MV vacuum circuit breaker PILOT monitoring device For Evolis 24 kv circuit breaker Installation and user s manual 2004 Evolis
PILOT Contents Introduction 2 PILOT presentation 2 PILOT device 3 Description 3 Characteristics 4 PILOT setting and operating software 5 Description 5 Detailed description of functions 6 Monitoring operating conditions 6 Auxiliary voltage 6 Ambient temperature 7 Number of switching operations 8 Maximum time between switching operations 9 Recording of usage conditions 10 Notepad 11 Monitoring circuit breaker behaviour 12 Event log 12 Installation 15 Device identification 15 Mounting 16 Connecting 17 Accessories to be wired 17 PILOT device on a circuit breaker with an LV plug & socket 18 PILOT device on a circuit breaker without an LV plug & socket 19 Modbus communication network 20 Setting parameters 21 Principle 21 Detailed description of the PILOT software Setup screens 22 Commissioning 24 General examination and preliminary actions 24 Troubleshooting 25 Operating 26 Processing alarms 26 Using the PILOT software 27 Saving data on the PC to send to an expert 28 Visualizing monitoring values 29 Event display 30 Operating conditions display 31 Reading recorded maintenance notes 32 Writing a new maintenance note 33 Modifying an existing maintenance note 34 Modbus communication 35 Presentation 35 Modbus protocol management 36 Implementation 37 Installing the communication network 37 Connection test network 39 Data addressing and coding 40 1
Introduction PILOT presentation The PILOT monitoring device allows the change in the circuit breaker s condition to be assessed in order to ensure that the network protection system works correctly. Introduction Fitted in an Evolis 24 kv circuit breaker, PILOT connects directly to the control mechanisms to enable: b verification of circuit breaker operating conditions: auxiliary voltage level, ambient temperature, number of switching operations and time between two operations, b recording of circuit breaker operating parameters. This data will be used by specialists to make a diagnosis of the circuit breaker s mechanical condition. Recorded data can be collected from PILOT either locally, or remotely via a local network or possibly via the Web using a concentrator. PE55600 PILOT functions Monitoring of circuit breaker operating conditions b The device permanently monitors: v opening coil voltage, v circuit breaker ambient temperature, v number of switching operations, v time between 2 switching operations and gives an alarm in the case of measured values exceeding the set points. b Operating conditions are dated and recorded every 24 hours: v minimum and maximum values of the monitored voltage, v minimum and maximum values of ambient temperature. The maintenance service will therefore be able to monitor the circuit breaker s environment over time (PILOT has a capacity of 1000 recordings). b The alarms are visible on the device s front face or can be consulted on a remote display. Monitoring of circuit breaker behaviour b PILOT records the last 1000 events concerning the circuit breaker: opening, closing, motor arming. PILOT energizing, exceeding an auxiliary voltage set point, exceeding an ambient temperature set point, exceeding the number of switching operatings, exceeding the time between two switching operations. b The recorded data can be given to a circuit breaker expert in order to make a diagnosis of the circuit breaker s mechanical condition. Maintenance notepad PILOT provides maintenance services with a maintenance log zone enabling information on circuit breaker operation to be recorded: 250 notes of 250 characters are available. Local front-face indication The unit s status and detected alarms are indicated on the device s front face using LEDs. PILOT parameter setting and operating software PC-based software gives access to configuration data, data recorded by the unit and data input on the notepad. This data can be accessed when a PC is connected to the PILOT unit: b either directly to the front face, b or via a remote connecting kit in the LV control box of the cubicle in which the circuit breaker is installed, an arrangement that gives access to PILOT data when the circuit breaker is not accessible. Data is presented on standard Internet Explorer software. Communication interface The PILOT device can be connected to a Modbus communication network via a connecting kit. All of the circuit breaker s monitoring data, available in the PILOT device, can then be used remotely via a supervisor. 2
Introduction PILOT device 0 Description 1 - On LED: indicates the presence of power supply on the device 2 - Fault LED: indicates the exceeding of one or several conditions, and possibly a device fault 3 - Fault reset: allows - a fault to be cleared when the cause has been removed - testing of the indication LEDs by pressing and maintaining 4 - Aux. voltage LED: indicates a fault on the opening coil auxiliary voltage 5 - θ C LED: indicates the exceeding of ambient temperature 6 - Setting of the maximum temperature 7 - D-SUB 9 LV socket for connecting a laptop PC with the PILOT setting and operating software The PC can also be connected to the remote communication connector in the low voltage control box. 8 - Max. number LED: indicates an exceeding of the number of switching operations 9 - Max. time LED: indicates an exceeding of the time between 2 switching operations 10 - Date and time backup battery DE55531 Front face operating condition aux. voltage θ C between 2 operations PILOT on fault fault reset HMI 1 2 3 4 5 6 7 8 9 10 Rear face F A B Fast-on connector LV plug (Modbus communication) LV plug (circuit breaker auxiliary contact) DE55532 0 - Not used F A B 0 Communication device C Connection to the communication interface ACE949-2: RS 485 2 wire link or ACE959: RS 485 4 wire link or ACE937: optical link. G Connection to PC via a D-SUB 9 cable PE55596 C G 3
