Powell CBM User manual

Instruction Bulletin - 01.4IB.48070A
Circuit Breaker Monitor (CBM)
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Circuit Breaker Monitor 01.4IB.48070A
Contact Information
Powell Electrical Systems, Inc.
powellind.com
[e-mail]
Service Division
7232 Airport Blvd
Houston, Texas 77061
Tel: [phone]

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01.4IB.48070A
Signal Words
As stated in ANSI Z535.4-2007, the signal word is
a word that calls attention to the safety sign and
designates a degree or level of hazard seriousness.
The signal words for product safety signs are
“Danger”, “Warning”, “Caution” and “Notice”.
These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
DANGER
!
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
CAUTION
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
CAUTION, used without the safety alert
symbol, is used to address practices not
related to personal injury.
CAUTION
NOTICE
NOTICE is used to address practices not related
to personal injury.
Qualified Person
For the purposes of this manual, a qualified
person, as stated in NFPA 70E®, is one who has
skills and knowledge related to the construction
and operation of the electrical equipment and
installations and has received safety training to
recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.

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i
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01.4IB.48070A
Contents
Ch 1 General Information ................................................................................................1
A. Scope ...............................................................................................................................................................2
B. purpoSe ............................................................................................................................................................2
c. InStructIon BulletInS AvAIlABle electronIcAlly ....................................................................................................2
Ch 2 Safety .......................................................................................................................3
A. SAfe Work condItIon .........................................................................................................................................3
B. SAfety GuIdelIneS ...............................................................................................................................................3
c. GenerAl ............................................................................................................................................................4
d. SpecIfIc .............................................................................................................................................................4
e. SAfety lABelS ....................................................................................................................................................4
Ch 3 Equipment Description ............................................................................................6
A. overvIeW ..........................................................................................................................................................6
1) Circuit Breaker Monitor (CBM) .............................................................................................................................................. 6
2) Infrared Interface Module (IRIM)......................................................................................................................................... 6
3) External Indication Module (EIM) ....................................................................................................................................... 7
B. HAll effect SenSor ............................................................................................................................................8
c. InputS And IndIcAtorS .........................................................................................................................................9
d. cIrcuIt BreAker MonItor (cBM) operAtIon ...................................................................................................... 11
e. IrIM operAtIon .............................................................................................................................................. 11
1) Infrared Communication Interface ...................................................................................................................................11
2) IRIM Operation .......................................................................................................................................................................11
3) Communication Interfaces .................................................................................................................................................11
4) IRIM Wiring ..............................................................................................................................................................................13
f. externAl IndIcAtIon Module (eIM) operAtIon ................................................................................................... 13
Ch 4 Installation .............................................................................................................15
A. receIvInG ........................................................................................................................................................ 15
B. HAndlInG ....................................................................................................................................................... 15
c. StorAGe ......................................................................................................................................................... 15
d. MountInG ...................................................................................................................................................... 15
e. BrIteSpot®SlIdInG contAct teMperAture .......................................................................................................... 16
f. cIrcuIt BreAker MonItor WIrInG ...................................................................................................................... 17
G. MountInG And plAceMent of IrIM And eIM ...................................................................................................... 18
Ch 5 Usage ......................................................................................................................20
A. SoftWAre overvIeW ......................................................................................................................................... 20

ii Powered by Safety®
Circuit Breaker Monitor 01.4IB.48070A
Contents
Ch 6 Troubleshooting .....................................................................................................22
A. trouBleSHootInG tHe cIrcuIt BreAker MonItor .................................................................................................. 22
1) CBM Alarm Events .................................................................................................................................................................23
2) CBM System Failure Indications .........................................................................................................................................24
Ch 7 Specifications .........................................................................................................25
A. cBM HArdWAre SpecIfIcAtIonS ........................................................................................................................ 25
B. envIronMentAl ServIce condItIonS ................................................................................................................... 27
Appendix A ModBus Memory Map for CBM System .......................................................28

iii
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01.4IB.48070A
Figures
Figure 1 Circuit Breaker Monitor (CBM) .......................................................................6
Figure 2 Infrared Interface Module (IRIM) ...................................................................6
Figure 3 External Indication Module (EIM) ..................................................................7
Figure 4 Circuit Breaker Monitoring System Overview ...............................................7
Figure 5 Hall Effect Sensor Module Wires ....................................................................8
Figure 6 Hall Effect Sensor Module Installed ...............................................................8
Figure 7 Circuit Breaker Monitor (CBM) Input Connections ........................................9
Figure 8 IR Transceiver Window and LED Indicator Location ....................................10
Figure 9 CBM System Block Diagram .........................................................................12
Figure 10 IRIM Input Connections ................................................................................13
Figure 11 Breaker Status Indicator ..............................................................................14
Figure 12 Typical Mounting Location ..........................................................................15
Figure 13 CBM Bolt Hole Pattern .................................................................................16
Figure 14 Fiber Routing ................................................................................................17
Figure 15 Typical Circuit Breaker Monitor Wiring Diagram ........................................18
Figure 16 Mounting Locations of IRIM and CBM .........................................................19
Figure 17 IRIM Mounted on Inside of Door ..................................................................19
Figure 18 EIM Mounting Hole Pattern .........................................................................19
Figure 19 IRIM Mounting Hole Pattern ........................................................................19
Figure 20 BreakerView Overview Screen .....................................................................20
Figure 21 IRIM Production Assistant Screen ................................................................21
Figure 22 CBM LED Indicator .......................................................................................22
Figure 23 Hall Effect Module LED Indicator .................................................................22
Figure 24 IRIM LED Indicator ........................................................................................22
Figure 25 EIM LED Indicator .........................................................................................23

