Category: ABB

It’s a known fact that downtime, resulting from the malfunction of electronic

systems which control or regulate the production process, causes irrecoverable

losses. Although modern systems are carefully engineered to provide a high

degree of reliability, components can fail and cause unscheduled shutdowns,

even in the best systems.

With DriveMonitor™ ABB experts are ready to go on-line and guide the customer‘s

maintenance engineer through a fast and efficient fault-finding procedure.

Diagnostic procedures can cover not only the converter itself but other parts of

the drive system as well – everything according to customer needs and preferences.

Furthermore, long-term monitoring functions deliver important information on

equipment status, tasks needed and possible performance improvements.

Functions

Triggering

• Programmable event-driven analysis

• Initiation of time-based predefined diagnostic actions such as data collection,

processing and reporting

Fault treatment

• Registration of fault history by:- saving the content of data loggers, – executing

preventive monitoring of predefined signals and parameters after the drive restart

Monitoring

• Continuous monitoring of pre-selected signals and parameters

• Calculation of performance indicators and alarms according to customized rules

• Aggregation and use of other signals from external OPC sources to enhance the

diagnostic capability

Reporting

• Comprehensive customized status reports on predefined time schedule

What is DriveMonitor™?

DriveMonitor™ is a diagnostic intelligent system that consists of a hardware

module inside the drive, as well as a software layer that automatically collects

and analyses selected drive signals and parameters.

In its basic functionality DriveMonitor™ “watches” the converter of a drive system.

Its role is to continuously monitor the status and to respond when changes occur.

Potential trigger events are unexpected drive stoppages, alarms

(signals crossing threshold values) and user parameter changes. DriveMonitor™

also generates application-specific alarms and measurements.

This data is extremely useful in determining the root cause of an event.

With extra diagnostic packages, DriveMonitor™ can also monitor other drive system

components, such as main circuit breaker, transformer and the driven machine.

At the highest level, special packages related to the application, such as rolling mills,

water pumps, and compressors, can be integrated into the system.

This expansion can be done at any point in time according to customer preferences.

Scalability and flexibility are the biggest advantages of the DriveMonitor™ system.

DriveMonitor™-based diagnostic routines are valuable extensions to any plant-level

asset management program.

DriveMonitor hardware and optional touch screen display

It continuously monitors status and responds when changes oc

cur. Analysis of error logs enables detection of drive mechanical

or electrical problems, which can be managed and corrected.

Potential trigger events include unexpected drive stoppages,

alarms (signals crossing threshold values) and user parameter

changes. DriveMonitor also generates application-specific alarms

and measurements. This data is extremely useful in determining

the root cause of an event. The software also helps identify drive

setup and running issues that lead to poor product quality.

With extra diagnostic packages, DriveMonitor can also moni

tor other drive system components such as the main circuit

breaker, transformer and the driven machine. At the highest

level, special packages related to the application including roll

ing mills, water pumps, and compressors, can be integrated

into the system. This expansion can be done as required.

Features

− Scalable and flexible

− Strict security procedures

− Complex data encryption

− Data logging and event driven data capture

− Automated diagnostic tools

− Optional Touch Screen

Benefits

− ABB expert assistance

− Reduced maintenance cost

− Reduced MTTR (Mean Time To Repair)

− Improved drive access through user interface

− Aggregate long-term statistics

Benefits

Up-to-date information on drive system status ensures maxi

mum productivity at all times

Root cause analysis support reduces MTTR (Mean Time To

Repair), thereby ensuring uptime

Optimized maintenance schedule and costs throughout the

entire product life cycle thereby keeping OPEX under control

Early diagnostics helps reduce the risk of failure thereby

avoiding costly repairs

Remote expert access reduces on-site work, eliminating labor

and travel costs and minimizing downtime

Easy operation due to user guidance by the system enhances

site maintenance skills

Optimized process performance by aggregating long-term

statistics ensuring the most efficient production run

High productivity depends on uptime. In turn, uptime depends

on fast and precise identification of system irregularities.

DriveMonitor, ABB’s award-winning monitoring and diagnostic system,

watches the drive system, continuously tracking its status and

collecting data.

DriveMonitor can be used as a stand alone system, where it

logs application-related events and stores high-resolution

loggers together with pre-trigger information. This data is

extremely useful when identifying the root cause of an event.

Furthermore, long-term monitoring functions deliver important

information on equipment status, upcoming service routines,

trends and input for possible performance improvements.

