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Bus communication with ABB circuit

1. 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 the 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 sible For instance in the bit fram
2. TI L1 i X3 TI L2 CR i IN Auxiliary power TI L3 q p supply Vaux J l amer Remote TUN e ee E See 2224 23 ri supervision system l w 2 m 3 y a a 2 B i al ee P M l A Eo Cable A N mE Digital signals open closed tripped Terminals 1 and 2 l of X3 rear connector 2 Sy eee eae a 2 c z x 2 b p 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 Figure E 3 Operating principle of MOE E and AUX E
3. Bus communication with ABB circuit breakers bo mr 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 consti tuted 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 acertain number of data bits e g 8
4. i 1 a JER rT 4 T BA 1f 1 27 2 3 3 if OK PR123 P PR123 P 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 Bus communication with ABB circuit breakers 4 3 1 Modbus 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 commu
5. 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 f uo esiunwwo jebad Z p E E Star network Star networks are based on a central node to which all the other peripheral nodes are connected Figure 3 Star network i Eli f a 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 B
6. Supervision with fieldbus Profibus DP and DeviceNet Table A 3 Measures data alarms and commands available with Emax air circuit breakers X1 air circuit breakers and Tmax T7 moulded case circuit breakers E _ E1 E6 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 pala pie dpiaes IL1 IL2 IL3 neutral current IN E a a m Voltages phase to phase phase to neutral residual B E E E Total power active P reactive Q apparent A E E L E Total power factor A E E Frequency E Total energy active reactive apparent E E E E Harmonic analysis THDi THDv and spectrum m m up to 25th harmonic odd order harmonics State Circuit breaker state open closed tripped E E E E E E information Circuit breaker position racked in racked out m Spring state charged discharged E a E E E Mode local remote m E o E L a Protection parameters set E B B E Maintenance Total number of operations L H L L m data Total number of trips B E E g E E Protections Protection L a E E E m a alarms Protection S a a Protection E E E B m Protection G E E E E E 123 eae unbalanced phase currents U P P Protection against overtemperature of the trip unit OT E B
7. Bus communication with ABB circuit breakers MAIN NODE Modbus network to which the devices are connected SUBNODES Connected devices During the scanning process the presence of every device even if not a circuit breaker connected to the bus and able to communicate via Modbus protocol is detected and signaled with the relevant communication parameters At the end of the scanning operation SD Testbus2 dis plays any warning message about possible problems or configuration errors of the devices e g two devices with different transmission speed allowing a complete diagnosis of the communication network Moreover thanks to the function Find Master SD TestBus2 can monitor the presence of any master on the bus showing its characteristic parameters of com munication COM port speed and parity During the testing phase of an electric switchboard i equipped with devices which communicate via Modbus and designed to be installed in a plant with supervision systems scanning of the system bus is particularly useful In fact this control operation allows to identify any pos sible fault of connection between the different devices or setting errors of the communication parameters e g speed parity stop bit number etc or configuration er rors of the connected devices e g logic address with the possibility to correct the errors when the switchboard is not in an operating phase yet Thanks to th
8. 9 B Aiea Application Popers i pp p January 2009 Bus communication with ABB circuit breakers 1SDC007108G0201 a Bus communication with ABB circuit breakers Index 1 Introduction 2 2 Digital communication 3 21 Communication protocols cceee 4 2 4 4 Physical lay rsrsinaree a 5 2 1 1 1 RS 232 and RS 485 interfaces 6 8 1 2 Datalink ayot ernia a R 8 2 1 3 Application layer c cccccccscssssesessesssesessseesessseseseseeeees 8 2 1 4 Compatibility between the layers 0 eee 9 3 Supervision of electrical distribution plants 10 3 1 Supervision with ABB SACE circuit breakers 0 2 cccccececeeeceececeeeeeeeeneeeeeeenees 12 4 ABB solution for bus com munication 44 Air and moulded case circuit breakers cccceeeeeeeeeeeeeeeseeeeeeees 14 4 1 1 Emax air circuit breakers E1 E2 E3 E4 E6 14 4 1 2 Emax X1 air circuit breakers and Tmax T7 moulded case Circuit breakers ssec 16 4 1 3 Tmax moulded case circuit breakers T4 T5 T6 18 4 2 SD030DxX solution for the circuit breakers without Modbus interface ccccccceee 21 4 3 Network Modbus RS 485 Rules for a correct wiring cece 25 4 3 1 Modbus system functioning ccceceseteeseeeseeeeees 29 4 4 SD TestBus2 and SD View 2000 software PIOQlAMMES iisisti iieri 30 441 e D T E T 4 4 1 1 Scanning of the system bus 4 4 1 2 Interaction with the single
9. DI4 CB auxiliary contacts Q 1 DI4 CB auxiliary contacts Q 1 DI5 switching contact for electrical signaling of local remote selector status 83 1 DI5 switch for setting remote local control 843 22 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 UOl LOIUNWIWWOD snq 104 uonnjos ggy p F M geared motor for the automatic charging of the closing springs Circuit breaker type Accessories for the command actuation Commands TAAA 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 release 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
10. Bus communication with ABB circuit breakers Annex B Electrical characteristics of the auxiliary power supply Emax air circuit breakers E1 E2 E3 E4 and E6 Electrical characteristics PR122 P PR123 P Rated voltage 24 V dc 20 Maximum ripple 5 Inrush current 24 V 10A for 5 ms Rated current 24 V 170 mA Rated power 24 V 4W Value referred to the supply of PR12X P PR120 D M communication module Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers Electrical characteristics PR332 P PR333 P Rated voltage 24 V dc 20 Maximum ripple 5 Inrush current 24 V 2 A for 5 ms Rated current 24 V 170 mA Rated power 24 V 4 W Value referred to the supply of PR33X P PR330 D M communication module Tmax moulded case circuit breakers T4 T5 and T6 Electrical characteristics PR222DS PD PR223DS PR223EF Rated voltage 24 V dc 20 24 V dc 20 Maximum ripple 5 5 Inrush current 24 V 1 A for 30 ms 4A for 0 5 ms Rated current 24 V 100 mA 80 mA Rated power 24 V 2 5 W 2W As regards the air circuit breakers type Emax and Emax X1 and Tmax T7 moulded case circuit breakers the auxiliary power supply is delivered to the terminal box and precisely to the terminals K1 and K2 As regards the moulded case circuit breakers type T4 T5 and T6 the auxiliary supply is provided to the trip units PR222DS PD PR223EF and PR223DS through the terminals 3
11. access to the information about previous trips For more detailed information on the use of the software and on all the available functions please refer to the User Manual SD TestBus2 Bus communication with ABB circuit breakers 33 UOI EDIUNWIWOD snq JO uonnjos ggY p i UO I EDIUNWIWOD snq 104 uonnjos ggY p Hl Seer TT 34 att Technical Application Papers vA 4 4 2 SD View 2000 SD View 2000 is a software for personal computers used for data acquisition control and supervision of low voltage small and medium distribution plants with ABB equipment This software can be installed by the user who is only required to know the installation characteristics which and how many circuit breakers are installed and how they are connected to each other and to insert the addresses and the typologies of the units to be controlled This software recognizes the devices connected and configured through the Modbus address and shows the graphic pages already configured for each of them It is also possible to recognize automatically the units installed and connected to the bus by passing directly to the putting in service without carrying out any con figuration Figure 31 Two level architecture Modbus RTU on RS 485 Tmax T4 T5 Tmax T4 PR223DS PD Tmax T4 PR223EF Bus communication with ABB circuit breakers SDO30DX The installation of SD View 2000 allows using the per sonal comp