Introduction PILOT device 0 Description Electrical characteristics Power supply Voltage 24 to 250 Vdc; 30% +10% 110 to 240 Vac; 15% +10% Maximum consumption < 150 ma Inrush current < 10 A for 10 ms < 15 A for the first half period Measurement input Voltage 24 to 250 Vdc; 30 % +10 % 110 to 240 Vac; 15 % +10 % Alarm indication relay outputs Voltage Direct 24 Vdc 48 Vdc 120 Vdc 220 Vdc Alternating (47.5 to 63 Hz) 100 to 240 Vac Permanent current 2 A 2 A Baking capacity Load L/R < 20 ms 2 A 1 A 0.5 A 0.1 A Load cos ϕ > 0.3 1 A Backup battery Battery Lithium 3 V 550 mah CR2450 (IEC standard) Service life 10 years PILOT energized 5 years PILOT de-energized Environmental characteristics Insulation Standard Level/Class Value Dielectric strength at power frequency IEC 60255-5 2 kv rms 1 min. Impulse wave 1.2/50 µs IEC 60255-5 5 kv Electromagnetic compatibility Rapid burst transients IEC 61000-4-4 IV Immunity to radiated fields IEC 61000-4-3 III 10 V/m Immunity to conducted RF disturbances IEC 61000-4-6 III 10 V Immunity to high energy transients IEC 61000-4-5 2 kv Electrostatic discharge IEC 61000-4-2 III 6 kv / 8 kv Conducted disturbance emission EN50022 A Disturbance field emission EN50022 A Mechanical strength Vibrations IEC 60255-21-1 2 Impact IEC 60255-21-2 2 Protection index IEC 60529 IP52 front face IP20 rear face Climatic withstand Operation IEC 60068.2.1/2 25 C to +70 C Storage IEC 60068.2.1/2 25 C to +70 C Humid heat IEC 60068.3 93% HR; 40 C, 10 days 4
Introduction PILOT setting and operating software 0 Description PE55625 Introduction PC-based software gives access to configuration data, data recorded by the device and data input in the notepad. This data is available when a PC is connected to the PILOT device: b either directly to the front face, b or via the optional remote connecting kit in the LV control box of the cubicle in which the circuit breaker is installed, an arrangement that allows PILOT data to be accessed when the circuit breaker is not accessible. Each PILOT device is also delivered with: b the PILOT setting and operating software set-up CD-ROM, b the link cable required to connect the PC to the PILOT device. Characteristics Minimum PC configuration: b Processor Pentium 133 MHz or faster, b Operating system: Microsoft Windows 98 SE/NT4.0/2000/XP, b Internet Navigator: Microsoft Internet Explorer 5.0 or higher, b RAM memory: 64 Mo minimum, b COM1 serial port, b CD-ROM reader. 1 - Title bar 2 - General internet explorer bar 3 - TR applications generic menu bar. In our application only Home, Monitoring, Maintenance and Setup are used. 4 - Second level menu 5 - Active part of each window PE55601 General screen organization All of the screens are organized as follows: 1 2 3 4 5 Home page of the PILOT setting and operating software Generic menu bar PE55602 Connection return Not used Not used Actual values Events Condition line records Not used Circuit Breaker Characteristics Configuration parameters Communication parameters Installation parameters Warning parameters Initial measurements Maintenance bloc-notes 5
Detailed description of functions Monitoring operating conditions 0 Auxiliary voltage Why monitor the voltage? Circuit breaker operation is guaranteed when all of the auxiliary voltages are within the authorized limits. Should these limits be exceeded, the switching time may become abnormally long and the circuit breaker s operation may be deteriorated. A voltage level outside of the limits can be a sign of a fault in charge level of the batteries, in which case maintenance operations will be necessary. The auxiliary voltage used for opening is constantly monitored to guarantee the circuit breaker s key functions. Monitoring principles PILOT is supplied power via the energy source used for circuit breaker opening. PILOT permanently samples the supply voltage and, after filtering, compares it with the monitoring set point. DE55535 +x% +10% type U (V) Set point definition By default, PILOT indicates any exceeding of values relative to the standardized coil operating range (of 30% to +10% of the rated dc voltage level or 15% to +10% of the rated ac voltage level) guaranteed by Schneider Electric. However, it is possible to modify the minimum and maximum thresholds by a correction factor (+x%, y% of the rated voltage) in order to extend the monitoring range. 30% y% t (s) The set point then becomes: 30% x% to +10% +y%. The values x and y are input when setting parameters in PILOT using setup/ installation parameters in the PILOT software. Monitoring auxiliary voltage Light gray zone: auxiliary voltage within the standardized operating range of the coil. Dark gray zone: auxiliary voltage in an extended operating range for the coil. Beyond that: auxiliary voltage outside of the coil s operating range V alarm. Voltage Coil type Rating Tolerance Umin Umax Direct 24 V 24-30 V 30% +10% 17-33 V 48 V 48-60 V 30% +10% 34-66 V 100 V 100-130 V 30% +10% 70-143 V 200 V 200-250 V 30% +10% 140-275 V Alternating 100 V 100-130 V 15% +10% 85-143 V 200 V 200-250 V 15% +10% 170-275 V 6
Detailed description of functions Monitoring operating conditions Ambient temperature Why monitor the temperature? Circuit breaker operation is guaranteed when the ambient temperature is within the authorized limits. Beyond the maximum temperature, the circuit breaker must be operated at lower current levels than its maximum performance levels. Near to the minimum temperature, the mechanisms require closer monitoring. The PILOT device permanently monitors the circuit breaker s ambient operating temperature and indicates any exceeding of the set points. Monitoring principle A sensor permanently measures the temperature inside the device. Corrections are provided to take account of self-heating inside the casing and the device in order to give the ambient temperature around the circuit breaker. PILOT compares the measured values with the upper and lower set points of the authorized values. However PILOT does not take account of circuit breaker heating which is dependent on the installation architecture (cubicle type) and operation. Set point definition The maximum permissible upper temperature set point is defined by the position of the switch on the front face of the device. Four threshold values are available: 40 C, 45 C, 50 C and 55 C. The lower minimum admissible temperature set point is defined by the value given when setting parameters using the device s PILOT software in setup/warning parameters. The possible setting ranges from 25 C to +5 C in increments of 1 C 7
