Electricity + Control August 2017

FEATURES: · Control systems + automation · Electrical protection + safety · Temperature measurement · Transformers + substations · Standby + back-up

COMMENT

ON THE COVER

A positive attitude will take you far!

W hat a noisy, muddy and messy time we’re living in! I am a firm believer in the view that an at- titude (and I mean a positive one) can take you far. There is, for instance, the oft-quot- ed comment of ‘hire for attitude; train for competence’. And there is little doubt this has merit. I have engaged with quite a number of my colleagues from industry of late – many in the manufacturing sector, quite a few from the organised professions, some from State Owned Companies, and some from the education and training sectors. What strikes me is how genuinely diffi- cult things are right now – and the less said about that the better. The interesting issue for me, however, is the vastly differ- ing views that people take regarding the way things are and how to react. And they intrigue me. At one end of the scale are those who see opportunity in calamity – and who are of the view that this too will pass (it will, of course – I just find myself wondering when), but that this too is the time to wade in where giants fear to tread, capture mar- kets, enter new markets, promote your goods and services and find new business. What characterises this end of the scale is the sense of being able to change the way things pan out … perhaps take ownership of one’s own organisation and move it forward, largely unhampered by the noise around one.

grabbing the limelight while others with- draw and reflect.

At the other end of the scale are those who feel trapped by the depth of the mud about them, despondent and tired − their ears blocked against all the noise. I fully understand that view. What one does see emerging from this perspective is a perva- sive sense within an organisation that there is not much that can be done, and more specifically that the fault lies elsewhere. This may well be the case, but the trick is to separate out the things that one can influence and trade those off against the things that one cannot change. I realise how simplistic this may sound to those immersed in the mud and the noise – but the simple act of changing a mindset can have a remarkable impact. One area that I have seen develop is the way that the attitude, demeanour and be- haviour of those at the very top – can pro- foundly redevelop that sense of self-belief within an organisation. When I think of attitude in this context, this is what I see playing a really signifi- cant role in dealing with the changed reali- ty in which we operate – at the same time seeing and seeking out opportunities that have simply been invisible until now.

FEATURES: · Control systems+ automation · Electrical protection+ safety · Temperaturemeasurement · Transformers+ substations · Standby+ back-up

ECAUGUST2017 cover.indd 1 7/19/2017 3:52:43PM www.electricityandcontrolmagazine.co.za

ACDC Dynamics is a market leader in the manufacture, import and distribution of quality products in the electrical, lighting, solar power, pumps, alarm, security and surveillance systems and tools industries. Read more on page 11.

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CONTENTS

14

Features

Control systems + automation 4 Using AMI Data to Analyse the Safety of the

Distribution Network Desmond Mabilo, Siemens

8 Round UP

Electrical protection + safety 12 Is a UPS Alone Sufficient for your Power Requirement? Kevin Norris, Jasco Power 14 From the Sensor to the Controller: Reliable Signal Trans- mission in Confined Spaces Dipl.-Ing. Ralf Hausmann, Phoenix Contact 17 Round UP Temperature measurement 18 Ground Water Cooling System Jesper Thurba, Danfoss 20 3 Ways to Connect the Pt100 to the Transmitter Roland Sachs, WIKA 22 Round UP Transformers + substations 24 Cast Resin Transformer Technology: An Efficient Low Risk Peter Middleton, Crown Publications 27 Round UP Standby + back-up 30 Energy Storage Solutions in South Africa Charlotte Smith, Arup 32 New IPC Platform Empowers Engineers with the Latest Advances in IT Driaan Coetzer, Omron 33 Round UP

18

20

24

Regulars

1 Comment by Ian Jandrell 11 Cover article 34 Light + Current 38 New Faces & Places

39 Social Engineers 40 Write @ the Back 40 Not to be Missed 40 List of Advertisers 40 Brain Block

32

2 Electricity + Control

AUGUST 2017

TRANS ELECTRON

SPECIALISING: - Transformer Manufacturing - LV Switchgear

Email: Direct Fax: m Email: Direct Fax:

Tommy Goodrich Sales ri Sales

Tel: - Voltage Stabilizers and Regulators - Electrical Panels and Accessories - Water Pumps Tel:

tommyg@transelecton.com +27 (0) 86 762 1813 tom yg transelecton.com +27 (0) 86 762 1813

+27 (0) 86 111 5075 +27 (0) 11 873 1016 +27 (0) 11 873 1329 www.transelectron.com Sharland Street, Driehoek, Germiston PO Box 19208, Fisherhill, 1408 +27 (0) 86 1 5075 +27 (0) 1 873 1016 +27 (0) 1 873 1329 w .transel ctron.com Sharland Stre t, Driehoek, Germiston PO Box 19208, Fisherhill, 1408

Fax: Web: Physical Address: Postal Address: Fax: Web: Physical Ad res : Postal Ad res :

Contact Details:

Sharland Street, Driehoek, Germiston, Johannesburg

Physical Address:

Distributors of :

Postal PO Box 19208, Fisherhill, 1408 NS E LECTRON CTRO Address: Tel: +27 (0) 86 111 5075 +27 (0) 11 873 1016 +27 (0) 11 873 1329 info@transelectron.com www.transelectron.com Fax: Email: Web:

CONTROL SYSTEMS + AUTOMATION

Using AMI Data to Analyse the Safety of the Distribution Network

Desmond Mabilo, Siemens

AMI systems can offer much more than the ability to accurately produce a bill to customers on their electricity consumption.