12. Terminal resistor nections A to B of a device besides making communi cation 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 cB delivery termi Emax ERIE eme w1 w2 nal box or sliding contacts CB delivery termi Emax X1 PR332 P and E w1 W2 nal box or sliding Tmax T7 T7M PR333 P zontacis Tm PR222DS PD terminals 1 and 2 T eas PR223EF X3 1 X3 2 __jof the rear con PR223DS nector X3 This table shows the information given in the wiring diagrams of Annex C Main cable Main cable Terminal resistor Auxiliary terminals PR123 P PR223DS Terminals 1 and 2 of the X3 connector CB terminal box or sliding contacts Terminal box of the X3 connector Emax terminal box Bus communication with ABB circuit breakers 25 UOI EDIUNWIWOD snq 104 uonnjos ggY p i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i 26 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
13. reactive Q apparent S E Total power factor o Total energy active reactive apparent State Circuit breaker state open closed tripped a iotormaion Mode local remote E E E Protection parameters set E E Data records of the last n trips il 20 20 20 20 Maintenance Total number of operations E E E E gata Total number of trips E E E a Number of test trips E E E E E Number of manual operations E E E a pa U RE according to the protection n m m m a Number of trips separated according to the protection a a functions EF SOS Protections Protection trip E E E alarms Protection L S G timing and trip o E E a 5 Protection EF SOS trip E E Diagnostic Trip command failed E E E E alamme MOE E overheating m m m m m Trip coil disconnected or damaged E Commands Circuit breaker opening closing with MOE E a a a a E Alarms reset E E E B Circuit breaker reset with MOE E L L o E Setting of protection curves and thresholds E E E a Events Changes of state of the circuit breaker of the protections m m m m m and of all the alarms For further information about the electric quantities the data and the alarms available re Instruction manual PR223EF Modbus System Interface Instruction manual PR223DS Modbus System Interface Instruction manual PR222DS PD Modbus System Interface Bus communication with ABB circuit breakers erence must be made to the following documentation
14. 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 23 shows the example of a correct bus connection Bus communication with ABB circuit breakers Figure 23 Network with bus structure Backbone lt gt be m On the contrary Figure 24 shows some examples of wrong bus connection Oca Figure 24 Examples of wrong bus connection M X 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
15. E E ee unbalanced phase voltages U a a a a Protection against undervoltage UV timing and trip a E W Protection against overvoltage OV timing and trip E E E amp Protection against residual voltage RV timing and trip E E a S a iets reversal of active power RP a a a a Protection against under frequency UF timing and trip E E E Protection against over frequency OF timing and trip o Directional protection D timing and trip E E Diagnostic Trip command failed E L L o o a alarms Contact wear 100 m n E 7 E m Rating Plug error a E a m a a Trip coil TC disconnected or damaged a E E a E E Current sensors disconnected w o Commands Circuit breaker opening closing a E E E m B Alarm reset E E E i E 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 Bus communication with ABB circuit breakers 49 y xouuy J01 U09 0w 1 pue UOISIAJOdNs 10 SPUBLULUOD pue e ep sanseow y xouuy J01 U09 8 0W9d4 pue UOISIAJOdNS 10 SPULWWOI pUe E ep seinses 50 echnical Application Papers Table A 4 Measures data alarms and commands available with Tmax moulded case circuit breakers type T4 T5 and T6 PR222DS PD EP010 PR223EF EP010 PR223EF VM210 EP010 PR223DS EP010 PR223DS VM210 EP010 Electr
16. 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 French data link layer and on the subject matter of the conversation application layer To ge
17. Interface Instruction manual PR222DS PD Modbus System Interface 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 Modbus YES COMMUNICATION Physical layer RS 485 RS 485 Compatibility on all the layers of the protocol Logical layer Modbus Modbus YES COMMUNICATION Physical layer RS 232 RS 232 Compatibility on all the layers of the 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 NO COMMUNICATION Physical layer RS 485 RS 485 Incompatibility on the logical layer of the protocol Logical layer Modbus Modbus NO COMMUNICATION Incompatibility on the physical layer of the Physical layer RS 485 RS 232 protocol Logical layer Profibus DP Modbus NO COMMUNICATION Physical layer RS 485 RS 232 Incompatibility on all the l
18. Testbus2 SD TestBus2 is ABB SACE installation and diagnosis free software for starting of the Modbus network and of the relevant connected devices detection of faults and anomalies in a network com munication already functioning testing inspection and setting of the protection trip units and of the devices provided with Modbus com munication functions SD TestBu2 allows to 1 carry out a control and a complete scanning of the Modbus network in order to identify all the slave de vices connected and to detect any possible error of connection or setting in the communication parameters such as address parity baud rate parity check of the circuit breakers 2 interact in real time with the following devices e PR122 P and PR123 P with PR120D M communi cation module e PR222DS PD e PR223EF PR223DS e PR332 P and PR333 P with PR330D M communi cation module e SD030DX flex interfaces 4 4 1 1 Scanning of the system bus Thanks to this function the software carries out an au tomatic scan of RS 485 bus and identifies all the slave devices present on the bus pointing out their com munication parameters ABB devices are automatically recognized and are displayed both in the Device List as well as in the surfing page panel Figure 30 Window of SD Testbus2 with the Device List and the surfing page panel Root node of the surfing page panel i HB PR2zz 2 cE PRize 3 H E pRa 13
19. and 4 of X3 rear connector as shown in the following figure Figure B 1 Wiring diagram of the auxiliary power supply connection for PR228DS trip unit Circuit breakers Say EN TAS a F Eaa Fi SAA j X3 TLA eo Auxiliary power supply Vaux TVL2 q E5 O ITVL23 L i J NATS aea eel ae STUN pe ie ea LE i E 24V 1 N J Lo Terminals 3 and 4 of X3 rear connector PR223DS Figure B 2 Auxiliary power supply for moulded case circuit breakers T4 T5 and T6 Auxiliary power supply Vaux Bus communication with ABB circuit breakers 51 g xouuy Ajddns samod Auerixne y JO s nsu peIeyI jed 9 x uuy i s jnpow UONESIUNWIWOS oy L Technical Application Papers Annex C The communication modules Emax air circuit breakers E1 E2 E3 E4 and E6 PR120 D M communication module Protocol Modbus RTU Physical interface RS 485 Baud rate 9600 19200 bit s The communication module is supplied directly through PR122 P or PR123 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 PR122 PR123 PR120 D M Supply auxiliary power galvanic insulated supply 24 V de from PR122 PR123 20 Maximum ripple 5 Inrush current 24 V 10 A for 5 ms Rated current 2
20. 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 E E Measures history Imax L Measures history Vmax Vmin Pmax Pmean Qmax Qmean Amax Amean State Circuit breaker state and position information open closed racked in out 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 I 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 Protection against under frequency UF timing and trip Protection against over frequency OF timing and tri