Detailed description of functions Monitoring operating conditions Number of switching operations Why monitor the number of switching operations? Circuit breaker operation is guaranteed for a maximum number of operations. Whilst exceeding this value can be tolerated, it requires closer monitoring of the device. The PILOT device permanently monitors the number of circuit breaker switching operations and indicates when the set point is exceeded. Monitoring principle The switching operation counter is incremented every time the circuit breaker is electrically closed in the same way as the circuit breaker mechanical counter. However, manual switching operations of the circuit breaker will not be taken into account. When the device is installed, the electronic counter must be set to the same value as the mechanical counter. Set point definition The set point for the maximum permissible number of switching operations is defined by the value input when setting the device s parameters in the Setup/warning parameters part of the PILOT software. 8
Detailed description of functions Monitoring operating conditions Maximum time between switching operations Why monitor the time between 2 switching operations? If the circuit breaker is not switched for a long period of time, this can cause it to malfunction (seizing of mechanisms). Exceeding of this value requires closer monitoring of the device. It is recommended to operate the device once a year. The PILOT device permanently monitors the time between 2 switching operations and warns if a value is exceeded. The time is expressed in days. Monitoring principle The switching counter is incremented every time the circuit breaker is electrically closed. This switching operation is dated, the device permanently calculates the time since the last operation and compares it with the set point. When the device is de-energized, the calendar circuit is supplied power from the lithium back-up battery. When re-energized the device updates the time since the last switching operation. d Please note: manual switching operation does not increment the counter and does not re-set the time counter, it is therefore recommended to carry out an electrically controlled operation. Set point definition The set point for the maximum time between 2 switching operations is defined by the value input when setting parameters for the device in Setup/ warning parameters in the PILOT software. 9
Detailed description of functions Monitoring operating conditions Recording of usage conditions Introduction PILOT records the daily minimum and maximum values of the voltage supplying the opening coil together with minimum and maximum values of ambient temperature. Characteristics of the usage conditions buffer The daily values of usage conditions are stored in a rotating buffer of 1000 lines (only the last 1000 events are saved). Each event line comprises 5 fields: Date θ min. θ max. Vaux min. Vaux max. 06/03/2003 23 26 87 114 05/03/2003 23 26 87 114 04/03/2003 23 26 114 114 03/03/2003 23 26 114 114 02/03/2003 23 26 114 114 01/03/2003 23 26 114 114 28/02/2003 23 26 114 114 27/02/2003 23 26 114 114 26/02/2003 23 26 114 114 Date Calendar date saved on the day of the recording. θ min. Minimum ambient temperature sampled during the day. θ max. Maximum ambient temperature sampled during the day. Vaux min. Minimum auxiliary opening voltage sampled during the day. Vaux max. Maximum auxiliary opening voltage sampled during the day. 10
Detailed description of functions Notepad 0 Introduction To facilitate monitoring of circuit breaker maintenance, the PILOT device provides maintenance services with a maintenance log book using a notepad feature. 250 notes are available in the device. The actual number of notes used is given in the number of notes field. The notepad can be accessed via the PILOT software. Notepad characteristics The notepad has zones of free text. The last recorded note or the last modified note is always the first note to be visualized. PE55603 11
Detailed description of functions Monitoring circuit breaker behaviour Event log Introduction A circuit breaker s behaviour can be characterized by the change in the time it takes to open, close and arm the motor. PILOT records these operating parameters, measured on each switching operation. This data provides a historical log of the circuit breaker switching operation. To supplement these measurements, PILOT also records: b the energizing of the device, b alarms given from monitoring operations (auxiliary voltage, ambient temperature, switching operating counter, time between 2 switching operations). Characteristics of the events buffer Events are stored in a rotating buffer of 1000 lines (only the 1000 last events are saved). Each event line comprises 8 fields: CPT Type Vaux Time θ Date Hour State 2000 Overflow cpt 0 0 24 10/01/2003 14 Overflow cpt...... 95 Open 102 48.3 ms 24 10/01/2003 14 Normal 95 Close 102 69 ms 24 10/01/2003 14 Normal 95 Motor 100 4.843 s 24 10/01/2003 14 Normal 95 Restart 0 0 24 10/01/2003 14 Normal 95 Voltage 69 0 24 10/01/2003 14 Voltage 95 Temperature 0 0 46 10/01/2003 14 Temperature 95 Overflow time 0 0 24 10/01/2003 14 Overflow time CPT: counter value managed by the device Type: event type b Open: opening operation b Close: closing operation b Motor: mechanism arming b Restart: device energizing b Voltage: auxiliary voltage overflow alarm b Temperature: temperature overflow alarm b Overflow cpt: switching counter overflow alarm b Overflow time: time between 2 switching operations overflow alarm Vaux: value of measured voltage as a function of event type Time: switching operation duration measured as a function of the event type (opening, closing, motor arming) θ: ambient temperature Date: event date Hour: event time. State: device operating status b Normal: the device is functioning at rated values b Voltage: the device has a voltage alarm b Temperature: the device has a temperature alarm b Overflow cpt: the device has a counter alarm b Overflow time: the device has a time between switching operations alarm. 12
