SYNCHRONIZING M-5072 Retrofit Kit For M-4272 Digital Motor Bus Transfer System Adapts M-4272 Digital Motor Bus Transfer System as a replacement for existing analog motor bus transfer equipment Provides direct mechanical and electrical replacement of existing analog transfer logic controller M-0272/M-0236B Connects easily to the M-4272's terminals without any wiring change The physical change is simple and cost effective Enhances the security, reliability and performance of your facility with additional features in the digital motor bus transfer equipment Optional M-3919A Graphic Display Unit (GDU) and Touch Screen Human Machine Interface (HMI) for communicating with one or two M-4272 units Industry Leader Since 1969 Made in the USA
M-4272 Features The new M-4272 Digital Motor Bus Transfer System combines our decades of operating experience in this field and our proven relay hardware platform to provide the most comprehensive and cost effective Digital Motor Bus Transfer equipment available. A comparison of the M-4272 and M-0272/M-0236B is presented in Figure 1. Automatically selects transfer type: - Fast transfer - In-phase transfer - Residual voltage transfer - Fixed time transfer Manually selects transfer type: - Fast transfer - In-phase transfer - Residual voltage transfer Manual Hot parallel transfer Comparison of Digital M-4272 and Analog M-0272 & M-0236B M-4272 M-0272 & M-0236B Automatically selects transfer type: - Fast transfer - In-phase transfer - Residual voltage transfer Manually selects transfer type: - Fast transfer - In-phase transfer - Residual voltage transfer Not included, had to be performed externally Load Shedding: - Fast transfer - In-phase transfer - Residual voltage transfer - Fixed time transfer Breaker failure (using breaker status contacts) Automatic transfer bi-directional Trip and Close coil monitoring 16/32 samples/cycle waveform measurement following bus frequency decay rate yields higher accuracy for phase angle displacement and frequency rate-of-change calculations. Patented algorithm used for zero crossing prediction under dynamic condition produces much higher accuracy for In-Phase transfer operation which resulted in minimum closing angle error. Bus voltage measurement maintains accuracy down to 4 Hz; thus it produces more precise residual voltage transfer level and reduces inrush current. More motors can be carried over under this condition. - 81 Under-frequency function - 81R Rate of Change of Frequency function - 60FL Bus VT Fuse-Loss - 50BF Breaker Failure Four 27B Settings Physical size: 19 rack mount 4u height Load Shedding: - Residual voltage transfer Not included, had to be done externally Automatic transfer only one direction Not included, had to be done externally 2 samples/cycle sample-and-hold technique for waveform measurement. Residual voltage transfer level is set using potentiometer. None Single Automatic Undervoltage Transfer (27B) 19 rack mount 7u height Figure 1 (1 of 2) M-4272 Feature Comparison to M-0272/M-0236B 2
Comparison of Digital M-4272 and Analog M-0272 & M-0236B M-4272 M-0272 & M-0236B 18 Output Contacts - 4 contacts (2 trip and 2 close) for Main and Startup sources - 1 contact for power supply (P/S) - 1 contact for self-test - 1 contact for lockout/blocking - 11 User programmable output contacts 7 Output Contacts - 4 contacts (2 trip and 2 close) for Main and Startup sources - 1 contact for power supply (P/S) - 1 contact for lockout/blocking - 1 contact for load shed 18 Inputs - 6 Inputs (52a, 52b and 52sp) for two breaker positions - 12 User programmable Inputs 9 Voltage Inputs can be connected: 1-Phase Line to Ground OR 1-Phase, Phase to Phase for Main, Bus and New Source Voltages 3-Phase Line to Ground OR 3-Phase