21. as a SCADA system ac quiring processing and storing the data sent by all the circuit breakers The field level is constituted by the protection circuit breakers Tmax moulded case and Emax air circuit breakers equipped respectively with electronic micro processor based trip units type PR223DS QF4 QF5 QF6 and QF7 PR123 P QF2 and QF3 See clause 4 4 2 Figure 34 Supervision and control system of a LV distribution plant Control level RS 232 RS 485 converter pi x a Field level QF4 o 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 Tmax T4 molded case circuit breakers QF4 QF5 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 power supply Vaux see Annex B Ee iH QF3 Choice of products and accessories for remote control To perform circuit breaker remote control the following accessories are necessary e For Emax E1 air circuit breakers QF2 a
22. breakers 57 s jnpow Bulunseow oy g xeuuy f J xouuy f 40 e19d0 10 0W 3 JOWN pue s pezuos Auelyixne 3 XNY Technical Application Papers Annex E AUX E auxiliary contacts and MOE E motor operator For Tmax circuit breakers type T4 T5 and T6 some _ the plant through the contacts SQ and SY see Figure special accessories are needed E 2 in this way it is possible to obtain a redundancy of AUX E auxiliary contacts in electronic version for the CB state signals supervision only Figure E 1 Auxiliary contact module AUX E mounted on Tmax T5 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 Signaling r Ernan A circuits X ag Po NS BE i ran LDSQ amp amp LDSY
23. exceed a set threshold or under other programmed working conditions These conditions vary according to 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 dD WwW amp WwW amp Room lightning Emergency lightning system system Annex A Measures data and commands for super vision 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 E 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 F Electric Phase currents IL1 IL2 IL3 neutral current IN quantities ground current a l a a a a Voltages phase to phase phase to neutral residual Total and phase power active P reactive Q apparent A Power factor Peak factor Ip Irms a Frequency Total
24. modules Circuit breaker ule Trip unit i 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 shall 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 AUX E i Trip unit Bus communication with ABB circuit breakers 59 10 21 do 1030W 3 JOW pue speyuos Auelixne 3 XNY 3 xouuy f uq Amed oy 4 xouuy i 60 y ON EA mon ee aa Vy Technical Application Papers Annex F The parity bit The parity bit is an additional control bit placed in queue after each transmitted character to avoid errors in recep tion With the parity control in even mode this bit is set to 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 nu
25. 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 helps 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
26. 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 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 Bus communication with ABB circuit breakers 5 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
27. 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 direct 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 cos of the plant has been lower than the value fixed by the power supply authority of the electrical network 5 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 use 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 c
28. 120 D M communication module remote control accessories YO YC M Supervision PR122 P 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 Bus communication with ABB circuit breakers PR122 P PR120 D M communication module remote control accessories YO YC M Supervision and remote control 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 and remote control 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 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 15 UO I EDIUNWIWOD snq 104 uonnjos ggY i UO I EDIUNWIWOD Snq 104 uonnjos ggY i 16 Technical Application Papers 4 1 2 Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers Modbus communication supervision and remote control Emax X1 air circuit breakers provided with the electronic trip unit type PR332 P or PR333 P and Tmax T7 moulded case ci
29. 4 V 130 mA 40mA Rated power 24 V 3W 1W Connection to the Modbus network PR122 P and PR123 P 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 supply Vaux A B EIA RS 485 interface for Modbus network CB terminal box K1 1 p K2 er or sliding contacts Ki K2 PR120 D M PR122 P PR123 P S33M 1 a S751 1 7 l W1 W2 terminals for the connection of the Modbus cable K1 K2 terminals for auxiliary power supply Vaux S33M 1 3 contacts signaling spring charged 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 supply Vaux VA 24v EP010 L 4 EIARS 485 Modbus interface for the connection to EP010 ail 1 A B K1 T K2 wi4 yp we CB terminal box K1 l K2 Wie wo or sliding contacts PR120 D M PR122 P PR123 P 33M 1 3 751 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 th
30. R333 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 CB terminal box or sliding contacts me t e Auxiliary power ii supply Vaux EP010 L J1 Z 7 4 e EIA RS 485 interface for Modbus network 24V wap A B K1 1 f K2 Wi f W2 C134 C12 C3 f T C2 Ki K2 Wi W2 C13 C12 C3 C2 l l SOR SCR YV V aD K51 SOR K51 SCR PR330 R PR330 D M gt PR332 P PR333 P Note Q 1 6 S 33M 1 3 S75I 1 7 W1 W2 terminals for the connection of the Modbus cable A 4 K1 K2 terminals for Vaux auxiliary power supply L 1 terminals for the Modbus port L__ 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 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 breaker
31. T5D T6D Stored energy motor operator MOE Opening Closing T7DM X1B MS 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 MS E6 MS YO shunt opening release Opening YC shunt closing release Closing YR reset coil Reset Figure 20 Circuit diagram of SDO30DX Vaux auxiliary supply gt AJ DAV EIARS 485 interface for the connection to Modbus network Digital outputs Digital inputs Bus communication with ABB circuit breakers 23 UO I EDIUNWIWOD Snq 104 uonnjos ggY Technical Application Papers The proper wirings for a correct functioning of SDO30DX As an example Figure 21 shows the wiring diagram of the are connected to SDO30DX 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 communicate with the supervision system PC PLC or SCADA the Vaux auxiliary supply Supply voltage 24 V dc 20 Maximum ripple 25 Rated power 24 V 2W Figure 21 Wiring diagr
32. ain parts introduction to digital communication and basic concepts regarding communication protocols supervision of electrical distribution plants ABB solution for bus communication some application examples regarding ABB SACE circuit breakers used for the automated manage ment of electrical distribution plants In addition there are also some annexes giving a deep insight into the functional and applicative aspects of the products Communication modules measuring modules auxiliary contacts in electronic version and suitable con nectors necessary for the measuring and bus communi cation functions of automatic circuit breakers De T T C el e a y shir ao i KiE elsi j i 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 that is the bits which constitute a message or a data packet are transmitted one after the other over the same transmis sion 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
33. am of SDO30DX for a CB type Emax E6 EIA RS485 AUXILIARY CHARGED PROTECTION CB CB REMOTE LOCAL cB CB CB SPRING o INTERFACE SUPPLY SPRINGS TRIPPED RACKED IN CLOSED MODE OPENING CLOSING RESET MOTOR SD030DX SD030DX 24 Bus communication with ABB circuit breakers 4 3 Modbus network RS 485 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 Figure 22 Electrical wiring diagram of an Emax and a Tmax to the Modbus network