I n recent years there has been a great drive, in utilities, to deploy Advanced Metering In- frastructure (AMI) systems, commonly known as smart meters [1]. They are called smart meters in a sense that they not only measure electrical power consumed by utility customers but they can record events such as power outages, tampering etc. They are fitted with communications modules allowing them to transmit the measured data to utility data centres via telecommunications net- works, allowing utilities to receive meter data in almost real time. The initial driver to deploy AMI systems was to ensure accurate collection of consumption data from customer points, ensuring accurate billing of electricity usage. This is a great improvement to the previously used method, where utility per- sonnel were sent to customer sites to collect consumption data, introducing human error in the recording process of the consumption data. With AMI systems, utilities can introduce software sys- tems which collect and analyse the received me- ter data, and generate bills automatically and send to customers for payment. The deployment of AMI systems, introduc- es value to utilities, by coming forth as a Smart Grid enabler. This is initially realised by introducing web and mobile applications where customers can view their historical power consumption, and see the impact of their usage on the grid. These platforms can influence customers to change or optimise their power consumption to reduce the load on the grid. Utilities can unlock further the potential of deployed AMI systems, by analysing

the collected data to get an understanding of the performance of the distribution network infrastruc- ture.This may include analysis of the power quality delivered to customers and analysis of equipment (transformer) loading at distribution level. In this article we will focus on describing how data from AMI systems can be used to analyse equipment loading on the distribution network, predict po- tential for failure, and help with preventive main- tenance and right sizing of distribution network components. This analysis will greatly help utilities in that failures on the distribution network equip- ment not only result in immediate outages for cus- tomers and large costs to utilities, but can present a serious safety hazard to living creatures in the vicinity and damage to property. Overview of AMI enabling Smart Grid Figure 1 is an overview of how AMI systems are deployed by utilities, integrating them to Meter Data Management (MDM) Systems and facilitat- ing utilities to get more value from the systems by introducing Analytics in the architecture. From the diagram we can see that an AMI system is made up of the Meter (Industrial, Commercial and Resi- dential), the telecommunications infrastructure to transmit the meter data and events, and the Head End System (HES) for collection of the meter data and storage in databases. The MDM system per- forms synchronisations functions with Customer Information Systems (CIS), to create a relationship between AMI systems data and utility custom- er information during installation. Thereafter the MDM performs the processing of data received

abbreviations AMI – Advanced Metering Infrastructure CIS – Customer Information Systems ELM – Equipment (Transformer) Load Management HES – Head End System MDM – Meter Data Management SDP – Service Delivery Point VEE – Validation, Estimation, Editing

4 Electricity + Control

AUGUST 2017

CONTROL SYSTEMS + AUTOMATION

Analytics

Customer Information Systems

Residential Meters

Meter Data Management (MDM) System

Head End System

Billing System

Industrial & Commercial Meters

MDM Systems & other Smart Grid Applications

AMI Systems

Utility Enterprise Applications

Figure 1: Smart Metering Architecture enabling Smart Grid.

plementing solutions to minimise the overloading and prevent failure of the transformer, which could result in hazardous fires, causing injuries, fatalities and property damage and a great loss in the utili- ties investments. Methodology As described before, transformer overload oc- curs when demand for power downstream of a transformer frequently approaches or exceeds the transformer maximum capacity. The maxi- mum transformer capacity describes the rating of the transformer given in kVA. Now the load on the transformer is compared to this rating to de- termine if the transformer is loaded. The rating of the transformer is compared to the power (kVA) described below:

from AMI systems, through Validation, Estimation and Editing (VEE), and billing preparation functions. Thereafter the processed data can be transferred to billing systems. MDM systems such as Ener- gyIP by Siemens have the capability to integrate to other Enterprise applications where AMI data can add value, this may include grid applications, customer operations applications etc [2]. Analytics is one of the applications which MDM systems can integrate with by feeding it with val- idated AMI data. Equipment (Transformer) Load Management (ELM) is one of the functions that can be implemented within the Analytics applica- tion, allowing utilities to detect equipment loading anomalies which may cause hazardous failures of distribution equipment or transformers. E(Transformer)LM Transformers are the core of the power distribu- tion grid and are built to last for years. However grid conditions can change during the period of their lifespan, causing issues that might shorten the lifespan of the transformers or even cause out- ages or fires when they fail. The common problem resulting to this is transformer overloading. This occurs when demand for power downstream of a transformer frequently approaches or exceeds the transformer maximum capacity. Over time, this damages the transformer hence increasing chanc- es of failure [1]. Traditionally utilities only knew when their over- all system was overloaded and not down to equip- ment level. Now with the introduction of Smart Meters and analytics, utilities can spot transform- ers which are experience overloading, to what de- gree and predict when [1] failures may occur. With analytics utilities can spot patterns and trends in downstream loads being served by overloaded transformers. Based on this information utilities are able to be pro-active and react quickly by im-

kVA = (kW) 2 + (kVar) 2

Utilities can unlock further potential of deployed AMI systems, by analysing the collected data to acquire an understanding of the performance of the distribution network infrastructure.