DriveMonitor can also be used in combination with the remote

services offered by ABB Drives. This service provides real-time

access to dedicated ABB specialists who can guide the main

tenance engineer through the fault-finding procedure and the

implementation of corrective actions.

DriveMonitor and remote services are covered by a service

agreement with an ABB Drives service site or provider.

The ABB life cycle management model is designed to manage an orderly

transition to new replacement products or to choose from various lifetime

extending services. At the same time the model ensures access to continuing

support for our customers.

Current life cycle status

The DriveMonitor 4000 is in the Obsolete life cycle

phase according to the ABB life cycle management

model outlined above since 1.1.2023

Product availability in Obsolete phase

This product not available anymore.

Recommended actions

In Obsolete life cycle phase ABB does not provide any

services for the product, except disposal & recycling

and replacement service.

It is recommended to start planning for a replacement

of an alternative service as 1-to-1 replacement cannot

be guaranteed.

ABB has the following alternative services for certain

drive products in place as potential replacements for

this product:

 ABB AbilityTM Remote Condition Monitoring

 ABB AbilityTM Remote Assistance

Besides SCADA data communication, distribution control

centers have additional requirements. It might be necessary to

provide a telephony system for operational purpose or chan

nels for Renewable Energy (e.g. wind farms).

Since MV networks might be restricted to city areas or larger

rural areas, the network design needs to be adapted as per

actual requirements. Accordingly communication networks

providing L2 Ethernet switching or L3 IP routing might be

required. For installation in MV substations extended tempera

ture range and immunity against EMC/EMI is required.

Distances to be overcome are typically in the range of a few

kilometers.

Today’s In-plant applications require enhanced Ethernet

communication functionality. Various services such as CCTV,

public address or access control systems require communica

tion with a central server or operator console.

In-plant communication refers to applications dealing with

security of the infrastructure and recovery to normal operation

after an incident. Therefore high availability of the communica

tion network and high performance features are required.

Some of the In-Plant applications require significant band

width (e.g. CCTV), therefore a proper planning of the network

for the initial and future expansion is needed.

To allow supervision and historical analysis it is necessary to

synchronize end devices (e.g. cameras) from a central time

server.

Typical Topology

State of the art substation automation systems use the

IEC61850 protocol for communication between IEDs (Intel

ligent Electronic Device), as well as from IEDs to the station

control computer. The IEC61850 protocol transmits different

signals, such as GOOSE messages (e.g. interlocking, trip, …),

Sampled Values and Client Server communication via an Eth

ernet network. Since these are mission critical services, the

data packet should reach its receivers with highest security

and minimum delay.

Communication networks applicable to substations based

on IEC61850 require a network with high availability. Accord

ingly, the requirements for the communication network include

beside IEC61850 specific features, fast network recovery time

in case of link failures and high MTBF figures.

As communication equipment has to work in harsh electro

magnetically polluted environments, mainly optical connec

tions are used, with distances to be covered of maximum a

few 100 meters.

Technical solution

– Intra Substation communication solution

− Utility hardened switches supporting IEC61850

− High number of optical ports required, mainly fiber opti

cal ports (multimode)

− Pure Layer 2 (switched) Ethernet network

− Need for redundant network topology

− Fast redundancy protocol needed (for fast network

recovery time)

− QoS (Quality of Service) and VLANs used to provide per

formance levels needed for Substation Automation

− Management of the network via SNMP

− IEEE1613 compatibility for EMC/EMI

– Communication between Distribution Substations

− FE/GbE backbone for distribution SCADA systems pro

viding data channels e.g. for:- SCADA communication as per

IEC60870-5-104- Voice over IP- CCTV (video)

− High number of electrical ports required, FO ports are

typically singlemode (uplink ports)

− Need for highly secured and reliable communication

− Depending on network design switching or routing func

tionality required

− Need for redundant network topology

− Fast redundancy protocol needed (e.g. MRP/E-MRP)

− Temperature rating of up to +85°C continuous operation

required

− Management System for supervision of the communica

tion network

– In-plant communication

− FE/GbE Backbone for In-plant applications- GbE uplinks for connection to server

− Optical access ports for distances longer than 100m

− Power over Ethernet (PoE)

− Port based rate control

− 802.1x Port Authentication for maximized security on

outdoor cameras

− SNTP (Simple Network Time Protocol) for time distribu

tion down to end devices for accurate time stamping of

video, audio and log files

− Fast reboot after power failure