Detailed description of functions Monitoring circuit breaker behaviour Event log DE55536 Opening cycle Voltage present across the opening coil terminals Circuit breaker position input: 1 = open 0 = closed Opening command Mechanism switched Opening time Event types Circuit breaker opening When an electrical opening order (on fault or on command) is given a voltage is generated across the terminals of the coil, the voltage is maintained until the position contact changes status. The device, via its corresponding measurement input: b detects the appearance of the voltage, b triggers the timer, b measures the value of the voltage applied across the coil terminals, b detects the disappearance of the voltage, b stops the timer. Via its auxiliary NC contact, the device monitors the circuit breaker position. The circuit breaker is in the OPEN position. d Please note, mechanical opening does not generate measurement and recording. DE55537 Closing cycle Voltage present across the closing coil terminals Closing command Circuit breaker position input: 1 = open 0 = closed Mechanism switched Closing time Circuit breaker closing When an electrical closing order (on command) is given, a voltage is generated across the coil terminals, this voltage is maintained until the position contact changes status. Through its measurement input, the device: b detects the appearance of the voltage, b triggers the timer, b measures the value of the voltage applied across the coil terminals, b detects the disappearance of the voltage, b stops the timer. Via its auxiliary NC contact, the device monitors the circuit breaker position. The circuit breaker is in the CLOSED position. d Please note, mechanical closing does not generate either measurement or recording. DE55538 Motor cycle Voltage present across the closing coil terminals Circuit breaker position input: 1 = open 0 = closed Voltage present across the arming motor terminals Motor arming When the circuit breaker has completed its closing cycle, it rearms the mechanism using the rearming motor. This motor is activated as soon as the circuit breaker is switched to the closed position right through to the appearance of the end of arming contact which breaks the power supply to the motor. Through the NC and measurement inputs, the device: b triggers the timer, b measures the value of voltage applied across the motor terminals, Through its measurement input, the device: b detects the disappearance of voltage and stops the timer. Arming time 13
Detailed description of functions Monitoring circuit breaker behaviour Event log Energizing Every time the PILOT device is re-energized, it records the fact that it has been reset and notes the sampled ambient temperature, the date and the time as well as the device status. Auxiliary voltage alarm The appearance of an auxiliary voltage alarm causes the device to record its fault status and notes the fault voltage, the sampled ambient temperature, the date and the time as well as the device status. Ambient temperature alarm The appearance of a temperature alarm causes the device to record its fault status, noting the fault temperature. Alarm for exceeding the authorized number of switching operations The appearance of an alarm for exceeding the authorized number of switching operations causes the device to record its fault status and note the value of the switching operation counter, the sampled ambient temperature, the date and the time as well as the device s status. Alarm for exceeding the time between 2 switching operations The appearance of an alarm for the time between 2 switching operations causes the device to record its fault status, noting the value of the switching operation counter, the sampled ambient temperature, the date and the time as well as the device status. The time calculated by the device can be seen in Actual values in the PILOT software. 14
Installation Device identification We recommend that you follow the instructions given in this document for quick and correct installation of your device: b device identification, b mounting the PILOT device, b connecting measurement inputs and logical inputs, b connecting the power supply, b mounting and connecting the communication connection kit, b checking before energizing. PILOT basic kit Each PILOT device is delivered in a pack that includes: b 1 device, b 1 user s manual, b 1 CD-ROM with the PILOT parameter setting and operating software, b 1 PC link cable, b 1 PILOT device mounting bracket for the Evolis circuit breaker, b 4 M6x16 bolts for fixing the bracket and for M3x16 bolts for fixing the PILOT device to the bracket, b 1 set of factory-built cables to connect the PILOT device to the Evolis circuit breaker: v 1 O cable to connect to the opening coil input, v 1 F cable to connect to the closing coil input, v 1 M cable to connect to the arming motor input, v 1 B cable to connect to the circuit breaker positions input, v 1 earthing braid. Connecting kit The connecting kit exists in 2 versions, according to the circuit breaker characteristics: b Connecting kit without LV plug, comprising: v 1 PILOT communication interface, with the prefabricated connection cable to connect the PILOT communication interface directly to the PILOT device, v 4 wires (length: 2 m) 2 for the remote alarm output (black wires), 2 for the device power supply (1 red wire, 1 blue wire). b Connecting kit with LV plug: v 1 PILOT communication interface with the factory built connection cable for the LV plug to the PILOT communication interface, v 1 factory built connection cable for the PILOT device to the LV plug, v 1 black wire to supply power to the device. 15
Installation Mounting 0 d Warning: It is essential to open the Evolis circuit breaker before working on the PILOT device. Fixing the bracket b Turn off the circuit breaker s auxiliary power supply. b Carry out an opening/closing cycle using the mechanical push buttons to be sure that the mechanism is disarmed. b Remove the two upper parts of the circuit breaker front face cover to access the circuit breaker control mechanism plate. b Attach the bracket to the control mechanism plate using the 4 M6x16 bolts supplied. Mounting the device b Fit the PILOT device into its bracket and fix it using the 4 M3x16 bolts supplied. b Cable the PILOT according to instructions in the Installation/connecting chapter. b Put back the two upper covers on the circuit breaker. b See the Commissioning/General examination and preliminary actions chapter to test the PILOT. PE55598 PE55597 16