Open Delta for Main, Bus and New Source Voltages 8 Inputs - 2 Inputs (52a) for two breaker positions - 1 Input for protective relay initiate - 1 Input for remote manual initiate - 1 Input for external lockout - 1 Input for auto transfer enable - 1 Input for external reset - 1 Input for auto trip enable 3 Voltage Inputs can be connected: 1-Phase Line to Ground OR 1-Phase, Phase to Phase for Main, Bus and New Source Voltages None 2 Current Inputs None Power Supply Options: - 24/48 V dc - 120/240 V ac or 125/250 V dc M-3872 ISScom Communications Software: - Entering / Modifying Settings - Metering of all measured inputs, measured and calculated quantities - Mimic Single Line Diagram - Sequence of Event logs - Transfer Event Log - Phasor Diagram - Synchroscope - Oscillograph recording ISSlogic for programming additional nonstandard applications and conditions if needed. ISSplot Oscillography Analysis software to playback captured waveforms Cost Effective 125 V dc Power Supply None Fixed standard transfer logic. None Higher cost, and may be difficult to maintain future production due to some components being discontinued and unavailable. Figure 1 (2 of 2) M-4272 Feature Comparison to M-0272/M-0236B 3
The following is a list of the additional features that have been incorporated in the digital equipment that can enhance the security and performance of your facility: Bi-Directional Operation: The legacy equipment does not support automatic transfer from the standby source to the main source. The M-4272 supports automatic transfer in either direction by providing independent bus under voltage elements and transfer initiation inputs for each direction. Hot parallel Transfer: The legacy equipment does not support Hot Parallel Transfer. For routine transfers, the breakers must be operated manually. The safety of this method depends on the plant operator verifying the voltages are satisfactory prior to paralleling the sources. In addition, this transfer method is very slow which results in the sources being paralleled for long periods of time and provides no breaker failure protection. The M-4272 provides programmable, fully supervised closed transitions in either direction. This provides additional safety by ensuring the sources are compatible prior to paralleling, minimizing the time that the two sources are paralleled, and providing breaker failure protection for the entire operation. Self Diagnostics: The legacy equipment provides limited self diagnostics. Like our relay products, the M-4272 incorporates extensive self diagnostics that will automatically remove the equipment from service and notify operators in the event of input power failure or internal equipment fault. Programmable Logic Digital Oscillography Transfer Event Log Sequence of Events Logs Breaker performance monitoring Programmable load shedding Extensive metering and status Communications capability M-5072 Retrofit Kit Features The M-4272 Digital Motor Bus Transfer System and a M-5072 retrofit kit provide the direct replacement of the M-0272/M-0236B Analog Transfer Logic Controller. The physical change is very simple and cost effective. The M-5072 retrofit kit consists of a bracket and wiring harness (Figure 2) that replicates the existing M-0272 terminal block locations. The M-5072 terminal blocks are located in the same positions (Figure 3) as the M 0272 and it is attached to the M-4272. The wire harness connects the appropriate terminals between the M-4272 and the M 0272. This will allow a very simple replacement of the existing M-0272 equipment. Since the existing analog M-0272/M-0236B takes 7u height while the M-4272 takes only 4u height. One rack mount black blank panel with 1u height and one rack mount black blank