Where, kVA = Apparent Power, kW = Real Power and kVar = Reactive Power Figure 2 is a line diagram of a portion of a distribution network; in this dia- gram we can see all the devices in the network from Substation to the metering device at the customer metering points or Service Delivery Points (SDPs). From this diagram we can see that metering capability is only at the substation transformer and at the customer points and not on the distribution transformers. To

get the load details on the distribution transform- er, a virtual meter technique is employed. This will aggregate the entire load from each of the cus- tomer meters, resulting in the load on each of the transformers as indicated in Figure 2 .

Electricity + Control

AUGUST 2017

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CONTROL SYSTEMS + AUTOMATION

Substation Transformer

Substation Meter

Virtual Meter

180 160 140 120 100

Take Note!

Transformer Rating (kVA) Hourly Max Load (kVA)

AMI Systems are com- monly known as smart meters. AMI Systems can be uti- lised as drivers of smart grid technologies. AMI Systems’ data can be used as inputs to Analytics Smart Grid Applications which can trigger programs that prevent equipment fail- ure.

1

80 60 40 20 0 Load kVA

2

Distribution Transformer

0 2 4 6 8 10 12 14 16 18 20 22 24 Time (Hour)

SDP Meters

3

Figure 2: Virtual meter implementations on distribution transformers.

Figure 4: Daily load curve on the distribution transformer.

We can look into the different loads connected to the overloaded transformer, to understand why the transformer is overloaded, how the customers are connected and how they are utilising power. Is re-allocation of customers needed or not. From Figure 5 we can see that the customer with the meter ‘Meter_01’ consumes almost five times the power compared to other customers in its group. This could be the reason the transformer is over- loaded due to customer consuming much more than it is planned for.

Data Analysis Once the MDM system has processed meter data received from AMI systems, this can be fur- ther made useful by Analytics Smart Grid Applica- tions. In this case the ELM Analytics application will perform the aggregation and other compu- tation of the load at the distribution transformer, giving a clear analysis of the status of the distribu- tion transformers in the distribution network. The analysis will allow utilities to react quickly should anomalies be observed; an in-depth understand- ing of the distribution grid can be acquired, allow- ing optimal distribution grid planning. Below are examples of how analytics functions can be implemented and used to present the sta- tus of the distribution network equipment. Firstly from Figure 3 we have a view of the number of overloaded transformers in the utility’s distribution grid on daily basis.

Load (kVA) 60 50 40 30 20 10 0

100 90 80 70 60 50 40 30 20 10 0

Meter_11

Meter_10

Meter_01

Meter_09

Meter_08

Meter_07

Meter_06

Meter_05

Meter_04

Meter_03

Meter_02

Figure 5: Daily Max Load Demand by customers con- nected to a transformer.

The above is just basic analysis of what AMI data can offer to create Smart Grid Applications that can be used to optimise the distribution Grid, by allowing its infrastructure to operate within safe boundaries. Conclusion It is very clear that AMI systems can offer much more than the ability to accurately produce a bill to customers on their electricity consumption. AMI systems can be utilised as drivers of smart grid technologies. In this article we have seen how AMI system data can be used as inputs to Analyt- ics Smart Grid Applications, which analyse the dis- tribution network equipment such as transform- ers, detecting anomalies which may result into

2016-06-01

2016-06-09

2016-06-08

2016-06-07

2016-06-06

2016-06-05

2016-06-04

2016-06-03

2016-06-02

2016-05-31

2016-05-30

2016-05-29

Date (YYYY-MM-DD)

Figure 3: Number of overloaded equipment (transform- ers) on the distribution network.

From Figure 4 we can further dive into each trans- former, to see how it is overloaded on daily basis, which hours of the day contribute to the major overloading of the transformer. From here we can see that the transformer is overloaded (exceeding the rated load demand) for approximately 20 hours in a day.

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CONTROL SYSTEMS + AUTOMATION

[2] Siemens - Digital Grid, EnergyIP: A Flexible, Scalable Platform for Smart Grid Applications http://w3.siemens.com/smartgrid/global/en/ products-systems-solutions/software-solu- tions/emeter/pages/energyip.aspx, Last Ac- cessed: 28/06/2017

equipment failures. This analysis can be used to trigger programs that prevent equipment failure, which may be hazardous causing injuries and fa- talities to life in the surroundings of the equipment and damage to property and large costs to utilities. The Siemens EnergyIP MDM Systems and Analyt- ics Foundation is currently installed on many sites globally, executing accurate billing functions, and analytics functions enabling the smart grid drive operate distribution grid infrastructure within safe boundaries. References [1] Johnson L, Potreck L. Getting smart about smart meter analytic: Satisfying customers, enhancing operations, and running a better utility business, August 2016.