34. ar 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 Figure 8 Multi drop system with bus type connection Backbone The mostly used physical layer interfaces in industrial networks are RS 232 for point to point connections and RS 485 for multipoint connections Bus communication with ABB circuit breakers 5 uo esiunwwo jesd Z p uo esiunwwo jefa z H 6 Technical Application Papers 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 in tervals 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 RS 232
35. at 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 PR332 P PR330 D M communication module accessories for the remote control PR330 R SOR SCR M Supervision PR332 P For Tmax T7 only For remote control with Tmax T7 the motorizable version T7M is needed oo wp SOR SCR 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 PR332 P PR330 D M communication module PR330 V measuring mo
36. ated 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 down times and guarantee service continuity 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 switchb
37. ayers of the protocol Note With logical layer the combination of link layer application layer is meant Bus communication with ABB circuit breakers 9 uOoHeSIUNWIWIOD jesd zZ s uejd UO NL SIP ed O9 9 Ul UOISIAJEdNS f Seer TT 10 att Technical Application Papers vA 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 16 Representation of the main flow and of the information flow Main flow Information flow Bus communication with ABB circuit breakers 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 an information flow or informative flow digital flow constituted by all the information the data and the commands useful for the management and cont
38. d to share the costs among the different production lines RS 232 RS 485 8 8 Converter X x y a a QBT PRI QBT AUT QBT PR2 QBT AU2 l QBTPR3 QBT AU3 1 X wt x 1 1 wt X 1 1 wt x 1 1 1 AR G AR A es ee ak 1 E 1 wl 1 uw 1 1 uw E 1 1 uw 1 1 pi 1 1 af 1 pi 1 1 og ae Li 1 ut 1 ii i i four g i yok ae eee bo X X x La ee 8 Aa a ea a a E Y I wt I it Li i ea 1 1i 1 1i 1 1 uw 1 1 pi 1 I pt i ti 1 ve eleceeceedoed l a ee aed eel ose sede eee Eee eee eee Vecbosseeeedoed ee eee eae paral Y Y y y Y y y Y y y y y A A A A A A A A A A o wo U W M oO V W o oOo U Q Manufacturing line 1 Manufacturing line 2 Manufacturing line 3 Bus communication with ABB circuit breakers 45 s jdwex uoneojddy G i s jdwex uonjesjddy G k 46 5 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 therm
39. device 2 32 4 4 2 SD View 2000 ccseccessessesteseesessestsseeseesssteseeseeneasess 34 45 Example of product selection for supervision and remote control 36 46 Circuit breaker integration into Profibus DP or DeviceNet fieldbus 38 4 6 1 Supervision and remote ContrOl c ccceceeeeeseees 39 4 6 1 1 Emax air circuit breakers E1 E2 E3 E4 E6 39 4 6 1 2 Emax X1 air circuit breakers and Tmax T7 moulded case cCircuit breakerS cccceeeeeees 40 4 6 1 3 Tmax moulded case circuit breakers T4 T5 T6 41 5 Application examples 51 Supervision of protections and circuit breaker switching 43 5 2 Allocation of the energy costs inside a PLAN eee ee cece eeeeeeetteeeeeeeeeees 44 5 2 1 Description of the distribution and communication Syston divine ia aA NTE 45 5 2 2 FUNCtiONING scsscccssssscessssssssssesssssseersesnsetsssssesssnees 45 53 Management of priority and non priority loads 2 0 0 eeeeeeeeeeeeteeeeeeeeees 46 Annex A Measures data and commands for supervision and remote COMMO asninn ensen ENER 47 Annex B Electrical characteristics of the auxiliary p ower SUP DIV aiiiar iiiaae aeania 51 Annex C The communication modules cccceeeeeeeeeeeeeee 52 Annex D The measuring modules eeeeeeeeeeeeeeeeeeneeeeeeeee 56 Annex E AUX E auxiliary contacts and MOE E MOTON OP ONatOl sisigan iu caniae aiden 58 Annex F The paniy Dif rcsca
40. dule accessories for the remote control PR330 R SOR SCR M Supervision and remote control Supervision PR330 V PR330 D M PR330 R AUX PP E E For Tmax T7 only PR332 P SOR SCR M SOR 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 Supervision and remote control 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 Bus communication with ABB circuit breakers 17 uo esviunwwo snq 104 uonnjos ggY r t i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i 18 4 1 3 Tmax moulded case circuit breakers 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 for
41. e Modbus port S33M 1 3 contacts signaling spring charged 751 1 7 contacts signaling circuit breaker racked in for CBs in withdrawable version EIA RS 485 Modbus interface for the connection 751 1 7 contacts signaling circuit breaker racked in for CBs in withdrawable version 52 Bus communication with ABB circuit breakers 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 V 2 A for 5 ms Rated current 24 V 130 mA 40 mA Rated power 24 V 3 W 1W 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 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 networ
42. e 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 through 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 IL1 Current in the phase 1 A 30101 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 Bus communication with ABB circuit breakers When the master unit e g a PC wants to read the cur rent values it sends to the circuit breaker a message containing the numbers of the registers where the reques
43. e electrical distribution plant which supplies it SELOTA Note as regards the connection between EP010 and trip unit see Figure C 2 in Annex C 4 6 1 Supervision and remote control 4 6 1 1 Emax air circuit breakers E1 E2 E3 E4 E6 ProfibusDP and DeviceNet supervision and remote control Emax air circuit breakers equipped with electronic trip units type PR122 P e PR123 P are connected to EP010 unit through PR120 D M communication module as shown in Annex C The power supply at 24 Vd c for EP010 is delivered through the FBP connector which provides also bus communication The trip unit connected to EP010 must be supplied with the auxiliary power supply Vaux for the electrical char acteristics see Annex B Supervision DeviceNet EP010 PR120 D M PR120 V ProfibusDP remote PR122 P PR123 P The interface of the circuit breakers with the field bus is implemented through the suitable FBP connector PDP22 FBP for ProfibusDP DNP21 FBP for DeviceNet Electronic trip units type PR122 P and PR123 P For information about the measures data and alarms made available by the electronic trip units type PR122 P and PR123 P in the following configurations see Table A 3 of Annex A For the remote control operations which can be per formed on the circuit breaker see Table A 3 of Annex A at the entry Commands All the commands from remote control through the bus can be disabled by setting the trip
44. e of Figure 13 it is possible to identify 1 start bit 8 bits b0 67 constituting the character the trans mitted data 1 stop bit Figure 13 8 bit character 1 kaia I Start Stop 0 is 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 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 recep tion showing a high impedance on the communicatio
45. eakers The protocols used to let the different devices in industrial applications communicate are very numerous and vary according to the communication requirements of each application and 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 relevant peripherals In the following chapters these protocols are not taken into consideration the discussion shall be limited to a description of the protocols dedicated to the industrial communication between the field devices that is those devices which interact directly 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 protocol three levels can be distinguished a physical layer a data link layer and an application layer