panel with 2u height are provided to fill up the empty spaces after the replacement. Refer to Figure 4, M-0272 versus M-4272 front panel layout drawing for details. An Optional M-3919A Graphic Display Unit (GDU) and Touch Screen Human Machine Interface (HMI) for communicating with one or two M-4272 units. M-4272/M-5072 Installation The existing M-0272 wiring would be labeled and then disconnected. The M-0272 equipment would be disconnected and removed. The M-0236B would also be disconnected and removed. Then the M-4272 with the supplied bracket/harness already mounted would be installed in the same location as the M-0272. The labeled wires would be reconnected to the new bracket. Refer to Figure 3, M-5072 Terminal Block assignments and Figure 5, M-4272 Versus M-0272 External Connections for details. All wiring connections should be connected directly to M-4272 s terminals. 4
28 27 5 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Figure 2 M-5072 Retrofit Kit Bracket and Wiring Harness 26 M 5072 Retrofit Kit
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Figure 3 M-5072 Terminal Block Arrangements 6
Optional M-3919A GDU Figure 4 M-4272 Versus M-0272/M-0236B Rack Mount Layout 10.47" (6U) 7
TB1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 H N N H N H ANALOG GND (0V) PROTECTIVE RELAY INITIATE AUTO TRANSFER ENABLE MANUAL INITIATE START UP BREAKER STATUS MAIN BREAKER STATUS EXTERNAL LOCKOUT AUTO TRIP ENABLE (SHORT TO ENABLE) POWER STATUS CONTACT (CLOSED WHEN POWER OK) LOCKOUT STATUS CONTACT (CLOSED WHEN M-0236B MOD259 VOLTAGE STATUS NOT OK OR WITH ANY LOCKOUT CONDITION) LOAD TRIP (CLOSES TO TRIP LOADS FOR RESIDUAL VOLTAGE TRANSFER) MAIN VT START UP VT BUS VT M-0275 TRIP MAIN M-0275 TRIP STARTUP M-0275 CLOSE MAIN M-0275 CLOSE STARTUP TB2 + A - B DIODE C + D - E DIODE F + G - H DIODE I + J +VDC EXTERNAL RESET - K DIODE L -VDC M N O P TRIP MAIN INDICATION TRIP STARTUP INDICATION PHASE ANGLE STATUS BUS VOLTAGE STATUS RESIDUAL VOLTAGE TRANSFER DISABLE INPUT CLOSE MAIN INDICATION CLOSE STARTUP INDICATION PREVIOUS RESIDUAL VOLTAGE TRANSFER STATUS MANUAL TRANSFER STATUS PREVIOUS FAST 15 TRANSFER STATUS 16 PREVIOUS IN-PHASE TRANSFER STATUS LOCAL COMMON REMOTE TB3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 M-0272 TRANSFER LOGIC CONTROLLER 3 J1 PLUG IN CONNECTOR 10 8 22 14 1 4 11 21 16 17 7,13,&25 TB1 1 H 2 N 3 N 4 H 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 N 27 H 28 23 9 TB2 A B C D E F G H + - SHIELD OF CABLE GND GND M-0272A & M-0236B INTERCONNECTION CABLE Figure 5 M-0272/M-0236B External Connections 8
Figure 6 M-4272 External Connections For The Existing M-0272 Wiring 9
Physical M-5072 Size: 8.37" high x 17.25" wide x 3.89" deep ( 21.26 x 43.82 x 9.88 ) Approximate Weight: 3 lbs (1.4 kg) Approximate Shipping Weight: 5 lbs (2.3 kg) M-5072 with M-4272 Size: 8.37" high x 19" wide x 12.86" deep ( 21.26 x 48.26 x 32.66 ) Approximate Weight: 23 lbs (10.5 kg) Approximate Shipping Weight: 35 lbs (15.9 kg) Warranty The M 5072 is covered by a five-year warranty from date of shipment. The M-3919A is covered by a two-year warranty from date of shipment. Specification subject to change without notice. 10
M-3919A Graphic Display Unit/Touch Screen Human Machine Interface Provides a MIMIC Single-Line Diagram of the Motor Bus Transfer System in Two-breaker or Threebreaker Bus Transfer Configuration 16.2 Million Color 1024 x 768 Pixel TFT Display 12.1 Inch Touch Screen Human Machine Interface (HMI) Includes a separate power supply, nominal 120 Vac (50/60 Hz) or 125 Vdc (250 Vdc optional) Remote Target Reset Capability Remote Manual Transfer Capabilty Figure 7 Graphic Display Unit/Touch Screen Human Machine Interface 11