<>

Desmond Mabilo is a Systems Architect in Energy Management – Digital Grid, Siemens.

+27 (0) 11 652 3667 desmond.mabilo@siemens.com www.siemens.com

round up

CONTROL SYSTEMS + AUTOMATION

Object detection for long ranges and difficult surfaces Alternative for difficult surfaces: Ultrasonic sensors transmit and receive sound waves in the ultrasonic range. The object to be detected reflects the sound waves and the distance information is determined via time of flight measurement, as opposed to photoelectric sensors colour, trans- parency or the object’s surface shine do not play a role. Blister packages in packaging technology or transparent plastic bowls in the food industry, for example, can be reliably detected. High performance: The ifm ultrasonic sensors in M18 design provide a particularly small blind zone and long sensing ranges which are usually only achieved by sensors of a considerably larger design. The sensors operate reliably with heavy soiling so that they can be used in applications in which photoelectric sensors meet their limits. Enquiries:Tel: +27 (0) 12 450 0400 or email info.za@ifm.com

Connection for intelligent sensors Robust field bus modules with safe connection: The decentralised IO-Link master mod- ules are used as gateways between intelligent IO-Link sensors and the fieldbus. They are the perfect choice, even in the most difficult environments: The materials and production methods are identical to the ifm jumper cables of the tried-and-tested EVC product series. The ecolink technology guarantees reliable, permanently ingress-resistant M12 connections of the connection cables. Energy limitation for UL class 2 units: Many sensors require an energy-limited supply with UL class 2 approval. The limitation of energy is usually achieved via a corresponding power supply. With the AL series IO-Link master, sensors can be supplied according to UL class 2 without using an energy-limited power supply approved to UL class 2. Enquiries:Tel: +27 (0) 12 450 0400 or email info.za@ifm.com

Electricity + Control

AUGUST 2017

7

round up

CONTROL SYSTEMS + AUTOMATION

Why use a colour mark sensor with RGB technology?

Is it true that processing time for the colour mark sensor af- fects speed? Speed is more of an issue for a true colour sensor rather than a colour mark sensor. The R58E from Banner can perform 10 000 actuations per second, which is very fast! Why does Banner’s R58E colour mark sensor use the red, green, and blue combination of LED colours? The R58E uses this combination so that it can reliably sense virtu- ally any registration mark/background combination. The RGB (red, green, and blue) combination can be combined to create almost any colour. Your computer monitor, for example, which is capable of millions of colours, uses RGB technology. The R58E, using these three colours, is able to determine the colour of the registration mark and the colour of the background. The sensor will then use the LED that provides the best contrast between the registration mark and the background. How do I pick the right LED colour for my application? With the R58E, you do not need to choose an LED colour. The R58E selects the proper LED colour automatically during the initial TEACH function. However, when using a monochromatic colour mark sensor, resources such as colour selection charts are used to select the proper LED colour. How do I switch between the different LED colours? You don’t need to manually switch LEDs. The R58E will automati- cally select LED colours during the TEACH function. Can I choose the LED colours in the R58E? No. The R58E comes with only the possibility of three LED colours: red, green and blue. Does having 3 LED colours affect the sensor’s response time? No. After the initial TEACH process, the R58E’s response time is the same as comparable registration mark sensors. The R58E has a 50 microsecond response time, which allows 15 microsecond repeatability. How do I sense a registration mark on clear material? Clear materials (e.g. a clear poly web) do not reflect light very well, so when sensing a registration mark on a clear material, position a reflective surface directly behind the clear material to return light to the sensor. The registration mark will block the light from reaching the reflective surface and will be detected by the sensor. To avoid the shine from clear materials, you might consider mounting your sensor at a 15° skew angle. How can I maximise sensing in my high-sensitivity applica- tions with the R58E? Use the dynamic TEACH function to teach the sensor a series of conditions on the fly. The R58E takes multiple samples of a regis- tration mark against its background and is able to automatically set the sensitivity at the optimum level. Enquiries: BrandonTopham. Email brandon.topham@retautomation.com

What is the difference between a true colour sensor and a col- our registration mark sensor? True colour sensors can be taught to detect minute colour differ- ences (for example, tell dark blue from black), while colour mark sensors detect a grayscale change in colour. True colour sensors, like Banner ’s QC50, reflect light off a target using a white LED and red, green and blue filter elements. A colour value is then assigned to the light returning to the sensor based on the amount of light reflecting off the target. With colour mark sensors, the sensor uses just a LED and no filters. The sensor distinguishes the target colour based on how it contrasts with the background colour. Not always. A large number of colour sensing applications can be done quite effectively by detecting a grayscale change in the colour mark. In these instances, we recommend using a colour mark sen- sor like the R58E, especially in high-speed applications. A true colour sensor is required when sorting out targets that differ only in colour; for example, when you need to distinguish between light blue and dark blue. However, when distinguishing a registration mark on a constant background, a colour mark sensor is your best choice. What is the difference between a colour mark sensor and a registration mark sensor? There is no difference; these terms are synonymous. What does 16 grayscale contrast levels specification mean? One way to spec a colour mark sensor is to understand how many levels of grayscale it can detect. The finer the sensor’s resolution, the more levels can be detected. A commercial grayscale printer’s chart is divided into 20 segments ranging from black to white, and the shades of gray between. Many sensors are able to detect the first 16 segments starting at white. Does Banner’s R58E have a spec for grayscale contrast levels? The R58E can easily meet the spec for 16 levels of grayscale. Because of the combination of RGB LEDs, the R58E’s resolution capability far exceeds grayscale charts. The R58E’s capability for subtle contrast changes far surpasses the specification for 16 levels of grayscale. Isn’t it better to use a true colour sensor rather than a colour mark sensor?

