see Annex C which is the communication interface necessary to connect the above mentioned electronic trip units to the fieldbus and make them dialogue with the supervision systems Thus it is possible to acquire from remote all the measures
134. of the auxiliary systems thus making more efficient the logistic management of the plant In addition also the data relevant to the life of each circuit breaker e g number of operations carried out and percentage of contact wear are transferred over the local network to the database and used to schedule the preventive maintenance on the circuit breakers in order to guarantee operation continuity of the essential services 6 2 Allocation of the energy costs inside a plant In a manufacturing process it is very important to know the energy cost associated to the different manufacturing lines in order to allocate correctly the various manufactur ing costs for each type of product Take into consideration an industrial plant for the produc tion of cleansing agents with three different manufac turing lines Each line produces one type of detergent distinct due to composition packaging and final packing These lines carry out similar manufacturing processes starting from various mixtures of raw materials The three lines need to produce different quantities of product and therefore also the running times are planned independ ently at a definite instant one of the lines can work at full speed while the others may not be running For a correct management of the plant it is necessary to know the energy costs referred to each type of pro duction In particular the energy supply costs to be taken into account are the direc
135. ommands Configurations Run Time events CB open close with MOE E motor operator CB reset with MOE E motor operator Reset alarms Trip reset Trip test Protection parameter setting curves times and thresholds Neutral configuration ON OFF 50 100 of phases Thermal memory enabling disabling Rated voltage setting State changes of CB of protections and of all alarms 1 Measurements available with neutral connected with four pole CB or 3 Measurements available with neutral connected with four pole CB or three pole CB CT for external neutral conductor 2 Only with Ekip LSIG trip unit three pole CB external neutral conductor 4 Available information upon request by sending a command 5 It signals that 90 I1 lt I lt 120 l11 Bus communication with ABB circuit breakers Annex A Measures data and commands for supervision and remote control Ekip LS I Ekip Com TMD TMA Ekip Com XT2 Ekip M LRIU Ekip Com a a m a a a a E E E E E E E E XT4 Ekip LSI Ekip Com Ekip LSIG Ekip Com E E 2 E E E E M M E M E E E E E E c 2 Ekip E LSIG Ekip Com E a a a a a a a a a a a a a a a a a a a a a a a a a a m a a a a a a a a a a a Bus com
136. on against under frequency UF timing and trip Protection against over frequency OF timing and trip Diagnostic Trip command failed alarms Contact wear 100 Rating Plug error Trip coil TC disconnected or damaged Current sensors disconnected Commands Circuit breaker opening closing Alarm reset trip reset Setting of protection curves and thresholds Time synchronization of each circuit breaker carried out by system Events State changes of CB protections and alarms the latest 80 For further information about the electric quantities the data and the alarms available reference must be made to the following document Modbus system Interface for Protection relays PR122 P and PR123 P communication module PR120 D M mounted on CB New Emax Protection relays PR332 P and PR333 P communication module PR330 D M mounted on CB Emax X1 Tmax T7 and Tmax T8 document code 1SDH000556R0001 Test isolated position in which the power contacts are disconnected whereas the auxiliary contacts are connected 82 Bus communication with ABB circuit breakers Supervision with fieldbus Modbus RTU Table A 1A Measures data alarms and commands available with air circuit breakers type Emax DC Emax DC PR122 DC PR120 D M PR123 DC PR120 D M Electrical quantities State information Plant current Earth fault current Voltage
137. on impossible for them the whole communication system might not work properly due to the continuous incorrect voltages present on the device terminals badly connected In ABB SACE circuit breakers the communication termi nals are represented as shown in the following table Circuit Trip uit Terminal Terminal Note breaker A B Emax PR122 P e W1 W2 CB delivery terminal box or sliding contacts PR123 P Emax X1 PR332 P e w1 W2 CB delivery terminal box or sliding contacts Tmax T7 T7M PR333 P Tmax PR222DS PD X3 1 X3 2 __ terminals 1 and 2 of the rear connector X3 T4 T5 T6 PR223EF PR223DS SACE Tmax Ekip E LSIG cable W1 cable W2 cables W1 and W2 outgoing from Ekip Com module with fixed circuit breaker XT2 XT4 Ekip LSIG cables W1 and W2 outgoing from fixed part the socket of JF3 connector for withdrawable Ekip LSI circuit breakers Ekip M LRIU cables outgoing from clamps 1 for W1 and 2 for W2 of the fixed part the socket of the 6 pin XC5 plug and socket adapter on the back of the panel for plug in circuit breakers This table shows the information given in the wiring diagrams of Annex C Figure 23 Electrical wiring diagram of an Emax and a Tmax to the Modbus network Terminal resistor Main cable Main cable Terminal resistor Auxiliary terminals PR123 P X3 1 X3 2 PR223DS CB terminal box or sliding contacts Terminals 1 a