Features The M-3919A includes the following features and functions: Display & Touch Screen 12.1" TFT 16.2 Million colors Size 9.75" x 7.25" [248 mm x 184 mm], 12.1" diagonal Brightness 500 cd/m 2 Contrast 700:1 Resolution 1024 x 768 pixels Backlight LED with up to 50,000 hour life span Touch Screen type 4-wire Analog Resistive Microprocessor 800 MHz 32-bit CISC (Fanless CPU) Flash Memory 256 MB SDRAM 256 MB Material Aluminum Enclosure Serial Ports The M-3919A includes two serial ports, which provide the connections to one or two M-4272 Digital Motor Bus Transfer Systems using RS-232 (standard) or RS-485 (optional) communications. The RS-485 serial port also provides the ability to connect multiple M-4272s in series to a single HMI. The M-3919A serial communication ports include the following capabilities: One RS-485 serial port (DE9S) used for RS-485 M-4272 communications One RS-232 serial port (DE9P) used for RS-232 M-4272 communications Baud rates from 9,600 to 115,200 Point-to-point serial communications for all protocols One 10 foot RS-232 Y Cable, BECO Part Number B-1527 Compact SD Card Slot USB Ports 1 Host 2.0 Port, 1 Client 2.0 Port Ethernet Port 10/100 Base-T (RJ45) used for Operator Interface Terminal (OIT) (PC) configuration, downloading program to HMI and Point-to-Point connection and communications using MODBUS TCP/IP. PWR (yellow) illuminated icon indicates if power is applied to the unit CPU (green) illuminated icon indicates if the unit is operating correctly COM (red) illuminated icon indicates communications activity on PLC port RESET Switch to reinitialize the unit if an operational failure occurs 12
Single Line Diagram (SLD) Screens When the MBT SYSTEM PRI Metering menu item is selected from the Selection Menu screen the unit displays either the pre-programmed Two-Breaker or Three-Breaker configuration of the MBTS Single-Line Diagram (Figures 8 and 9 respectfully). The Single-Line Diagrams include a graphical representation of either a Two or Three Breaker configuration with the appropriate number of M-4272 connected units. Also, remote manual transfers and target reset can be performed from the Single-Line Diagram. Included in the graphical representation are the following real-time parameters: Voltage (Three-Phase or Single-Phase) Current (Source 1 and Source 2) Frequency (Delta Angle, Delta Frequency and Delta Voltage) 52-S1 Breaker status (Open/Closed) 52-S2 Breaker status (Open/Closed) Manual Transfer Ready status Lockout/Block status Remote/Local status Device ON/OFF status 52-S1 Circuit Breaker In-Service status 52-S2 Circuit Breaker In-Service status Transfer Complete Transfer Incomplete Figure 8 MBTS Single-Line Diagram Screen (Two-Breaker Configuration) 13
Figure 9 MBTS Single-Line Diagram Screen (Three-Breaker Configuration) Initiating Manual Transfers The GDU/HMI includes the capability to initiate Manual Transfers from the Single-Line diagram. See M-3919A Specification for additional details. Optional Features 250 Vdc Power Supply, BECO Part Number 430-00444 Two-Breaker or Three-Breaker configuration RS-485 Communication with one 10 foot RS-485 Y-Cable, Beco Part Number B-1301 19" Mounting Panel, 6u height, BECO Part Number 441-41530 Physical Size: 9.61" high x 12.49" wide x 1.82" deep (24.4 cm x 31.7 cm x 4.6 cm) Approximate Weight: 4.6 lbs (2.1 kg) Warranty The M 3919A is covered by a two-year warranty from date of shipment. Specification subject to change without notice. 14
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BECKWITH ELECTRIC CO., INC. 6190-118th Avenue North Largo, Florida 33773-3724 U.S.A. PHONE (727) 544-2326 FAX (727) 546-0121 marketing@beckwithelectric.com www.beckwithelectric.com ISO 9001:2008 2010 Beckwith Electric Co. All Rights Reserved. Printed in USA 800-5072-SP-02 01/15