8 Electricity + Control

AUGUST 2017

round up

CONTROL SYSTEMS + AUTOMATION

Wide range of automation cables for sophisticated equipment

Speciality cable manufacturer, Helukabel , is gaining global recognition for its wide range of automation cables that have been specially designed for optimal performance on sophisticated automation equipment. Automation cable systems are unique in that they require precision manufacture that not only ensures the total integrity of information relayed and current transport- ed, but also need to be durable and reliable to handle the high mechanical stress and repetitive movements that is often associ- ated with automated processes. In South Africa, there is an increased move towards automation as stricter stand- ards require ever tighter tolerances, while the market place requires higher volumes and keener pricing. It is therefore essential that cabling systems, which are effectively the lifeblood of automation project, are of the highest quality and fit-for-purpose. According to Helukabel South Afri- ca sales manager, Hardus van Dyk, au- tomation is becoming commonplace in manufacturing, be it packaging, food and beverage processing, automotive, phar-

maceuticals and a host of other production lines. “Our high-quality cables and cable accessories (e.g. cable tracks, glands and connectors), guarantee durable and relia- ble systems that can handle the high me- chanical stress and repetitive, automated movements. Pre-assembled servo, motor and feedback cables are also available for the world’s leading drive system manufac- turers and these offer an economical alter- native to track cables. In addition, our tech- nical teams are more than happy to assist with the design and specification of cable system solutions to suit customers’ own

Helukabel’s advanced Topserv Hybrid is a single cable servo motor and controller cable in one.

An advanced Servo Motor control cable.

unique requirements,” he says. Pre-Assembled Cables include: • SIEMENS drive systems • REXROTH drive systems • LENZE drive systems • SEW drive systems • HEIDENHAIN drive systems • Robot cables • Connecting cables • Extensions/Supply cables

Enquiries: Doug Gunnewegh. Email doug.gunnewegh@helukabel.co.za

Best practices for industrial risk management Industrial organisations around the world struggle to manage risk. Incidents, such as product recalls, data breaches and worker inju- ries, have immediate consequences and can impact customers, employees, intellectual property and revenue. Risk management should be focused on where problems originate. In many cases, that is within the automation infrastructure. Rockwell Automation has outlined four key areas for managing risk at its source: • Equipment Obsolescence: Modernising production systems can play a major role in minimising downtime and improving quality, safety and security • Quality: Harnessing the power of existing operational data can improve quality management and help drive adherence to regu- latory requirements • Safety: Addressing safety in crucial areas of culture, compliance and capital helps reduce the number of safety incidents and im- prove operational performance • Security: Embracing end-to-end security across facilities and enterprises helps to protect people, intellectual property and physical assets “We view enterprise risk management as a continuous cycle of im- provement that includes assessments, technology and infrastruc- ture,” said Christo Buys, Business Manager for Control Systems, Rockwell Automation sub-Saharan Africa. Enquiries: Christo Buys.Tel. +27 (0) 11 654 9700 or email cbuys@ra.rockwell.com

round up

CONTROL SYSTEMS + AUTOMATION

Innovative modular power solution

energy consumption and facility growth is ensured through planned incremental addi- tions. Overcapacity is just as serious an is- sue for data centre operators as downtime. To be most effective, a data centre and its power supply must grow simultaneously,

to Cisco Systems. This is the equivalent of 300 billion hours of video or 5 000 times all the words ever spoken by mankind. With this explosion of data and today’s informa- tion economy, data centres have become one of a mission critical infrastructure that requires reliable, efficient and scalable power supplies. “As a pioneering technology innovator, we deliver solutions that meet our custom- ers’ most complex challenges. MNS-Up is a modular solution that can help data centre operators scale up their business as required,” said Graham Abrahams, Vice President of the Electrification Products

ABB has a scalable power distribution and protection solution for use in mission-critical ap- plications such as data centres. ABB’s MNS-Up solution integrates uninterrupted power supply (UPS) and switchgear technologies into a single, modular system, which can lower footprint up

as the business ex- pands. MNS-Up can be quickly scaled to support this require- ment. In 2016 global internet traffic was expected to surpass

to 30%, increase uptime, and significantly reduce maintenance costs. As a highly integrat- ed, fully scalable solu- tion, MNS-Up allows switchgear and UPS

To be most effective, a data centre and its power supply must grow simultaneously, as the business expands.

modules to be safely and rapidly exchanged without disconnecting power. Responsible