138. onnectors and mechanical components are largely standardized which allows a re duction in the total cost of the communication system The use of Ethernet in industrial control systems is also based on standardized components e g shielded twisted pair cable STP RJ45 connectors which are widespread in Ethernet industrial applications even if more suitable for office applications or M12 connectors but more resistant to mechanical and thermal stresses vibrations high humidity electromagnetic interferences dust and chemical agents which might be present in industrial environments For this reason we generally speak of components for industrial Ethernet However the described mechanism suffers some limi tations The main one is the lack of certainty of transfer times since a collision is always possible the time nec essary to transmit a single datum cannot be definitely known The more collisions occur the more frequently the packets experience delays Because of the random waiting time after a collision it is possible that many subsequent collisions occur if both the devices randomly select the same delays Bus communication with ABB circuit breakers 67 SIOMJOU dI dOL PUY U S19yeOIG 1INOIID JAY G SYIOMIOU _I dOL PUY U Ss4 Ldq YNI JAY G 68 4 Technical Application Papers hM y It is theoretically possible even if little likely that a packet may have to wait for a long time before being del
139. ore ABB low voltage equipment This software can be used for commissioning testing and monitoring of the Modbus RS 485 network and of the relevant connected devi ces detection of faults and anomalies in a communication network already active interaction and data exchange with the electronic trip units equipped with Modbus communication interface This document deals with the use of Ekip Connect software for the communication between a PC and one or more ABB devices simultaneously connected in a serial bus This configuration called Ekip Connect with serial line is used for communication via Modbus RS 485 networks with the electronic trip units fitted with communication module e g PR12X P with PR120 D M module for Emax Ekip Ekip LSI Ekip LSIG Ekip M LRIU and Ekip E LSIG with Ekip Com module for SACE Tmax XT and with the electronic trip units which have an integrated communication interface e g PR223DS EF PR222DS PD for Tmax T To make the PC on which Ekip Connect is installed communicate with the trip units it is necessary to use a serial converter for converting from the physical level RS 485 on the trip unit side to the physical level throu gh which you wish to connect to the PC e g RS 232 USB Ethernet The communication protocol to be used is Modbus RTU Bus communication with ABB circuit breakers With Ekip Connect it is possible to 1 carry out a check and a complete scanning of th
140. programmed alarms directly on the user s PC The performances are top level measurement and analysis of more than 60 electrical parameters voltage and current measures as true and effective value true RMS with accuracy class index 0 5 remote communication of measures according to dif ferent modalities programmable analogue outputs digital outputs for remote control programmable as threshold alarms or pulse outputs acquisition of the state of other devices in the panel communication protocols such as Modbus RTU Profibus DP Ethernet Modbus TCP IP Their use permits efficient monitoring of the quality of the energy in both single phase and three phase distribu tion networks through the instantaneous and historical analyses of voltage variations supply interruptions and of harmonics up to the 31st order and through the display of the wave shapes of voltage and current Their use allows also an optimization of the energy costs through an accurate historical analysis of energy consumption in four tariffs The main technical characteristics of the ANR net work analysers are summarized by the following table Voltage TRMS Direct measurement V Ratio transformer range kTV V 10 600 0 01 5000 00 Max overvoltage V 750 above this value it is necessary to use a voltage transformer Consumption VA 0 2 Input resistor MQ gt 2 Current TRMS 3
141. protocols used to make the different devices in industrial applications communicate are very numerous and vary according to the communication requirements of each application these may be the quantity of data to transmit the number of involved devices the characteristics of the environment where the com munication takes place the constraints of time the criticality of the data to be sent the possibility or not to correct data transmission errors and more There is also a further wide variety of protocols used to put into communication data processing apparatus such as the computers and their peripherals In the following chapters these protocols are not dealt with but the discussion is limited to a description of the protocols dedicated to industrial communication in fieldbuses that is those networks used to exchange information between a control system and the field de vices the sensors and the actuators provided with an advanced communication interface directly interacting with the physical process to be kept under control In particular the concepts of communication supervision and control shall be applied to the management of the low voltage electrical energy distribution installations 2 1 Communication protocols The protocols currently used in industrial communica tions are very complex In order to simplify their description it is usual to separate the operation levels In any prot
142. rear connector as shown in the following figure Figure B 1 Wiring diagram of the auxiliary power supply connection for P223DS trip unit Circuit breaker 7 en S L z is x mas EE SER Auxiliary power Lae Ey supply Vaux i KO TI L23 1 J N h 24V _ a 2 i i i i i iy 2 w f Terminals 3 and 4 of X3 rear connector PR223DS Figure B 2 Auxiliary power supply for moulded case circuit breakers T4 T5 and T6 Bus communication with ABB circuit breakers 91 g x uuy Ajddns z9mod Aeijxne y JO SO1 SI49 OeseYD E911 2913 s jnpow UONESIUNWILUOD OU 5 xouUy Technical Application Papers Moulded case circuit breakers SACE Tmax XT2 XT4 The auxiliary supply for the moulded case circuit brea kers SACE Tmax XT2 and XT4 is delivered to the Ekip Com module and to the electronic trip unit through the cables marked with K1 from the pole of the power supply and K2 from the pole of the power supply The electrical characteristics of the auxiliary supply vol tage Vaux are shown in the following table 92 Bus communication with ABB circuit breakers Ekip LSI LSIG Ekip E LSIG Electrical characteristics Ekip M LRIU Ekip Com Rated voltage 24V dc 20 24V dc 20 Maximum ripple 5 10 500 mA for 20 ms 1 A for 0