Installation Connecting 0 Accessories to be wired Layout of the various terminals and accessories to be wired D and XM do not exist in the case of the circuit breaker without a LV plug & socket. PE55599 LV plug & socket D-SUB 9 type for communication C.B. low voltage plug & socket Evolis 24 kv C.B. black terminal block fast-on type C.B. auxiliary contacts C.B. maintained release switch C.B. motor terminal block LV socket D-SUB 9 type for connection to PC from PILOT or from LV control box PILOT terminal block fast-on type PILOT LV plug & socket for C.B. position (B) and for communication (A) 17
Installation Connecting 0 PILOT device on a circuit breaker with an LV plug & socket DE55541 To communication interface ACE 949-2 or ACE 959 or ACE 937 CCA612 cable To PC Alarm PILOT LV auxiliary supply C.B. tripping C G E XM 11 15 4 10 9 12 A B PILOT LV plug & socket for communication PILOT LV plug & socket for C.B. position 1 2 3 4 5 6 7 8 8 M SE YF 11 QF 12 Y01 B C D E C.B. black terminal block fast-on type CCA612 link to communication interfaces LV plug & socket D-SUB 9 type for communication Remote communication device fitted in LV control box D 1 2 3 4 5 6 7 8 B F G PILOT terminal block fast-on type LV socket D-SUB 9 type for connection to PC from PILOT or from LV control box 70 89 88 M C.B. motor terminal block 8 Black Black Mark M Mark F Mark O Black Black QF SE C.B. auxiliary contacts C.B. maintained release switch F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Y01 C.B. shunt trip release Mark A B Alarm COM A YF XM C.B. closing release C.B. low voltage plug & socket 1 1 QF 25 26 Mark B 2 3 4 2 3 4 PILOT 5 5 6 6 7 7 G Not used Fitted on PILOT front face To PC 18
Installation Connecting 0 PILOT device on a circuit breaker without an LV plug & socket DE55542 To communication interface ACE 949-2 or ACE 959 or ACE 937 CCA612 cable To PC Alarm PILOT LV auxiliary supply C.B. tripping C G E A B PILOT LV plug & socket for communication PILOT LV plug & socket for C.B. position 1 2 3 4 5 6 7 8 M SE YF 11 QF 12 Y01 B C E C.B. black terminal block fast-on type CCA612 link to communication interfaces Remote communication device fitted in LV control box F PILOT terminal block Fast-on type G LV socket D-SUB 9 type for connection to PC from PILOT or from LV control box B M C.B. motor terminal block 70 89 88 QF C.B. auxiliary contacts SE C.B. maintained release switch 8 Black Black Mark M Mark F Mark O Red Blue Y01 C.B. shunt trip release F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 YF C.B. closing release Mark A B Alarm COM A 1 1 QF 25 26 Mark B 2 3 4 2 3 4 PILOT 5 5 6 6 7 7 G Not used Fitted on PILOT front face To PC 19
Installation Connecting 0 Modbus communication network DE55543 Interface ACE 949-2 V+ V L+ L 12 or 24 Vdc power supply 2-wire RS 485 network Connecting the PILOT to the communication network PILOT must be connected to the communication network via one of the Sepam range communication interfaces: b ACE949-2: RS 485 2 wire link, b ACE959: RS 485 4 wire link, b ACE937: optical link. C L L+ V V+ 2-wire RS 485 network 12 or 24 Vdc power supply For more information, consult the user or operator manuals for Sepam protection relays. CCA612 cable To PC A C PILOT LV plug & socket for communication CCA612 link to communication interfaces E D LV plug & socket D-SUB 9 type for communication C G E Remote communication device fitted in LV control box 1 2 3 4 5 6 7 8 G LV socket D-SUB 9 type for connection to PC from PILOT or from LV control box 8 Without LV plug & socket option D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 COM A 1 1 2 2 3 4 3 4 PILOT 8 5 5 6 6 7 7 Mark A G Not used Fitted on PILOT front face To PC 20
Setting parameters Principle 0 Before any operation, it is essential to check or up-date device parameters according to the circuit breaker s components or how it is intended to be used. Setting parameters for PILOT The parameters for a PILOT device should be input from the Setup menu in the PILOT parameter setting and operating software. 6 sub-menus are then provided to access parameter categories: b Circuit Breaker Characteristics, b Configuration parameters, b Communication parameters, b Installation parameters, b Warning parameters, b Initial measurements. The data input procedure of a parameter is always the same: b click on the modify function, b input the values of the various fields, b click on the save modification function. 21
Setting parameters Detailed description of the PILOT software Setup screens 0 Introduction The Setup screens allow parameters to be set for the device. Circuit Breaker Characteristics screen Groups all of the characteristics of the circuit breaker on which PILOT is mounted. The data input in this screen must be the same as that on the circuit breaker rating plate. PE55604 Configuration parameters screen Defines the type and voltage of control auxiliaries: circuit breaker opening and closing coils and motor arming. PE55605 Communication parameters screen Defines the PILOT communication port parameters. PE55606 22
Setting parameters Detailed description of the PILOT software Setup screens Installation parameters screen Defines the parameters to be input when installing PILOT: b electrical network frequency, b mechanical counter value, b current date and time, b measurement thresholds. The measurement threshold setting enables experts to fine-tune the measurements as required. It is recommended to keep the rated parameters: 60% Vn direct and 20% Vn alternating. Please note: Any modification in frequency parameter requires the device to be re-energized before it is taken into account. PE55607 Warning parameters screen Sets the thresholds for alarms that are monitored by the PILOT device: b auxiliary voltage thresholds, b permissible minimum temperature, b maximum number of switching operations, b maximum time between 2 switching operations. The auxiliary voltage thresholds are parameters intended for experts in order to fine-tune the measurements as required. It is advised to keep the rated parameters: 0 for direct and alternating. Please note: The maximum temperature should be set using the switch on the front face of the device. Choice between 4 values: 40 C, 45 C, 50 C and 55 C. PE55608 Initial measurements screen Enables the open/close time, measured by the PILOT device when commissioned, to be entered. These values will be used for reference by experts in order to assess any possible discrepancies. PE55609 23