1 zettabyte – 1 billion terabytes – a fivefold increase in the past five years, according

division for Southern Africa. “As part of ABB’s Next Level strategy, we are focused on supporting our data centre customers with their rapid growth with a range of inno- vative solutions.” Pilot applications by ABB’s global counterparts in Swit- zerland include Green ‘Da- tacenter’ AG of Switzerland, which uses a 5,2 MW MNS- Up system at its 7 265 m 2 facility in Zurich-West and the University Hospital in Basel. Enquiries: Avi Ramdhin. Email Avi.Ramdhin@ za.abb.com

Reliable condition monitoring for Factory Automation

other limit values simultaneously at two points in the control cabinet. The master processes the data of the slave and sends a signal to the controller. The standard IM12-CCM comes with two switch contacts and an IO-Link interface. Quick teach mode enables the user to set the limit values easily in the field. Alternatively, param- eters can be set via IO-Link or an FDT frame- work such as PACTware. The IM12-CCM is the second cabinet guard in the Turck portfolio. It supplements the IMX12-CCM module which is intended for use in hazardous areas. Enquiries: BrandonTopham. Email brandon. topham@retautomation.com

The IM12-CCM cabinet guard detects incor- rectly closed doors as well as the exceeding of moisture and temperature limits. It also de- tects unauthorised access to switch cabinets, thus providing protection against manipulation in compliance with IT security regulations. The slim 12,5 mm DIN-rail device can also be in- stalled easily in existing switch cabinets. The IM12-CCM features an internal data logger with time stamp and stores data for up to two years. This enables users to also detect creeping changes over long periods and recti- fy the cause. An interface enables two cabinet guards to be operated in master-slave mode in order to monitor correct door closing and the

10 Electricity + Control

AUGUST 2017

COVER ARTICLE

ACDC Dynamics Dynamic service and direct solutions to make your life easier A CDC Dynamics was founded in 1984 and is a market leader in the manufacture, import

FEATURES: · Control systems+ automation · Electrical protection+ safety · Temperaturemeasurement · Transformers+ substations · Standby+ back-up

ECAUGUST2017 cover.indd 1

7/19/2017 3:52:43PM

products are available to anyone, either directly through our branches, through one of our many franchises, one of our distributors or participating electrical wholesalers countrywide. This places ACDC Dynamics products within easy reach for anyone in Sub-Saharan Africa. We have a wide range of products that ad- dress the Manufacturing Industry ranging from industrial proximity switches, photoelectric sensors, safety light curtains, rotary encoders, module case circuit breakers, isolators, air circuit breakers, variable speed drives, soft starters, pro- grammable logic controllers, limit switches, junc- tion and terminal blocks, control stations, push- buttons and pilot lights, to mention a few. ACDC Dynamics products are specified in pro- jects ranging from stadiums to mines, hotels to homes, from farms to breweries and residential shelters. One of the company’s many strengths is its extensive catalogue which is widely recog- nised as a benchmark in the electrical industry. A fantastic new extension to the ACDC Dy- namics offering, is the brand new website, where the full ACDC Dynamics product range can be viewed with information on instant quotes, out- lets, franchises and distributors.

and distribution of quality products in the electri- cal, lighting, solar power, pumps, alarm, security and surveillance systems and tools industries. Our product ranges include some of the premium inter- national brands in low voltage switchgear, power tools, enclosures and accessories. Our skilled staff are able to assist in product selection and technical specifications, solutions and more. ACDC Dynam- ics is a family owned business with Mario Maio as the founder and managing member. We offer a wide variety of products including alarms and alarm systems, hygiene, industrial and domestic automation, telemetry systems, pumps, switchgear and instrumentation, energy management and power factor correction solu- tions, solar and wind generators, tools, wire, ad- hesives and consumables, cable and wire man- agement products, and the most comprehensive range of lighting, making use of new innovative technologies in energy saving solutions using CFL, Inductive and LED technologies. Our inter- national brands include:

Enquiries: Tel. +27 (0) 10 202 3300 Visit www.acdc.co.za

Datalogic (Italy) Terasaki (Japan) Vacon (Finland) Aucom (New Zealand)

Gewiss (Italy)

Rhomberg SolarLand SolarEdge

C&S TC (India)

Fulleon (UK)

BM (Italy)

Halo Lighting Solutions

Unitronics (Israel)

Gave (Spain)

Our manufacturing operations offer a wide range of solutions from the production of transformers, power supplies, electronic timers, motor starters to power factor correction systems. Through the years we have carefully built up strategic distri- bution channels to ensure that our wide range of

Mario Maio, founder and managing member of ACDC Dynamics, and members of his management team.

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abbreviations

IT – Information Technology PFC – Power Factor Correction UPS – Uninterrupted Power Supply

Is a UPS Alone Sufficient for Your Power Requirement? Kevin Norris, Jasco Power

Experience and the results of many site surveys have shown that UPSs are not completely effective on their own, and need to be supported by additional power conditioning equipment.

Take Note!