143. roller to assign priority and permission to transmit is not necessary In addition to being a critical element in case of fault the controller should be configured with the data of the devices in the network how many which ones trans mission priority etc an operation which is generally complicated and not within the user s reach all devices can have access to the network whenever necessary when they have some data to transfer and leave the network free when they do not use it it is not necessary that priority or other parameters relevant to communication are assigned to the single devices itis possible to add or remove devices at any moment without disturbing the network activity and without carrying out configuration operations Note addition or removal of nodes very common in office environment is rarer in industrial environment crossed communications are possible the device A can send data to B and the device C can send data to D without neither of the two couples has to take into consideration the other since all devices are connected to the same bus it is possible to transmit one to one broadcast or one to many devices multicast as the traffic on the network increases the perform ances average transmission times gradually get worse and worse In the course of the years these advantages have deter mined the development of a well established technology cables hardware interfaces c
144. rs The multimeters of the DMTME series are digital multi meters which enable the main electrical quantities to be measured TRMS values in 230 400 V a c three phase networks the maximum minimum and average values of the main electrical parameters to be stored and the active and reactive energy to be metered The multimeters of the DMTME series enable the same instrument to be used as a voltmeter ammeter power factor meter wattmeter varmeter frequency meter active and reactive energy meter and hour meter thus permit ting significant savings because both the size inside the panels as well as the wiring time can be reduced In the version DMTME I 485 the multimeter is provided with two digital outputs which can be programmed as alarm thresholds and pulse outputs for remote control of energy consumption and with a serial port RS485 From the serial port RS485 several multimeters and other digital instruments can be connected to a com munication network via Modbus RTU protocol up to 32 measuring instruments in addition to the master can be connected The main technical characteristics of these devices are summarized in the following table Rated voltage V rms 230 15 10 DMTME 72 and DMTME 96 V rms 240 15 10 DMTME 72 and DMTME 96 V rms 400 10 10 DMTME 72 V rms 400 10 10 DMTME 72 V rms 115 15 10 DMTME 96 V rms 120 15 10 DMTME 96 Frequency Power consumption
145. rs and terminals physically near one another for example loca ted in the same building Bus communication with ABB circuit breakers 5 1 1 IP protocol The IP control Internet Protocol allows a device on a local network to communicate with another device lo cated on another local network provided that the source network and the destination one are somehow intercon nected This interconnection can be realized with any number of intermediate networks The protocol is based on the presence of routing devices router which make the packet be delivered from one network to the other up to destination The power and the utility of the IP protocol is that it is not necessary for the sender to know the pathway that the data packet shall follow to reach its destination The IP system works like a mail system caring that a data packet marked with the recipient address travels up to its destination As a matter of fact the different packets transmitted by a sender could reach the same recipient through different pathways since the routers could decide different routes from time to time according to the network situation traffic etc The IP control describes in details what a device must do to send a data packet to another device or to send a response to a received packet the behavior of the devices which make the packets travelling from a network to another one to reach their destination The details of the protocol are
146. ry contacts and MOE E motor operator for Tmax T4 T5 T6 For Tmax circuit breakers type T4 T5 and T6 some special accessories are needed AUX E auxiliary contacts in electronic version for supervision only motor operator with electronic interface type MOE E for remote control too E 1 AUX E auxiliary contacts in electronic version Through the AUX E auxiliary contacts the micropro cessor based releases type PR222DS PD PR223EF and PR223DS detect the circuit breaker state open closed tripped and make available such information for the remote supervision system by communicating with it through the Modbus network see Figure E 2 The AUX E contacts make available the information about the circuit breaker state also on the signaling circuits of Figure E 2 Wiring diagram of AUX E contacts connected to PR222DS PD Main circuit breaker the plant through the contacts SQ and SY see Figure E 2 in this way it is possible to obtain a redundancy of the CB state signals Figure E 1 Auxiliary contact module AUX E mounted on Tmax T5 Signaling circuits LDSQ amp TVL1 i X3 TI L2 Zal i IN Auxiliary power TI L3 p supply Vaux D i d 74 Remote TAN aod ond 2 7 supervision system na 1 24V T K i B eg a eB E ob i N Gaia Cable A N cp Digital si