46. ections 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 Emergency generator vee LS gt gt eae 1 Command room Lightning system Circuit breaker and switch disconnector J motors J Non essential services Essential services Bus communication with ABB circuit breakers 43 sojdwexe uoneslddy 9 i s jdwex uoneojddy G g 44 Technical Application Papers a n 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
47. ed 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 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 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 P k t polling 354 ms or Q6 R6 Q1 R1 t MODBUS query LAN network tPC E Q QUERY waters __f ult RS232 p e query of the PC to the circuit breaker Modbus RTU _ MODBUS response R RESPONSE response sent by the circuit breaker to the PC LAN network u Modbus RTU T Bus communication with ABB circuit breakers 29 UO I EDIUNWIWOD snq JO uonnjos ggY p i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i titt 30 mR 1 Mezz Technical Application Papers vA 4 4SD Testbus 2 and SD View 2000 software programmes 4 4 1 SD
48. emote control opera tions are sending of opening and closing commands to the circuit breakers reading of the installation electrical values current voltage power factor power reading and modification of the trip characteristics of the protection units detection of the state of the apparatus open closed number of operations trip for fault detection of anomalous operating situations e g overload and in case of protection tripping in formation about the type of fault short circuit overload earth fault and value of the interrupted currents storage of the plant history energy consumption most loaded phase any possible warning of anoma lies or faults graphic representation of the temporal evolution of the plant This and other information are available for the operator through user friendly graphic pages which allow the user to manage the data coming from each circuit breaker Bus communication with ABB circuit breakers 35 uonesiunwwo snq 104 uonnjos ggY p UO I EDIUNWIWOD Snq 104 uonnjos ggY p i Hi Technical Application Papers rome EA A vA 4 Connectable devices SD View 2000 can manage all ABB low voltage circuit breakers provided with Modbus communication both new as well as belonging to previously designed product families among them Emax air circuit breakers from E1 to E6 see clause 4 1 1 Emax X1 air circuit breakers See clau
49. ers 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 5 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 Figure 36 Diagram of the auxiliary service of a power plant Supervisor PC RS 232 RS 485 converter Power supply by network L pp Hre hH ix a a a v vv Outlet Heating system Autoclave 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 prot
50. ese verifications if there is a fault in the communication with the supervision systems of the plant while the switchboard is put into service this problem will not be imputed to the switchboard devices Bus communication with ABB circuit breakers 31 UO I EDIUNWIWOD snq 104 uonnjos ggY i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i 1 32 att Technical Application Papers 4 4 1 2 Interaction with the single device For the circuit breakers equipped with electronic trip units the software provides some graphic pages through which it is possible to interact with them to read the information and the data contained send opening and closing commands set the protection functions Here are some graphic pages Information In this page it is possible to read the general information about the device software release and circuit breaker state and send commands of opening closing and wink This last activates a blinking light on the front panel of the circuit breaker so that the operator can identify it When the device is set in local mode the commands which can be present in the page are visualized in grey color and they cannot be activated Bus communication with ABB circuit breakers Measures This page reports the measures acquired in real time by the tri
51. finite 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 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 r
52. g 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 im plementation of the remote opening and closing com PR122 P electronic trip unit mands the circuit breakers of Emax series together 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 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 PR
53. ic quantities Phase currents IL1 IL2 IL3 neutral current IN ground current lg Phase to phase voltages V12 V23 V31 Phase to neutral voltages V1 V2 V3 Peak factor L1 L2 L3 N Frequency Total 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 trips separated according to the protection function L S I G Number of trips separated according to the protection function EF SOS Number of test trips Number of manual operations Protections alarms Diagnostic alarms Commands Protection L timing and trip Protection S timing and trip Protection G timing and trip Protection Protection EF SOS Trip command failed MOE E overheating Trip coil disconnected or damaged Circuit breaker opening closing with MOE E Circuit breaker reset with MOE E Alarms reset Events Changes of state of the circuit breaker of the protections and of all the alarms 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
54. ith electronic interface MOE E and the AUX E auxiliary contacts in electronic version For information about the measures data and alarms made available by the electronic trip units type PR222DS PD PR223EF and PR223DS in the following configura tions see Table A 4 of Annex A For the remote control operations which can be per formed on the circuit breaker see Table A 4 of Annex A at the entry Commands All the commands from remote control through the bus can be disabled by setting the trip unit to local mode MOE E PR222DS PD AUX E Supervision DeviceNet p PR223EF AUX E ESR MOE E EP01 E ay Connector X3 i i iy PR223EF AUX E Connector X4 VM210 ProfibusDP o RD Bus communication with ABB circuit breakers 41 UO I EDIUNWIWOD snq JO uonnjos ggY p P UO I EDIUNWIWWOD snq 104 uonnjos ggY p i iert att Technical Application Papers i r PR223DS electronic trip unit Supervision and remote control Supervision DeviceNet 2 PR223DS AUGE fa EP010 Connector X3 Bae MOE E y C Ort J PR223DS AUX E Connector X4 VM210 a i l NOTE For further information about the dialogue functions and the features of the products described in this chapter reference shall be made to the relevant technical catalogues and the product manuals 42 Bus communication with ABB circuit breakers 5 Application examples Here are some examples of application of ABB SACE circuit break
55. k 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 Figure C 3 Wiring diagram for the connection of PR33X P to the Modbus network through PR330 D M module Auxiliary power A B tio ee ee er Se ee ee supply Vaux EIA RS 485 interface for Modbus a network sma Spe pe ee vary 24v K1 1 f K2 w1 1 f w2 C13 1 1 C12 C3 f f C2 CB terminal box KI K2 Wie w2 Cis C2 C3 02 or sliding contacts SOR SCR V K51 SOR K51 SCR L d l E PR330 R PR330 D M PR332 P PR333 P Note Q 1 6 S33M 1 3 S751 1 7 7 W1 W2 terminals for the connection of the Modbus cable K1 K2 terminals for Vaux auxiliary power supply 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 Bus communication with ABB circuit breakers 53 5 xouuy j s jnpow UOIESIUNWWOD Oy L 9 xouuy f s jnpow UONESIUNWWOD OU L 54 Technical Application Papers Connection to EP010 unit PR332 P and P
56. mation 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 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 implementation of the remote opening and closing commands Tmax moulded case circuit breakers type PR222DS PD electronic trip unit 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 remind that the auxil iary 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