There are many factors that influence the type of UPS required. UPSs are not completely effective on their own. Lightning protection devices are necessary on UPS installations to protect the load and the UPS from failure during lightning activity.

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W hile load shedding has currently been suspended, the reality is that while you are connected to the utility supply, you are still susceptible to the vagaries of an unstable power system in South Africa. In addition, to pos- sible power outages, you are also exposed to volt- age variations, sags, surges, spikes and harmonic problems. Power assurance and power quality solutions are necessary to protect sensitive equip- ment from these problems. An Uninterrupted Power Supply (UPS) is es- sential to provide a failover system between utility power and secondary systems such as a gener- ator. They are also useful for providing sufficient time to safely shut down equipment in the case where secondary power is not available. However, choosing the right UPS technology to suit your ap- plication can be challenging. The right solution for you Determining what power solution is needed is a science that requires careful consideration of sever- al factors. Things such as the proposed installation environment, the dynamics of the load, and wheth- er the customer is looking for continuity of supply only or complete power conditioning. The outcome of this often not asked question will determine the technology required and therefore the final cost of the solution. If not properly planned, power condi- tioning solutions can be less than effective and end up costing businesses more than necessary. It is vital that businesses, particularly those for which quality of supply is critical, plan their solu- tions properly. Before purchasing one or more UPS, or any other power protection equipment, it can be highly beneficial to conduct a power qual-

ity survey. This will enable organisations to gain a sound understanding of the precise challenges of their power environment which, in turn, makes it possible for a tailored solution to be designed to achieve the desired results. Quality of Supply Quality of supply problems can generally be cate- gorised as follows: • Surges: These are sustained over voltage con- ditions, usually as the result of fault conditions on the electrical network. Faulty neutral con- nections and incorrectly tapped distribution transformers can also result in a sustained over voltage condition, resulting in damage to sensitive electronic equipment • Sags: These are generally as the result of poor or ageing electrical distribution networks and too large a load being switched in and out of a weak network, resulting in a sustained under voltage condition. Equipment such as electric motors and refrigeration compressors are very sensitive to these kinds of conditions and a continuation of this condition can lead to overheating and perma- nent failure of the motors. IT based equipment tends to switch on and off under these conditions leading to a disruption in the IT process through- out the environment in which they are being used • Spikes: These are very common during light- ning season and are short duration high voltage conditions. They can also result from network switching and power factor correction compen- sation. Depending on the frequency of these spikes, they can result in data corruption of process plants and IT networks and permanent damage to sensitive electronic equipment

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• Harmonics: These generally result from the load source and propagate themselves back into the local and distribution networks. De- pending on the type and severity of the har- monic, it can result in over heating of the neu- tral conductors, premature tripping of circuit breakers and possible reversing of electrical motors. The harmonics also influence the pow- er factor of the plant and can be responsible for the failure of the PFC capacitor circuits With these quality of supply problems, it’s easy to see that simply having a back-up power solution isn’t enough. Businesses that rely on power – and, let’s face it, they virtually all do – can find themselves faced with more than just a power outage. Damage caused by surges, sags, spikes and harmonics can costs businesses hundreds of thousands of rand in equipment repair and loss of productivity. UPS – the answer? UPSs are seen as the ‘one solution fits all’ option to protecting equipment and, while that’s not entirely true, it’s also not quite so simple. There are a lot of factors that influence what type of UPS is required, such as the nature of the equipment being sup- ported, the load, how critical maintaining constant power supply is, and the electrical environment, as indicated above. As can be seen from above, one requires continuity of supply, voltage stabilisation, filtration for the spikes and harmonics and galvanic isolation in order to be called a power conditioner. There are essentially three types of UPS, start- ing with the most basic, which is your offline UPS. These, offer just enough time to shut down equip- ment – usually 3 – 4 minutes and are commonly used to support things like office computers. This type of UPS offers limited protection from surges or voltage instability and are as susceptible to be- ing damaged themselves by poor quality power. The second type is your line interactive UPS, which has a small amount of power conditioning built in, such as voltage stabilisers to help regulate input power and has an element of line filtering and surge protection to reduce spikes and dips. Very

popular in small IT environments, these units are reasonably priced and typically offer about 15 min- utes of back-up time – just enough to facilitate auto- matic shutdowns of systems and servers. Howev- er, the extent of power conditioning is still limited. The last type of UPS technology is the true, on- line double conversion UPS, which is designed to run 24 hours per day, with large battery banks for extended back up during power failures.These UPSs act as intermediaries between the grid and equip- ment, offering good power conditioning and can tol- erating most surges, sags and fluctuations in supply. However, experience and the results of many site surveys have shown that UPSs are not com- pletely effective on their own, and need to be sup- ported by additional power conditioning equipment such as voltage stabilisers for extreme fluctuations in input voltage. The use of isolation transformers, offers very good common mode protection and can help to reduce or increase incorrect supply voltage conditions and are able to contain harmonic condi- tions in a network. It is also important to understand that a UPS is not a lightning protector and that a lightning protection device should be added to all UPS installations to protect both the load and the UPS from failure due to excessive lightning activity. Conclusion Finally, it is very important to refer to the UPS man- ufacturers electrical and environmental operating specifications, as too often the level of harmonics present and the extreme deviation of the power factor from unity can result in the inability of the UPS to function correctly and results in both the load and UPS being permanently damaged.