147. s generally with fast and cyclic data exchange between field apparatus and controllers DeviceNet also used to interface apparatus and con trollers PC PLC AS i for the communication with very simple sensors such as limit switches or switching devices e g push buttons 2 1 3 Application layer The application layer gives a meaning to the transferred data that is it associates commands e g open close the circuit breaker or a number e g voltage values with the data in binary format interchanged by the devices over the communication network For instance suppose to use the Modbus protocol for remote reading of the current values stored in a Tmax circuit breaker equipped with PR222DS PD trip unit Each trip unit stores the values of the quantities and of the parameters in dedicated registers these registers can be reading only e g register of current measures or reading and writing e g register for the setting of the curves and of the trip thresholds of the protections In the PR222DS PD the currents are stored in the reg isters starting from the number 30101 Figure 15 Registers of PR222DS PD with run time current values No Content of the Meaning of the of register register content 30101 198 IL1 Current in the phase 1 A 30102 298 IL2 Current in the phase 2 A 30103 447 IL3 Current in the phase 3 A 30104 220 ILN Current in the neutral A When the master unit e g a PC wants to read the
148. s provided with SW version 3 00 or following ones HMIO30 is configured in Master mode and with communication via Internal bus WI The 24 V DC auxiliary voltage kit must be used K1 K2 auxiliary supply Vaux WI Internal bus of the trip unit CAN Interface reserve for ABB devices cables W3 and W4 of the 24 V DC auxiliary voltage kit Maximum length of the connection between HMI030 and trip unit 15 m For lengths exceeding 15 m and up to 300 m it is necessary to set the unit HMIO30 to Master mode and use Modbus RS485 communication interface terminals 3 and 4 use the communication module type Ekip Com instead of the 24 V DC auxiliary voltage kit for the connection between HMI030 and trip unit HMI030 unit is to be connected to the System bus WS of the trip unit cables W1 and W2 of Ekip Com module set the following communication parameters of the trip unit Address 247 Baud rate 19200 Parity EVEN Stop bit 1 The connection between trip unit and HMI030 shall be achieved through twisted pair cables shielded and with characteristic impedance equal to 120 Q e g Belden 3105 cable type or equivalent The shield shall be connected to earth at one end of the connection Bus communication with ABB circuit breakers Display on panel front with more units HMI030 With this configuration it is possible to connect up to four HMIO30 units to the same trip unit on the same bus if the following conditions are complied with
149. s technical characteristics see Annex B The measures data information and control operations from remote are summarized in Table A 1A of Annex A All the commands from remote control via bus can be blocked by setting the trip unit to local mode As regards the configuration of use of PR122 DC and PR123 DC trip units with the accessories for the Modbus communication reference must be made to the configu ration of use of PR123 P trip unit for alternating current shown on page 15 of this document NOTE For a deeper analysis on direct current plants please consult Technical Application Paper No 5 ABB circuit breakers for direct current applications PR122 VF electronic trip unit for variable frequency applications Low voltage circuit breakers type E2 VF and E3 VF series SACE Emax VF for variable frequency applications in particular at low frequency from 1 to 60 Hz equipped with electronic trip unit PR122 VF can be integrated into the communication systems with the Modbus RTU field bus for the supervision and control of variable frequency installations e g wind power turbines with rated operat ing voltage up to 1000V a c and current up to 2500A For the connection to the Modbus network the com munication module PR120 D M must be used see Annex To implement from a remote supervision system open ing and closing commands on the circuit breakers series SACE Emax VF the following accessories are necessary
150. se Opening YC shunt closing release Closing YR reset coil Reset M geared motor for the automatic charging of the closing springs Disconnector type T1D T3D Solenoid operator MOS Opening Closing T4D T5D T6D Stored energy motor operator MOE Opening Closing T7DM X1B MS SOR shunt opening release Opening SCR shunt closing release Closing M geared motor for the automatic charging of the closing springs E1 MS E6 MS YO shunt opening release Opening YC shunt closing release Closing Figure 20 Circuit diagram of SD030DX Vaux auxiliary supply gt AJ 24V EIARS 485 interface for the connection to Modbus network Digital outputs Digital inputs Bus communication with ABB circuit breakers 27 UOHLOIUNWIWOD snq 104 uonnjos ggY p UONLOIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers The proper wirings for a correct functioning of SD030DX As an example Figure 21 shows the wiring diagram of the are connected to SDO030DX unit to an air circuit breaker type Emax E6 the auxiliary circuits of the circuit breaker through DI inputs and DO outputs so that the unit can interact In order to function SDO30DX unit needs to be sup with the CB and make it possible command actuation plied by an auxiliary voltage Vaux having the following opening closing reset and the detection of CB state characteristics the Modbus network through EIA RS 485 serial inter face to
151. ssing the phase voltages The measured data are transferred to the trip unit so that a series of electrical parameters see Annex A useful for the monitoring of the plant by the supervision system is made available or if necessary to allow the implementa tion of a protection logic for the plant Besides PR120 V and PR330 V measuring modules can give the trip unit an additional supply without replacing the self supply or the auxiliary power supply this last always necessary for the communication via bus re spectively to the trip units type PR122 P and PR123 P for Emax E1 E6 PR332 P and PR333 P for Emax X1 and PR332 P for Tmax T7 Bus communication with ABB circuit breakers Figure D 1 PR120 V measuring module N Figure D 2 PR330 V measuring module Tmax moulded case circuit breakers T4 T5 T6 Figure D 4 Connection of VM210 module to PR223DS trip unit Features of VM210 measuring module Circuit breaker VM210 module is a voltage transducer which can be ia connected directly to the electric network It provides a xg graduated output signal to be used by the ABB protec Anay power tion trip units PR223EF and PR223DS ace tae Figure D 3 VM210 measuring module 3 S 5 A Te 2av m A B a X4 Modbus cable 1 q D al Y