57. mber 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 QT4 Low voltage selectivity with ABB circuit breakers MV LV trasformer substations theory and exam ples of short circuit calculation Distribution systems and protection against indi rect contactand earth fault ABB circuit breakers inside LV switchboards QT5 ABB circuit breakers for direct current applications QT6 Arc proof low voltage switchgear and controlgear assemblies QT7 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 AA ED ED FADED ABB SACE A divi
58. 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 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 terminals Main cable Main cable L lt 1m L lt 1m ff __ ie ps a Y FF F Emax terminal box Terminal box of the X3 connector Bus communication with ABB circuit breakers 27 UO I EDIUNWIWOD snq JO uonnjos ggY p UO I EDIUNWIWOD Snq 104 uonnjos ggY p i Ppecaii 28 RIRN Technical Application Papers 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
59. n 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 connected to the same bus must have the same settings in
60. nd QF3 1 shunt opening release YO 2 shunt closing release YC 3 geared motor for the automatic charging of the closing springs M e For Tmax T4 molded case circuit breakers QF4 QF5 QF6 and QF7 1 motor operator with MOE E module see Annex E 2 AUX E auxiliary contacts in electronic version provided by default with MOE E O Bus communication with ABB circuit breakers 37 UO I EDIUNWIWOD snq JO uonnjos ggY p j UO I EDIUNWIWOD Snq 104 uonnjos ggY p i irt 38 att Technical Application Papers i r 4 6 Circuit breakers integration in Profibus DP or DeviceNet fieldbus Fieldbus EP010 interface unit allows the integration of ABB SACE circuit breakers in communication systems with Profibus DP or DeviceNet protocol To get this result ABB intelligent connectors FBP Field BusPlug which allow the communication with the differ ent protocols are used The connection of the circuit breakers to the fieldbus is realized as shown in the figure LAN network FBP connector Bus communication with ABB circuit breakers Next 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 more different applications thus combining the control of a process with the control of th
61. nication 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 giving the required data or informing the Master that its query cannot be satis fied 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 only the involved device shall send a response 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 equipp
62. nication 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 against 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 de
63. oards 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 RS 232 RS 485 converter Command Data S ModbusRTU Bus communication with ABB circuit breakers 13 s uejd UO NL SIP ed O9 9 Ul UOISIAJOdNS i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i N 1 i 7 14 _ Hee i Technical Application Papers 4 ABB solution for bus communication This chapter describes the electronic trip units and the products which allow ABB SACE circuit breakers to be interfaced on Modbus networks for the supervision and remote control of low voltage electrical distribution plants 4 4 Air and moulded case circuit breakers 4 1 1 Emax air circuit breakers E1 E2 E3 E4 E6 Modbus communication 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 receive from a remote supervision system the com mands e g opening and closin
64. of Tmax CBs T4 T5 and T6 through X3 connector Modbus cable Bus communication with ABB circuit breakers 55 s jnpow uoneviunwwo By 9 X uuy f s jnpow Buunse w y q i 56 i at Technical Application Papers Xs 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 processing 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 Figure D 2 PR330 V measuring module Tmax moulded case circuit breakers T4 T5 T6 Features of VM210 measuring module VM210 module is a voltage transducer which can be connected directl
65. ommunication 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 shielded cable to the 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 the plant LAN network M oe u 5 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 cosg 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 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 an
66. or the DI contact for the with 5 wire electrical signaling Zee Sg g DI4 CB auxiliary electrical signaling of 3 5 F of circuit breaker in ise solenoid operating of tripped protection akedi ootion contacts Q 1 circuit breaker mechanism 51 6751 1 tripped SY DI3 contact for the DI5 switching electrical signaling 22teal signaling pia Ce auxiiary electrical signaling of Contact for electrical Teale le a of tripped protection ai eee n contacts Q 1 circuit breaker signaling local 51 racked in position tripped SY remote selector S751 1 status S3 1 Bese DI3 contact for the 17 X1 Dit limit contact Sircuit breaker open electrical signaling Di4 CB auxiliary DIS switch for F1 E6 for spring charging due to the tripping of of circuit breaker in contacts Q 1 setting remote local a motor S33M 1 A racked in position control 843 the overcurrent trip 8751 1 unit S51 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 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 6751 1 DI3 contact for the electrical signaling of circuit breaker in racked in position 8751 1
67. 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 5 EIA 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 uo esiunwwo jeba z F uo esiunwwo jefa zZ i 4H 8 att Technical Application Papers vA 2 1 2 Data link layer As regards the data link layer it is sooken 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 it is spoken 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 actuators generally with fast and cyclic data exchang
68. ore 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 informative flow which runs on the bus Master a a Commands f Bus communication with ABB circuit breakers 11 s uejd UO NL SIP eO O9 9 Ul UOISIAJOdNS i s uejd UO NL SIP 3114 994 Ul UOISIAJOdNS i y A T echnical Application Papers 17 3 1 Supervision with ABB SACE circuit breakers In the field of energy distribution commu
69. ostat 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 lightning The last is considered anon priority load and when necessary can be discon nected to reduce energy consumption The main circuit breakers of each sub distribution switchboards QBT1 QBT2 QBT3 and QBT4 are series Tmax provided with PR222DS PD with Modbus com munication interface PLC AC500 U U WwW U U Ww Refrigeration Air conditioning system system Bus communication with ABB circuit breakers Moreover each circuit breaker is equipped with auxiliary contacts with electronic interface AUX E and motor op erator 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
70. p Diagnostic Trip command failed elem Contact wear 100 Rating Plug error Trip coil TC disconnected or damaged Current sensors disconnected Commands Circuit breaker opening closing Alarm reset Setting of protection curves and thresholds Time synchronization of each circuit breaker carried out by system Changes of state of the circuit breaker of the protections and of all the alarms the last 80 Events For further information about the electric quantities the data and the alarms available reference must be made to the following document Instruction manual PR122 3 P PR120 DM PR332 3 P PR330 DM Modbus System Interface Bus communication with ABB circuit breakers 47 y x uuy J0 1 U09 0w 1 pue UOISIAJOdNS 10 SPUBLULUOD pue e ep seinseo y f y x uuy J01 U09 8 0W9d4 pue UOISIAJOdNS 10 SPUBLILOD pUe E ep seinses 48 Technical Application Papers Table A 2 Measures data alarms and commands available with Tmax moulded case circuit breakers type T4 T5 and T6 PR223EF PR223DS PR222DS PD PR223EF VM210 PR223DS VM210 Rene TE hed IL1 IL2 IL3 neutral current IN ground a Phase to phase voltages V12 V23 V31 Phase to neutral voltages V1 V2 V3 B Peak factor L1 L2 L3 N a E E a Frequency Total and phase power active P