Commissioning General examination and preliminary actions 0 Verifications before energizing Using the diagrams, check: b the device s earthing, b the correct connection of the auxiliary voltage, b the tightening of various connections, b the correct plugging of connectors. See Installation/Connecting chapter. Starting the calendar back-up battery Remove the battery s insulating tab. Energizing Energize the auxiliary power source to the circuit breaker s opening coil. Check that the device runs through its initialization sequence: b the green On indicator light goes on, b the red Fault indicator light goes on for 5 seconds, b the Fault relay is armed. Implementing the PILOT software b Turn on the PC. b Connect the RS 232 to the COM1 series port on the PC to the front face of the device or to the D-SUB 9 LV socket of the remote communication device in the LV control box (ensure that COM1 is not used by another utility). b Run the PILOT software from its icon. Checking configuration parameters b Once the connection has been made between the device and the PC, successively check the content of the 6 parameter setting screens. b Do not forget to update the device time. b Do not forget to update the PILOT switching operation counter. See Setting parameters/detailed description of the PILOT software Setup screens chapter. Checking device functions b Check the data on the Actual Values screen: date, ambient temperature, switching operation counter, voltage. b Carry out an electrically commanded opening and closing operation on the circuit breaker. d Please note, mechanical opening and closing will not generate either measurement or recording. b Check the recording of actions on the Events screen. b Input the measured opening/closing time values in the Initial measurements screen. 24
Commissioning Troubleshooting 0 The fault indicator light remains on b Cancel the fault(s). b Clear the fault(s) by pressing the fault reset button. The PILOT software cannot run b Ensure that the short-cut path has not been changed. b Re-install he PILOT software using the supplied CD. No connection with the PILOT software Failure during initial connection: b check that the FIFO on the COM1 series port is disabled, b follow the instructions in the serial port parameters.txt document situated in C:\Program files\schneider\pilot\ No connection, but there was in the past: b check that another application that uses the COM1 port has not been run (e.g. using an organizer), b check that the device is in normal position, b check the condition of the cable. 25
Operating Processing alarms 0 Consequence of exceeding a threshold When the device detects a fault, it indicates an error causing: b the device switches to its fault position, b the fault LED comes on, b the LED corresponding to the fault comes on: the aux, temp, max, max time, b the fault relay is in the fault position, b the fault is recorded in the event buffer with its date. Return to normal position In order to return to the normal operating position, it is essential to cancel the cause or modify the monitoring set point and carry out a device reset via one of the following actions: b re-energizing, b or activating the fault reset button the front face, b or sending a supervisor command via the Modbus network. In these conditions: b the device returns to its normal position, b the LED corresponding to the fault goes off, b the fault LED goes off, b the fault relay is in the normal position. Block diagram on alarm DE55544 PILOT auxiliary supply PILOT internal fault fault u 1 u 1 Opening release supply < auxiliary voltage threshold low (warning parameters) > auxiliary voltage threshold high (warning parameters) u 1 1 0 u 1 aux. voltage Ambient θ C < ambient θ C threshold low (warning parameters) > fault panel switch u 1 1 0 u 1 θ C Operation counter > max. number (warning parameters) 1 0 u 1 max. number Time between 2 operations > max. time between 2 operations (warning parameters) 1 0 u 1 max. time between 2 operations Fault reset/leds test Legend: Logic functions OR X Y u 1 S Z S = X + Y + Z S R Bistable functions, may be used to store values 1 0 B = S + R x B B 26
Operating Using the PILOT software 0 d The procedure below should be followed whenever connecting in order to check the link between the PC and the PILOT device. The PILOT software must initially be installed on the PC. Use the PC link cable, and: b connect the D-SUB 9 LV socket to the PC COM1 port, b connect the D-SUB 9 LV plug to the PILOT device or to the remote communication device in the low voltage control box, b launch the PILOT software by clicking on the desk top shortcut created on installation, b select the serial line option with 1 as the slave number, b check the dialogue between the PC and the device by accessing normal device data. From the PILOT software home page, click on Monitoring. PE55601 The Monitoring screen describes the available information. Click on Actual values. PE55610 The Actual values screen is displayed. If the connection is established, the green comm OK indicator light is lit and the values are given. PE55611 You can now access all of the PILOT data.. 27
Operating Saving data on the PC to send to an expert 0 The data shown on each screen can be backed up on the PC hard disk using Save in folder in a TXT file under the circuit breaker identification address (the back-up path is given whenever saved). PE55612 The files to be sent to the expert are: b Pilot_breaker_param.txt b Pilot_configuration.txt b Pilot_communication.txt b Pilot_installation.txt b Pilot_warning_param.txt b Pilot_initial.txt b Pilot_maintenance.txt b Pilot_val_courantes.txt b Pilot_events.txt b Pilot_condition_line.txt 28
Operating Visualizing monitoring values 0 Data access PE55601 Click on Monitoring PE55610 Click on Actual values PE55611 Display data Displayed data Gives the device s monitoring values. b Circuit Breaker Status Circuit breaker position: open or closed. b PILOT Status Device status: normal or fault. b Actual date Date from the calendar circuit at the time of request. b Actual temperature Ambient temperature of the device sampled at the time of request. b Actual counter Value of the switching operation counter managed by the device. b Actual auxiliary voltage Value of the device power supply sampled at the time of request. b Actual time between operations Time calculated by the device since the last switching operation. b Software version Current software version. b Hardware version Version of the device circuit board. 29