152. state of the apparatus is carried out through the auxiliary contacts which therefore must be mounted on the circuit breaker As regards commands instead the circuit breaker switch disconnector must be fitted out with suitable accessories a The main characteristics of SDO30DX are shown in the following table Open Closed Reset SD030 DX 5 digital inputs Acquisition of CB state Figure19 SDO30DX solution Converter RS 232 RS 485 3 SD030DX SDO030DX Tmax T3 TMA Tmax T5 PR221DS im SDO030DX 5 SD030DX Tmax T4 PR221DS Emax E2 PR121 P Bus communication with ABB circuit breakers 25 uoesaiunwwo snq 104 uonnjos ggY p i UONLOIUNWIWOD snq 104 uonnjos ggY p 26 Technical Application Papers Reading of the circuit breaker state To read the circuit breaker state up to 5 auxiliary contacts can be used connected respectively to the five digital inputs DI1 DI2 DI3 DI4 and DI5 of SD030DX Circuit breaker type The following table shows the circuit breakers and the switch disconnectors which can be managed through SD030DX the information associated to each digital input with the corresponding auxiliary contact for the different type of circuit breaker Associated information Springs Protection CB state Mode Discharged 0 Normal 0 Racked out 0 Open 0 Normal 0 Remote 0 Charged 1 Tripped 1
153. t breakers T ay C ae n Tae 1 a8 a8 a8 a8 Wow 3 a a i i T L g 2 1 m T1 L2 n 5 Auxiliary power O lme d J supply Vaux Ae oes a i ee a a a SF i B 24V _ f q gt B i 5 A Modbus cable i op 1 Q o N Terminals 1 and 2 i T of X3 connector i A i 1 pees ee Oa a 2 Connection to EP010 unit The moulded case circuit breakers type T4 T5 and T6 are connected to the unit EP010 through the terminals 1 and 2 of X3 rear connector Figure C 7 Wiring diagram for the connection of the unit EP010 of a Tmax circuit breaker Circuit breakers alr i A i Q 1 X3 i TVL1 1 E 1 I gt Auxiliary power OEN supply Vaux a 1 _ foe Pe eet AA eel EEE Re soqbocdoed eed Lav x B 2 1 9 i 1 fF n T A L Ww E B I a The Modbus cable which i A connects EP010 to X3 connector i E shall have a maximum length of 1m SA i K Ke i j i Figure C 6 Connection to the Modbus network of Tmax CBs T4 T5 and T6 through X3 connector Modbus cable Bus communication with ABB circuit breakers 97 5 x uuy s jnpow UONeOIUNWWOD yL 5 xeuuy s jnpow UONESIUNWIWOS sy L 98 Techn
154. t cost of energy proportional to the number of kWh consumed by each manufacturing line the penalties relevant to the reactive power pro portional to the number of minutes during which the coso of the plant has been lower than the value fixed by the power supply authority of the electrical network Bus communication with ABB circuit breakers 79 sojdwexse uolnesjddy 9 sojdwexe uonesjddy 9 80 Technical Application Papers 6 2 1 Description of the distribution and communication system The electrical plant has a LV radial distribution structure Each line is supplied by means of a process switchboard QBT PR which delivers power to the real production plant and a switchboard for the automation of the pack ing system QBT AU which supplies the machines for the bottling and handling of the packages Each of the switchboards uses as main circuit breaker an Emax E2 equipped with the following accessories PR122 P trip unit PR120 V voltage measuring module PR120 D M Modbus communication module The trip units are supplied at 24 Vd c by ABB switching power supplies type CP 24 1 each one of them posi tioned in a main switchboard All the main circuit breakers are connected through a communication bus RS 485 to a personal computer on which the supervision application is installed The computer is in its time connected via a local network with the control systems of
155. t overcurrents and deliver energy to the loads also takes the function of field device of the supervision system functioning both as transmitter as well as actuator The use as a transmitter makes it possible to keep under control the electrical energy consumption and to improve the management of the electrical distribution plant The energy consumptions of an electrical plant which supplies a definite manufacturing process can be control led stored and analyzed with purpose of reducing the power consumption in real time by dis connecting the non priority loads if the effective drawn power exceeds the maximum contractual power so as to avoid the payment of penalties to the power supply authority identifying the type of electrical power supply contract which is most suitable and compatible with the real requirements of the plant through a continuous control and an analysis of the energy withdrawal In this way it is possible to avoid signing a contract which is not aligned with the variations of the energy withdrawals during the year and find yourself for instance to pay a fine for the periods when the consumed power exceeds the maximum power fixed by contract 7 For transmitter a sensor is meant which transmits the measured data through a com munication system In this document the two terms sensor and transmitter are used as synonym 12 Bus communication with ABB circuit breakers identifying and