71. p unit according to the type of trip unit installed the following measures can be taken current voltage power and energy power factor and frequency Measures History This page displays the measures recorded by the trip unit in the last hours In particular the phase at the maximum current the phase at the minimum and maximum voltage the medium and maximum active power the medium and maximum reactive power the medium and maximum apparent power measured in the last 24 periods of time which can be set at intervals from 5 minutes Storage of the last 2 hours to 120 minutes storage of the last 48 hours es C ee The function Measures History is available on the fol lowing trip units PR122 P and PR123 P for Emax PR332 P and PR333 P for Tmax T7 and Emax X1 Alarms Settings This page shows the protection alarms associated to In this page it is possible to view and adjust the settings the trip unit and the diagnostics alarms associated to thresholds and trip times of the protection functions the circuit breaker associated to a defined trip unit Trips Time current curves In this page it is possible to get further information onthe Thanks to this function it is possible to view the time cause of the trip of one protection and get to know which current curves for the main protection functions L S type of protection has tripped Some trip units allow also and G
72. rcuit breakers provided with PR332 P electronic trip unit to be interfaced with Modbus networks 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 su pervision To make available for the remote supervision system the information about the circuit breaker state open closed tripped Tmax T7 circuit breakers must be equipped with the auxiliary contacts AUX 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 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 PR830 D M communication module must be equipped also with the following accessories PR330 R actuation module see Annex 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 th
73. rineminranneiunndingmusa 60 uoonpo u aE a s Bi P ae a E A rete ee i alola O OON ee ett bs ale OI 6 Ooo F a JLL Technical Application Papers 1 Introduction Due to the ever growing use of the automation and su pervision systems for industrial processes for a better management of the electrical and technological plants the circuit breaker manufacturers have been driven to implement on the electronic trip units the dialogue inter faces for bus communication with control devices such as PLC PC or SCADA In this way automatic circuit breakers are used not only for the switching and protection but also for the supervi sion 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 intel ligent 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 es sential information for the correct choice of the trip 7 i i et Vo 4 DOOI ono Cie 1 units of the accessories 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 This document is divided into four m
74. rol of the plant It is the supervision system which manages the informa tion flow passing over the communication network PULL LAL 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 taken into consideration 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 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 Slave Slave ACB ACB Slave Slave Slave M
75. s from remote through the bus can be disabled by setting the trip unit to local mode Supervision PR332 P EP010 PR330 R SCR PR330 D M PR330 V PR332 P ProfibusDP PR333 P For supervision with Tmax T7 the auxiliary contacts AUX are needed For remote control with Tmax T7 the motorizable version type T7M is required Bus communication with ABB circuit breakers 4 6 1 3 Tmax moulded case circuit breakers T4 T5 T6 ProfibusDP and DeviceNet supervision and remote control Tmax moulded case circuit breakers type T4 T5 and T6 equipped with the electronic trip units PR222DS PD PR223EF and PR223DS are connected to EP010 unit through X3 rear connector as shown in Annex C The power supply at 24 Vd c for EP010 is delivered through the FBP connector which provides also bus communication The trip unit connected to EP010 must be supplied with the auxiliary power supply Vaux for the electrical char acteristics see Annex B The interface of the circuit breakers with the field bus is implemented through the suitable FBP connector PDP22 FBP for ProfibusDP DNP21 FBP for DeviceNet PR222DS PD electronic trip unit DeviceNet Supervision Connector X3 ProfibusDP PR223EF electronic trip unit C a UCE To perform the remote control and the mechanical imple mentation of the remote opening and closing commands Tmax circuit breakers type T4 T5 and T6 must be fitted with the motor operator w
76. s 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 Circuit breakers aa Ve er ia aa XOX Ok j i a aA i 1 i j X3 TW 1 s i TI L2 q fy Auxiliary power ma on supply Vaux 1 1 LO PP ITV Assah ET mea j o 5 LS a B i 2 A Modbus cable 1 n 1 a oO l N Terminals 1 and 2 i T of X3 connector 1 j o 1 Bens ey ree 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 7a a S A g i f 1 es a A A A 4 Bea X3 1 1 CO Tt gf iJ N CTE H gt Auxiliary power ees supply Vaux lms Hey e Lec dl E E Eo T T je 24V 1 1 B a 1 I E a T mmy ci i ep S I O o Q i Terminals 1 and2 i T of X3 connector 1 i T ws U u U z z Figure C 6 Connection to the Modbus network
77. se 4 1 2 Tmax T7 moulded case circuit breakers See clause 4 1 2 Tmax moulded case circuit breakers type T4 T5 and T6 see clause 4 1 3 and SDO30DX Flex Interfaces to interface the air and moulded case circuit breakers equipped with ther momagnetic trip unit or basic electronic trip unit and air or moulded case switch disconnectors see clause 4 2 All the characteristics of the connectable devices are preconfigured in the system The user does not need to set configurations neither to load tables showing the data to be displayed for each trip unit or to create graphic pages it is sufficient for him to load into the system only a list of the connected devices The graphic pages relevant to each circuit breaker are par ticularly direct and easy to use as shown in Figure 33 Figure 33 Main graphic page of an Emax air circuit breaker For more detailed information on the installation and the use of the softwa re please refer to the User Manual SD View 2000 Supervision System Bus communication with ABB circuit breakers 4 5 Example of product selection for supervision and remote control Take into consideration a low voltage distribution plant with a supervision system of the same type as shown in Figure 34 The supervision system uses a bus network with Modbus RTU protocol on RS 485 At the control level there is a personal computer with the software SD View 2000 by ABB SACE The personal computer works
78. sion of ABB S p A L V Breakers Via Baioni 35 24123 Bergamo Italy Tel 89 035 395 111 Telefax 39 035 395 306 433 http www abb com Due to possible developments of standards as well as of materials the characteristics and dimensions specified in this document may only be considered binding after confirmation by ABB SACE 1SDC007108G0201 January 09 Printed in Italy 6 000 CAL
79. st be mounted on the circuit breaker As regards commands instead the circuit breaker switch disconnector must be fitted out with suitable accessories Figure19 SDO30DxX flex interface noe a ee ee The main characteristics of SDO30DX are shown in the following table SD030 DX name 5 digital inputs Acquisition of CB state z Converter J RS 232 RS 485 SD030DX SD030DX Tmax T3 TMA Tmax T5 PR221DS z SD030DX SD030DX Tmax T4 E PR221DS Emax E2 PR121 P Bus communication with ABB circuit breakers 21 UO I EDIUNWIWOD snq JO uonnjos ggY p f uo esiunwwo snq 104 uonnjos ggY p T i J 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 SDO30DX The following table shows the circuit breakers and the switch disconnectors which can be managed through SDO30DX the information associated to each digital input with the corresponding auxiliary contact for the different type of circuit breaker Associated information Creat breaker Springs Protection CB state Mode type Discharged 0 Normal 0 Racked out 0 Open 0 Normal 0 Remote 0 Charged 1 Tripped 1 Racked in 1 Closed 1 Tripped 1 Local 1 TART Di2 contact for the DIP coraa T