Businesses, particularly those for which quality of supply is critical, must plan their solutions properly.

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Kevin Norris, Solutions Architect, Jasco Power.

makwe.ngwato@jasco.co.za www.jasco.co.za

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Figure 1: High safety for persons and the environment – ensured by a comprehensive surge protection with minimal space requirements.

From the Sensor to the Controller Reliable Signal Transmission in Confined Spaces

Dipl.-Ing. Ralf Hausmann, Phoenix Contact GmbH & Co. KG, Blomberg

A lightning and surge protec- tion concept is essential in large water and wastewater treatment systems−numer- ous manufacturers offer MCR surge protective devices for this. Most of these protective devices, however, do not feature a status indicator. The solution presented in this arti- cle – indicates an overload on the contactor module, and can be queried by the control cen- tre via the easily installed field telecommunications function. In this way, a surge protection concept can be implemented in the most confined spaces with protective devices featuring overall widths of 3,5 mm to 6 mm. Thanks to the multistage protective circuit, the three most important performance requirements − category D1, C2 and C1 − of the surge protection standard EN 61643-21 [4] are fulfilled.

The world’s narrowest surge protection for Measurement, Control and Regulation (MCR) technology recently launched.

T he needs of system operators in the water and wastewater industry have changed dras- tically – there is a trend for higher packing density in the control cabinet and consequently ever narrower components. With ‘Termitrab com- plete’, Phoenix Contact has launched the world’s narrowest surge protection for MCR technology – the narrowest devices are just 3,5 mm wide (see Figure 1 ). It is a characteristic of the water and waste- water treatment industry to have numerous net- worked processes − between field level, man- agement level, and subsections that are usually far apart. The requirements on planners, install- ers, and operators of the systems are increasing steadily. Failsafe concepts are becoming more important due to the increasing implementation

of electromechanical and electronic components, systems and solutions, as well as the networking between them. Megatrends in the market Overvoltage concepts play an important role. Fur- ther requirements on critical infrastructure have also developed due to the IT security law passed after concerns by the Federal Office for Security in Information Technology. Two major factors are at play: High system availability and the resulting security of supply for the population. As in other infrastructure fields, the trend to- wards implementing ever smaller and more com- pact components is also quite noticeable in the field of water and wastewater treatment. To opti- mise the costs of overall control cabinet manufac-

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turing, the surge protective devices (SPDs) should take up as little space as possible. The goal is to centralise numerous service functions − such as system monitoring − in the control room. To oper- ate the system safely from an EMC perspective, SPDs are implemented in large systems. Protection in a confined space Numerous channels often have to be housed with- in a small area in order to transmit analogue or digital signals. Since space is becoming increas- ingly valuable, the narrowest components of this product range have a width of only 3,5 mm. The components of Termitrab complete are equipped with six terminal points to which two signal lines each and a common reference potential can be connected. With this extremely compact and narrow con- tactor, which is being made available on the world market for the first time, up to 572 signal lines can be protected on one metre of DIN rail (see Figure 2 ). The power dissipation has been mini- mised significantly as well, due to the decoupling resistors in the protective circuits. This feature also aims to satisfy the demand for installing more de- vices in increasingly smaller spaces. Figure 2: 572 signals per metre: With its extremely narrow components, Termitrab complete saves a great deal of space in the control cabinet. The lightning protection standards recommend regular inspection of protective devices. This is only possible through visual examination. The Ter- mitrab complete product range features a status indicator that displays an overload of the surge protection directly on the device. Since no addi- tional power is needed for this indicator, the pro- tective device also displays the fault continuously during an overload. If this information is displayed in a control room, the optionally available ‘remote signalling modules’ (see Figure 3 ) ensure the nec- essary data transmission. Either the PLC (programmable logic control- ler) can query the potential-free contact directly by wire, or this contact is integrated by interface modules, with, for example, the compact mes- sage system TC Mobile I/O X200. This means that the status of the protective devices in large

systems can be monitored not only in the control room, but also sent via SMS to the cell phone of the service technician. If a contactor is overloaded, trouble-free replacement is possible, in particular with the pluggable protective devices.

Figure 3: Integrated status indicator: Thanks to the surge protection components of Termitrab complete, the user is kept up-to-date regarding the state of their system at all times. Permanent installation with push-in technology Classical screw connection technology is still com- monly used. If there are many signal lines to be installed however, considerable time can be saved with the quick push-in connection technology (see Figure 4 ). Comparisons with screw connection technology have shown, for example, that the wires can be connected up to 50% quicker. Dis- connection is also easily possible by pressing the ‘pusher’. Depending on his preference, the install- er can choose between screw and push-in con- nection technology with the Termitrab complete product range.

In water and wastewater treatment, there is an increased failure risk in large systems due to surge voltages – with far-reaching consequences.

Figure 4: Convenient connection: Conductors can be connected quickly with push-in technology and removed without any special tools.

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