156. t up to four HMI030 units to the same trip unit on the same bus if the following conditions are complied with trip unit type PR122 P PR123 P or PR332 P PR333 P each unit HMI030 has SW version 2 00 or following ones and is configured in Slave mode Modbus RS485 communication interface is used terminals 3 and 4 MMO030 unit is present supply with auxiliary voltage at 24 V d c Pn 2 5 W 24V four different operating modes Ammeter Voltmeter Wattmeter and Custom are selected for each HMIO30 Principle scheme PR122 P PR123 P PR332 P PR333 P Local bus W2 RS Rotative Selector W2 Local bus of the trip unit terminals W3 and W4 and of the unit MM030 terminals 10 and 11 W3 Accessory bus of MM030 unit terminals 13 and 14 Maximum recommended length for the Local bus W2 15 m Maximum recommended length for the Accessory bus W3 300 m For the connections twisted pair cables shielded and with characteristic impedance equal to a 120 Q e g cable type Belden 3105 or equivalent For the connection between trip unit and MMO30 it is advisable to ground the shield at the end of the connection towards the trip unit As regards wiring of the Accessory bus W3 it is advisable to ground the shield at the end of the connection towards MM030 unit As for wiring the instructions of the product technical manual Flex Interfaces for Accessory Bus should be followed With PR121 P and PR331 P trip units it is possi
157. tacts l l SOR SCR YW YW G K51 SOR K51 SCR PR330 R PR330 D M PR332 P PR333 P Q 1 6 ssam S751 1 7 i W1 W2 terminals for the connection of the Modbus cable K1 K2 terminals for auxiliary power supply Vaux L 1 terminals for the Modbus port SOR shunt opening release SCR shunt closing release K51 SOR control contact for the shunt opening release K51 SCR control contact for the shunt closing release Q 5 Q 6 circuit breaker auxiliary contacts 33M 1 3 contacts signaling spring charged 751 1 7 contacts signaling circuit breaker racked in for CBs in withdrawable version The Modbus cable which connects EP010 to the trip unit shall have a maximum length of 1 m The supply of the shunt opening release SOR and of the shunt closing release SCR must not be derived from the main supply and can have maximum voltage values equal to 110 120 V DC or 240 250 V AC Bus communication with ABB circuit breakers Tmax moulded case circuit breakers type T4 T5 T6 Connection to the Modbus network The connection to the Modbus network of the moulded case circuit breakers type T4 T5 and T6 equipped with PR222DS PD PR223EF and PR223DS trip units is car ried out through the terminals 1 and 2 of the dedicated X3 rear connector as shown in the diagram of Figure C 5 Figure C 5 Wiring diagram for the connection of PR223DS trip unit to the Modbus network through X3 connector Circui
158. tage for the relevant characteristics see Annex B The data alarms and measures made available by each trip unit are summarized in Table A 1 for Emax E1 E6 Emax X1 and Tmax T7 circuit breakers in Table A 2 for Tmax T4 T5 and T6 circuit breakers and in Table A 3 for SACE Tmax XT2 and XT4 circuit breakers of Annex A During the operation SD GEM must be supplied with 24 V DC auxiliary voltage For more detailed information please refer to the relevant catalogues and product technical manuals Bus communication with ABB circuit breakers 77 SIOMIOU qI dOL PUY U S19yeO1G 1INDIID JAY G sojdwexe uolnesjddy 9 78 Technical Application Papers 6 Application examples Here are some examples of application of ABB SACE circuit breakers with dialogue option for supervision of protections and switching of circuit breakers energy costs allocation inside a plant management of priority and non priority loads of an installation 6 1 Supervision of protections and circuit breaker switching Take into consideration a power plant In these types of installation it is very important to keep under control be sides the power production process also all the circuits which supply the auxiliary services command room heating system circuit breaker and switch disconnector motors fire prevention system ambient lightning outlets etc These are low voltage circuits
159. the converter receives a request telegram it takes the content without the TCP IP part and sends it as telegram on the serial port To all intents and purposes this telegram is a Modbus telegram destined to one of the slave devices which therefore shall reply with another Modbus telegram The converter shall receive this response shall insert it as content into a TCP IP telegram and transmit it to the client see Figure 38 Traditional Modbus telegram Modbus RTU V vy vy Transaction ID Protocol ID Length Function Code Modbus TCP telegram Bus communication with ABB circuit breakers Thus a Modbus TCP system can have access to alldata reading of the current values in the three phases and in present on the register map of any Modbus traditional the neutral of a SACE Tmax XT4 160 equipped with an device e g an automatic circuit breaker connected on electronic trip unit type Ekip LSIG in an Ethernet TCP IP a Modbus serial line network SD GEM gateway operates simultaneously both The following Figures conceptually show an example of as TCP IP server as well as Modbus RTU master Figure 39 Reading of the currents on an Ethernet TCP IP network Request IP address 5 6 7 8 IP address 1 2 3 4 SD GEM SS SS Gateway Request 123 4 1l04 100 8 Modbus serial line i Tmax T4 Tmax T4 T5 Tmax T4 Emax E1 E6 SACE Tmax XT4 PR223EF PR223DS PD SD030DX PR122 o PR123 Ekip LS
160. the latest 20 trips Protection alarms Protection L timing and trip Pre alarm protection L Protection trip Protection against overtemperature OT pre alarm and trip Diagnostic alarms Failure of opening mechanism TRIP command failed Contact wear 100 Rating Plug disconnected Trip coil TC disconnected or failed Controls CB opening closing command Reset alarms Trip reset Protection curve and threshold settings System time synchronization of each CB Events State changes of CB protections and alarms the latest 80 For further information about the electric quantities the data and the alarms available reference must be made to the following document Emax VF PR122 VF PR120 D M Modbus System Interface document code 1SDH000922R0001 Test isolated position in which the power contacts are disconnected whereas the auxiliary contacts are connected Bus communication with ABB circuit breakers Supervision with fieldbus Modbus RTU Table A 2 Measures data alarms and commands available with Tmax moulded case circuit breakers type T4 T5 and T6 PR222DS PD PR223EF PR223EF VM210 PR223DS PR223DS VM210 Electric quantities Phase currents IL1 IL2 IL3 neutral current IN ground current Ig Phase to phase voltages V12 V23 V31 Phase to neutral voltages V1 V2 V3 Peak factor L1 L2 L3 N Frequency Total