80. t a successful communication between two entity 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 RANSA 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 which are 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 share in parallel the same communication cable Among multipoint systems particul
81. te control 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 on and remote control Superv Supervision Connector X3 PR223DS AUX E Connector X4 MOE E a k NOTE For more detailed information on the dialogue functionalities and on the characteristics of the products described in this chapter please refer to the relevant product technical catalogues and manuals Bus communication with ABB circuit breakers 4 2 SD030DxX solution for the circuit breakers without Modbus 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 master 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 state of the apparatus is carried out through the auxiliary contacts which therefore mu
82. ted 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 understand 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 Figure15 shows the user interface of the software SD View2000 through which an operator can view the current values and the data contained in the circuit breaker protecting a section of an electrical plant carry out circuit breaker opening and closing opera tions from remote control Figure 15 Example of user interface for the supervision of an electrical installation 7 nem ei in aaa ae 6 For further information on the structure of the Modbus logical map of the ABB trip units equipped with communication interface reference shall be made to the following documents Instruction manual PR122 3 P PR120 DM PR332 3 P PR330 DM Modbus System Interface Instruction manual PR223EF Modbus System Interface Instruction manual PR223DS Modbus System
83. 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 PR222DS PD AUX E auxiliary contacts in electronic version X3 connector MOE E motor operator with electronic interface Supervision AUX E PR222DS PD Bus communication with ABB circuit breakers Connector X3 MOE E O 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 PR223DS AUX E auxiliary contacts in electronic version X3 connector X4 connector VM210 measuring module MOE E motor operator with electronic interface neIAn and ramn vision anda remo Supervision Connector X3 PR223EF AUX E Connector X4 MOE E Bus communication with ABB circuit breakers 19 UO I EDIUNWIWOD snq 104 uonnjos ggY p i UO I EDIUNWIWOD Snq 104 uonnjos ggY p i 20 Technical Application Papers PR223DS electronic trip unit PR223DS AUX E auxiliary contacts in electronic version X3 connector MOE E motor operator with electronic interface sion and remo
84. unit to local mode PR122 P Bus communication with ABB circuit breakers 39 UO I EDIUNWIWOD snq JO uonnjos ggY p i UO I EDIUNWIWWOD snq 104 uonnjos ggY p i Ht 40 HI 1 Technical Application Papers vA 4 6 1 2 Emax X1 air circuit breakers and Tmax T7 moulded case circuit breakers Profibus DP and DeviceNet supervision and remote control Emax X1 air circuit breakers equipped with electronic trip units type PR332 P or PR333 P and Tmax T7 moulded case circuit breakers equipped with PR332 P electronic trip unit are connected to the unit EP010 through PR330 D M communication module as shown in Annex C The power supply at 24 Vd c for EP010 is delivered through the FBP connector which provides also bus communication The trip unit connected to EP010 must be supplied with the auxiliary power supply Vaux for the electrical char acteristics see Annex B The interface of the circuit breakers with the field bus is implemented through the suitable FBP connector PDP22 FBP for ProfibusDP DNP21 FBP for DeviceNet Electronic trip units type PR332 P and PR333 P For information about the measures data and alarms made available by the electronic trip units type PR332 P and PR333 P in the following configurations see Table A 3 of Annex A For the remote control operations which can be per formed on the circuit breaker see Table A 3 of Annex A at the entry Commands All the command
85. us network Bus communication with ABB circuit breakers 3 uo esiunwwo jebad Z h Technical Application Papers TA n4 Some examples of process management where a dia logue is required between the devices in a communica tion network are 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 Actuator Sensor Actuator Sensor To manage the data traffic over the network and to allow understanding between two communicating devices a communication protocol is necessary The communica tion protocol is the whole of rules and behaviors which two elements must comply with to interchange informa tion between them it is a definite convention associated to the data exchanged between the communication partners 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 br
86. uter as SCADA of a supervision system with two level architecture 1 Control level Personal computer on which SD View2000 is installed 2 Field level ABB devices connected to the bus Modbus RS 485 The personal computer can use at most 4 serial ports and each of them can be connected to 31 devices For the supervision and control of the electrical plant the PC is used as operator station from which data can be viewed and printed commands can be sent to the devices and all the operations necessary for the management of the plant can be carried out RS 232 RS 485 converter Emax E1 E6 PR122 or PR123 PR120 D M Supervision of the electrical plant With SD View 2000 it is possible to have under control the situation of the plant at all times and to be able to control all the functions in an easy and immediate way The operator station personal computer on which SD View 2000 is installed makes it possible to receive information from the installation and to control the circuit breakers by acting on the relevant trip units Thanks to the synoptic panel of the installation it is possible to view the whole distribution network and to control the operation state through symbols represent ing the state of the protective devices open closed tripped racked in racked out and the presence of alarm situations Figure 32 SD View 2000 synoptic panel of the installation Thus the possible supervision and r
87. y to the electric network It provides a graduated output signal to be used by the ABB protec tion trip units PR223EF and PR223DS Figure D 3 VM210 measuring module The output signals on terminals 3 4 5 and 6 of VM210 associated with the system voltages are brought as input to the trip unit through the terminals 5 6 7 and 8 of the dedicated X4 connector according to the wiring diagram of Figure D 4 In order to operate VM210 shall be supplied through the terminals 1 and 2 with an auxiliary power supply of 24V dc having the following characteristics Supply voltage 24 Vdc 20 Maximum ripple 5 Rated power 24 V 3 5 W Figure D 5 Connection of VM210 module to X4 connector Modbus Cable gt Auxiliary power supply Vaux a Figure D 4 Connection of VM210 module to PR223DS trip unit Circuit breaker i a ry 7N ena ee es oa se 5 X3 Auxiliary power supply Vaux cam 5 es X i a 5 e m 24V m_e LFA B a F A 1 X4 Modbus cable ome ep Q LF TE pinn ai ia D N P dA fesse VM210 7 8 T i VM210 Connection table Terminal Signal Terminal Signal Input 1 Vaux Output 3 COMM 2 Vaux 4 Vout1 7 N 5 Vout2 8 Li 6 Vout3 9 L2 10 L3 Bus communication with ABB circuit

Bus communication with ABB circuit

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