Operating Event display 0 Shows the circuit breaker event log. The number of events recorded is defined by Number of events. The user chooses the number of events to be displayed in Number of events request. Data access PE55601 Click on Monitoring PE55615 PE55610 Click on Events Number of events PE55614 Number of events to be read Click on Post Display table 30
Operating Operating conditions display 0 Displays the circuit breaker event log. The number of events recorded is defined by Number of condition record. The user chooses the number of events to be displayed in Number of request. Data access PE55601 Click on Monitoring PE55617 PE55610 Click on Condition line records Number of events PE55616 Number of events to be read Click on Post Display table 31
Operating Reading recorded maintenance notes 0 Data access PE55601 Click on Maintenance PE55620 PE55618 Click on Maintenance bloc-notes Number of available notes PE55619 Number of notes to be displayed Click on Post Display bloc-notes 32
Operating Writing a new maintenance note 0 Data access PE55601 Click on Maintenance PE55621 PE55619 PE55618 Click on Maintenance bloc-notes Click on New maintenance Write the note Save 33
Operating Modifying an existing maintenance note 0 Data access PE55601 Click on Maintenance PE55619 PE55620 PE55618 Click on Maintenance bloc-notes Number of available notes Number of notes to be displayed Click on Post Modify the note Save PE55622 The modified note moves to the top of the list 34
Modbus communication Presentation 0 General Modbus communication allows the PILOT device to be connected to a supervisor or to any other piece of equipment with a Modbus maters communication channel. PILOT is always a slave station and must be connected to the communication network via one of the Sepam range communication interfaces Sepam: b ACE949-2: RS 485 2-wire link, b ACE959: RS 485 4-wire link, b ACE937: optical link. Accessible data The data that can be accessed from the RS 485 Modbus link include all of the data managed by the device, accessible via the PILOT software. Parameter setting data b Circuit Breaker Characteristics b Configuration parameters b Communication parameters b Installation parameters b Warning parameters b Initial measurements Monitoring data b Actual values b Events b Condition line records Maintenance data b Maintenance bloc-notes Access procedures According to the data, two different access procedures can be used: b direct access: the data is directly accessible in one reading or writing transaction, b indirect access: access to the data requires several reading transactions. This access is dedicated to read records: Events, Condition line records and Maintenance bloc-notes. Please, read each line of the data. Example: to read five lines of event records, you have to read data at addresses: 1000, 1001, 1002, 1003, 1004. 35
Modbus communication Modbus protocol management 0 Protocol principle Modbus allows the exchange of data between a master device and one of several slave devices, identified by a number. It is based on a request-response type dialogue, the request always being sent by the master. Modbus exists in ASCII or binary form (RTU mode). The data exchanged is of 16 bit type (still called registeror of single bit type. Each piece of data (bit or register) is identified in the device by a 16 bit coded address. The detailed protocol description can be obtained on the internet site: www.modbus.org. Supported Modbus functions The Modbus protocol in PILOT devices is a sub-assembly that is compatible with the Modbus RTU protocol. The following functions are processed by PILOT: b function 3: reading n output or internal words, b function 4: reading n input words, b function 6: writing 1 word, b function 8: reading Modbus diagnosis counters, b function 16: writing n words. The supported exception codes are: b 1: unknown function code, b 2: incorrect address, b 3: incorrect data, b 7: non acquittal (tele-writing and tele-setting). Multi-master operation When PILOT devices are connected via a gateway to a network authorizing multiple access (Ethernet, Modbus+, etc.), several master units are likely to address the same PILOT on the same communication port. The Modbus series protocol does not manage this type of architecture. The solving of any possible conflicts is the responsibility of the network designer. b For directly accessed data, no precaution is generally required. b For indirectly accessed, PILOT offers two exchange zones on each port allowing two simultaneous and independent access procedures by two different master devices. Performance levels The return time (the time between the end of reception of a request and supplying of the response) is typically less than 10 ms for 90% of exchanges. Sometimes it may be higher, without being more than 150 ms. In indirect mode, the time required between a request (or clearing) and the availability of the corresponding data is related to PILOT s non priority cycle time and can vary from a few tens to a few hundreds of ms. 36
Modbus communication Implementation 0 Installing the communication network Preliminary study The communication network must be subject to a preliminary technical study which will determine the following according to the installation characteristics and constraints (geography, quantity of data processed, etc.): b the type of media (electrical or optical), b the number of PILOT devices (or slaves) per network, b the transmission speed, b the configuration of ACE interfaces, b parameter setting of the PILOT device. Transmission characteristics Transmission type Character format Communication speed Asynchronous series 8 data bits 1 stop bit Parity according to parameter setting 4800, 9600, 19200, 38400 baud Characteristics of RS 485 electrical interfaces Electrical interface ACE949-2 Conformity with EIA standard ACE959 Differential RS 485 2-wire In conformity with EIA standard Differential RS 485 4-wire Power supply of electrical interfaces Connection type Maximum number of PILOT devices on a network Per external auxiliary supply 12 Vdc or 24 Vdc Screw terminals and tightening clamps for shielding 25 Maximum length of the RS 485 network with standard cable Number of PILOT devices 12 Vdc supply 24 Vdc supply 5 320 m 1000 m 10 180 m 750 m 20 160 m 450 m 25 125 m 375 m N.B.: links multiplied by 3 with a high performance FILECA F2644-1 cable (maximum 1300 m). Optical interface characteristics Optical fiber type Gradient index silica fiber Wave length 820 nm (non visible infrared) Interface power supply By the PILOT device Connection type ST connector Maximum optical network length Fiber diameter (µm) Digital opening (NA) Maximum attenuation (dbm/km) Minimum available optical power (dbm) 50/125 0.2 2.7 5.6 700 62.5/125 0.275 3.2 9.4 1800 100/140 0.3 4 14.9 2800 200 (HCS) 0.37 6 19.2 2600 Maximum fiber length (m) 37