161. the plant LAN network Th e 6 2 2 Functioning The presence of PR120 V modules allows the trip unit of each main circuit breaker to measure continuously active power reactive power and cos q relevant to its own load The trip unit is provided with an energy meter in which the total active power value is stored moment by moment All the above mentioned products are available as input registers accessible for reading via Modbus protocol The supervision application carries out a very simple cy cle which consists in querying each of the circuit breaker in reading the registers of total accumulated energy and in measuring the reactive power For instance reading can be made once in 5 secs Once in 15 minutes the application program writes in a file the values of total energy and of average reactive power for each circuit breaker Then such values are read by the people responsible for cost allocation thus allowing to know the use of active and reactive power consumed by the plant and to share the costs among the different production lines RS 232 RS 485
162. the wink command To send these commands it is necessary to insert a password When the device is set in local mode the commands may not be operated Lj ABE Ekip Connect r Amn vee Tose tp Measures This window shows the measures acquired in real time by the trip unit the information and the type of electrical quantities which can be displayed vary according to the type of trip unit involved see Annex A Bus communication with ABB circuit breakers 49 UOHPOIUNWIWOD snq 104 uonnjos ggY p 50 Technical Application Papers Measures history With the trip units type PR122 P and PR123 P for Emax and PR332 P and PR333 P for Tmax T7 and Emax X1 it is possible to view the values of the following electrical quantities the total active power medium and maximum value the phase at the maximum current the maximum current value RMS value the phase at the minimum and maximum voltage the phase at the minimum voltage and the minimum voltage value the total reactive power medium and maximum value the total apparent power medium and maximum value measured in the last 24 periods of time which can be set at intervals from 5 minutes storage of the last 2 hours 120 minutes storage of the last 48 hours With SACE Tmax XT4 circuit breakers thanks to the electronic trip units Ekip E LSIG it is possible to view the maximum and minimum values which the following quantities have reached up to
163. tinuity for the installation Moreover the use of circuit breakers as transmitters of the supervision system makes it possible measuring of the main electrical quantities of the plant currents volt ages powers without using dedicated instruments The above involves cost savings in terms of purchase costs of equipment and moreover it allows saving space inside the distribution switchboards since it is not neces sary to install inside it the sensors to be interfaced with the control system Figure 18 The circuit breaker as sensor and actuator of a supervision system iiin i RS 232 RS 485 converter Commands ModbusRTU Bus communication with ABB circuit breakers 13 s uejd uonnqiysip ed11 O9 9 JO UOISIAJOdNS j UONeDIUNWWOD snq JO uonnjos ggY p 14 d echnical Application Papers a 4 ABB solution for bus communication This chapter describes the electronic trip units the accessories and the pro ducts which enable ABB SACE circuit breakers to be integrated into the field buses Modbus RTU Profibus DP and DeviceNet for the supervision and the remote control of LV electrical distribution plants the front panel interface HMI030 the rules for the arrangement of the Modbus RS 485 network ABB digital measuring instruments with communication function 4 4 Emax air circuit breakers PR122 P PR123 P electronic trip units for alternating current applications Modbus communication
164. tion with ABB circuit breakers 85 erence must be made to the following document y xouuy J01 U09 0w 1 pue UOISIAJOdNs 10 SPUBLULUOD pue e ep Ssounseoyy y xouuy J01 U09 0w 1 pue UOISIAJOdNs 10 SPUBLULUOD pue e ep Sseinseo y 86 Technical Application Papers Supervision with fieldbus Modbus RTU Table A 3 Measures data alarms and commands available with moulded case circuit breakers type SACE Tmax XT2 XT4 Electrical quantities run time values Phase currents I I I Neutral current ly Ground current I Phase to phase voltages V V V Phase neutral voltages Vin Van Van Frequency Total active power P and phase power P P P Total reactive power Q and phase power Q Q Q Total apparent power S and phase power S S S Active energy positive negative Total active energy Reactive energy positive negative Total reactive energy Total apparent energy Total power factor COS and phase factor cos a ot COS yo cos Electrical quantities values on demand Harmonic analysis in the phases and in the neutral spectrum of current up to 11th harmonic at 50 Hz and 60 Hz THDi in the phases L1 L2 L3 and in the neutral Ne at 50 Hz and 60 Hz Measure history Phase currents iment Ih oman I aman I min liami Warn Neutral current Inemax Iemin
165. trical characteristics PR122 VF Rated voltage Maximum ripple 5 5 5 Inrush current 24V Rated current 24V 10Afor5ms 10Afor5ms 10A for5 ms 170 mA Rated power 24V 4 w0 4 W0 4 W0 1 Value referred to the supply of the trip unit PR12X P or PR12X DC or PR122 VF PR120 D M communication module 2 For the connection of the auxiliary supply to the trip unit a shielded twisted pair cable e g cable type BELDEN 3105A 3105B is to be used The shield of the cable must be grounded at one end of the connection towards the trip unit Emax X1 and Tmax T7 T7M Electrical characteristics PR332 P PR333 P Rated voltage 24 V dc 20 Maximum ripple 5 Inrush current 24V 2 A for 5 ms Rated current 24V 170 mA Rated power 24V 4W Value referred to the supply of PR33X P PR330 D M communication module Tmax moulded case circuit breakers T4 T5 T6 The electrical characteristics of the auxiliary supply vol tage Vaux are shown in the following table Electrical characteristics PR222DS PD PR223DS PR223EF Rated voltage 24 V dc 20 24 V dc 20 Maximum ripple 5 5 Inrush current 24V 1 A for 30 ms 4A for 0 5 ms Rated current 24V 100 mA 80 mA Rated power 24V 2 5 W 2W As for the moulded case circuit breakers type Tmax T4 T5 and T6 the auxiliary supply is provided to the trip units PR222DS PD PR223EF and PR223DS through the terminals 3 and 4 of X3
166. version see Annex E receive from a remote supervision system the com mands e g opening and closing of the circuit breaker or the settings of the protection functions thus imple menting remote control To perform the remote control i e the mechanical PR222DS PD electronic trip unit implementation of the remote opening and closing commands Tmax moulded case circuit breakers type T4 T5 and T6 must be equipped with the motor opera tor with electronic interface MOE E Annex E and the AUX E auxiliary contacts in electronic version Annex E As regards bus communication remember that the aux iliary supply voltage Vaux is necessary for the trip units PR222DS PD PR223EF and PR223DS for its charac teristics see Annex B Measures The trip units type PR222DS PD PR223EF and PR223DS give the measure of the currents in the three phases in the neutral and to earth Thanks to the voltage measuring module VM210 and X4 rear connector see Annex D the trip units type PR223EF and PR223DS can measure in addition to the currents also the main electrical quantities of the plant See An nex A The measured values can be sent to the remote supervision system by the trip unit through the terminals 1 and 2 of X3 connector For measures data alarms and remote control opera tions please refer to Table A 2 in Annex A All the commands from remote control through the bus can be disabled by setting the trip unit to local mode
167. y on the panel front the measured electrical quantities For more detailed information see the product technical manual Flex Interfaces for Accessory Bus document code 1SDH000622R0001 Bus communication with ABB circuit breakers 39 UOledIUNWIWOD snq 104 uonnjos ggY p UOHPIIUNWIWOD snq 104 uonnjos ggY p Technical Application Papers 4 7 Modbus RS 485 network Rules for a correct wiring The wiring of the industrial communication systems presents some differences in comparison with that used for power cabling and this may put into difficulties the installer if he is not experienced in Modbus communica tion networks A Modbus RS 485 system puts into communication a Master device with one or more Slave devices From now on only ABB SACE low voltage circuit breakers shall be considered as Slave devices even if wiring is similar for all Modbus devices Here is a presentation of the main rules to comply with for the wiring of this type of networks 1 Connection port Each device is equipped with a communication port with two terminals conventionally called A and B The communication cable is connected into these two terminals so that all the devices involved by the com munication are connected in parallel All the terminals A and B shall be connected together respectively A to A and B to B in case of reversed con nections A to B of a device besides making communi cati
168. y the involved device shall send a response giving the required data or informing the Master that its query cannot be satis fied The circuit breakers are queried by the PC with cyclic polling that is cyclically one after the other so that the complete scanning of the plant is carried out within a predictable time polling time For instance supposing we want to read the current values from 6 Tmax circuit breakers equipped with the electronic trip unit PR222DS PD For the communication sequence between each circuit breaker and the PC the following times are assumed query time tQ time necessary for the PC query to the circuit breaker 7ms time interval dt between query and response 43ms response time tR time necessary for the circuit breaker response to the PC 9ms k t polling 354 ms PF tQ dt tR tPC Q QUERY query of the PC to the circuit breaker Modbus RTU 4 Q6 R6 Q1 R1 t MODBUS query LAN network Il i RS232 4 Eno t ini i a MODBUS response LAN network R RESPONSE response sent by the circuit breaker to the PC gt C Modbus RTU Bus communication with ABB circuit breakers Under these suppositions the query time for each circuit breaker is about 59ms and considering it constant for all the circuit breakers the polling time for each com munication cycle shall be about 59 x 6 354ms When calculating the polling time the processing time of the
169. ystem 7 wI 3 8 CAN HMI030 CII Vaux ape _ 24V Wi Modbus cable ws JF3 4 XC5 K1 Twi T w2 yee K2 Gwagw3 XV K2 K1 W49W3 W1 W2 JF3 JE3 connectors for the auxiliary circuits of the CB in with drawable version XC5 6 pin plug and socket adapter on the back of the panel for the auxiliary circuits of the CB in plug in version XV terminal box of the CB appli cations I i I I Ekip Com module Ekip E LSIG Ekip LSI Ekip LSIG Ekip M LIRU This configuration can be achieved if HMI030 is provided with SW version 3 00 or following ones HMIO30 configured in Master mode and communication via Internal bus WI WI Internal bus of the trip unit CAN interface reserved for ABB devices cables W3 and W4 of Ekip Com module WS System bus of the trip unit cables W1 and W2 of Ekip Com module K1 K2 auxiliary supply Vaux Maximum length of the connection between HMIO30 and trip unit 15 m The connection between trip unit and HMI030 shall be achieved through twisted pair cables shielded and with characteristic impedance equal to 120 Q e g Belden 3105 cable type or equivalent The shield shall be connected to earth at one end of the connection Bus communication with ABB circuit breakers Display on panel front To achieve this configuration it is possible to use

4 - ABB

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