Modbus communication Implementation Installing the communication network Setting the communication parameters Commissioning of the communication option requires preliminary setting of several parameters using the PILOT software. These parameters are saved in the case of power outage. Communication parameters Factory setting Protocol type Without, Modbus, CAN If Modbus choice No. of slave units 1 to 255 Transmission speed 1200, 2400, 4800, 9600, 19200 or 38400 baud Parity Even, odd, without parity The allocation of the Modbus slave number must be carried out before connecting the PILOT to the communication network. It is also very advisable to set the other physical communication parameters (speed, parity) before connecting to the communication network. Modification of the communication parameters in normal operation does not disturb PILOT. The new parameters will be taken account of the next time the device is energized. 38
Modbus communication Implementation Connection test network Line activity indicator light The green indicator light on ACE949-2, ACE959 or ACE937 accessories is activated by variations in signal on the Modbus network. When the supervisor communicates with PILOT (either sending or receiving), this green indicator light will flash. After cabling, check that an indicator is given by the indicator light when the supervisor works. Please note: flashing indicates the flow of data to or from PILOT, it does not mean that the exchange is correct. Diagnosis counters Counter definition PILOT manages Modbus diagnosis counters. These are: b CPT1: number of correct frames received, whether the slave is concerned or not b CPT2: number of frames received with CRC error or physical error (frames comprising more than 255 bytes, frames received with at least one parity error or overrun or framing, break on the line). b CPT3: number of exception responses generated (even if not sent, due to a broadcast request being received) b CPT4: number of frames specifically addressed to the unit (apart from broadcast) b CPT5: number of broadcast frames received without error b CPT6: not significant b CPT7: not significant b CPT8: number of frames received with at least one character having a physical error (parity or overrun or framing, break on the line) b CPT9: number of correct requests received which are correctly executed Resetting counters The counters are reset to 0: b when they achieve the maximum value FFFFh (65535) b when they are reset to zero by a Modbus command (function 8) b when the auxiliary power supply is stopped to PILOT b when the communication parameters are modified. Use of counters Modbus diagnostic counters help detect and resolve communication problems. They are accessible via dedicated reading functions (functions 8 and 11 in the Modbus protocol). An erroneous speed (or parity) causes an incrementation of CPT2. A lack of reception is observed in the non-change in CPT9. Operating anomalies It is recommended to connect PILOT devices one by one on the Modbus network. Make sure that the supervisor sends frames to the PILOT concerned by checking the activity in the RS 232 - RS 485 or optical converter if there is one, and with the ACE949-2, ACE959 or ACE937 device. RS 485 network b Check the cabling to each ACE device b Check the tightening of the screw terminals on each device b Check connection of cable CCA612 connecting the ACE949-2 or ACE959 to the PILOT unit. b Check the polarization which must be single and the adaptors which must be placed at the ends of the RS 485 network. b Check that the cable used is the recommended type b Check that the ACE909-2 or ACE919 converter that this used is correctly connected, powered and set. Optical network b Check the connections to the ACE device b Check the connection of the CCA612 cable linking the ACE937 device to the PILOT unit. b Check that the converter or the optical star is correctly used, connected, powered and set. In all cases Check the slave number, the speed, the format with the PILOT software. 39
Modbus communication Data addressing and coding 0 Data Address Number of bytes Access mode Circuit Breaker Characteristics Access type Variables details Value/ Format Characteristics 0 54 Direct/read Structure Reference String 16 Serial number String 16 Rated voltage Ur (kv) rms kv 1 Reserved 1 Rated normal current Ir (A) rms A 2 Rated short-circuit breaking current Isc (ka) rms ka 1 Reserved 1 Reserved 1 User identification String 14 Reserved 1 Data Address Number of bytes Access mode Configuration parameters Access type Variables details Value/ Format PILOT serial number 33 4 Direct/read Structure Year YY 1 Week WW 1 Number XXXX 2 Open-coil 35 4 Direct/read Structure Reserved 1 Type 0: shunt 1 1: under V Type of voltage 0: ac 1 1: dc Nominal voltage Volts 1 Close-coil 37 4 Direct/read Structure Reserved 1 Type of voltage 0: ac 1 1: dc Nominal voltage Volts 1 Reserved 1 Motor 39 4 Direct/read Structure Reserved 1 Type of voltage 0: ac 1 1: dc Nominal voltage Volts 1 Reserved 1 Data Address Number of bytes Access mode Communication parameters Access type Variables details Value/ Format Protocol type 300 1 Direct/read Byte Protocol type 0: no com 1 1: Modbus 2: CAN Modbus 49 4 Direct/read Structure Slave number (1 247) Number 1 Baud rate 0: 1200 1 1: 2400 2: 4800 3: 9600 4: 19200 5: 38400 Parity 0: no 1 1: odd 2: even Reserved 1 Number of bytes Number of bytes Number of bytes 40