iv Powered by Safety®
Circuit Breaker Monitor 01.4IB.48070A
Tables
Table A Main Input Connections .......................................................................................9
Table B Hall Effect Input Connections .............................................................................10
Table C CBM LED Indicators ............................................................................................10
Table D Hall Effect Module LED Indicators .....................................................................10
Table E IRIM Wiring ..........................................................................................................13
Table F CBM LED Indications ...........................................................................................22
Table G Hall Effect Module LED Indications ....................................................................22
Table H IRIM LED Indications ..........................................................................................22
Table I EIM LED Indications .............................................................................................23
Table J Power Supply Details ..........................................................................................25
Table K Power/Signal Connector ....................................................................................25
Table L Hall Effect Connector ..........................................................................................25
Table M Analog Voltage Inputs .......................................................................................25
Table N Digital Voltage Input ..........................................................................................26
Table O Internal Environment Monitoring .....................................................................26
Table P Hall Effect Sensor ................................................................................................26
Table Q Optical Wireless Communication ......................................................................26
Table R Fiber Optic Temperature Measurement .............................................................26
Table S LED ......................................................................................................................26
Table T CBM Dimensions & Mounting .............................................................................27
Table U Environmental Conditions .................................................................................27
MODBUS Memory Map for CBM System ..........................................................................29

1
General Information Powered by Safety®
01.4IB.48070A
Ch 1 General Information
!
WARNING
The equipment described in this document may contain high voltages and currents which can
cause death or serious injury.
The equipment is designed for use, installation, and maintenance by knowledgeable users of such
equipment having experience and training in the field of high voltage electricity. This document and all
other documentation shall be fully read, understood, and all warnings and cautions shall be abided by. If
there are any discrepancies or questions, the user shall contact Powell immediately at 1.800.480.7273.
!
WARNING
Prior to adjustments, servicing, maintenance, or any act requiring the operator to make physical
contact with the equipment, the power source must be disconnected and the equipment grounded.
Failure to do so may result in death or serious injury.
NOTICE
The information in this instruction bulletin is not intended to explain all details or variations of the
Powell equipment, nor to provide for every possible contingency or hazard to be met in connection
with installation, testing, operation, and maintenance of the equipment. For additional
information and instructions for particular problems, which are not presented sufficiently for the
user’s purposes, contact Powell at 1.800.480.7273.
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.
NOTICE

2General Information
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Circuit Breaker Monitor 01.4IB.48070A
A. Scope
The information in this instruction bulletin
describes the following Circuit Breaker Monitor
(CBM):
• AP.CBM.01IRIMK3 - Circuit Breaker
Monitoring Kit (Includes IRIM & EIM)
• CBM - Circuit Breaker Monitor
• AP.CBM.01IRIM - IRIM
• AP.CBM.01EIM - EIM
• CBM-HE-SENSOR - Hall Effect Sensor
B. purpoSe
The information in this instruction bulletin
is intended to provide details required to
properly install and operate the Circuit Breaker
Monitor described in Ch 1 General Information,
A. Scope.
This instruction bulletin provides:
1. Safety guidelines
2. General descriptions on the operation of
the Circuit Breaker Monitor
3. Instructions for installation
4. Wiring instructions
5. Procedure for obtaining data from CBM
6. Illustrations, photographs, and description
of the modules
The illustrations contained in this document
may not represent the exact construction
details of the monitor. The illustrations in this
document are provided as general information
to aid in showing component locations only.
All illustrations and photos are shown using
deenergized equipment.
Be sure to follow the appropriate safety
precaution while handling any of the
equipment. Failure to do so may result in
serious injury or death.
!
WARNING
To the extent required, the products described
herein meet the applicable ANSI, IEEE, IEC, and
NEMA Standards; however, no such assurance
is given with respect to local codes and
ordinances which may vary greatly.
c. InStructIon BulletInS AvAIlABle electronIcAlly
For more information visit powellind.com. To
contact the Powell Service Division call
1.800.480.7273, or email
[email protected]om.
For specific questions or comments pertaining
to this instruction bulletin, email
[e-mail] with the Instruction
Bulletin number in the subject line.

3
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01.4IB.48070A
Ch 2 Safety
A. SAfe Work condItIon
The information in Section A is quoted from
NFPA 70E 2012 - Article 120, 120.1 Establishing an
Electrically Safe Work Condition.
120.1 Process of Achieving an Electrically Safe
Work Condition
1. Determine all possible sources of electrical
supply to the specific equipment. Check
applicable up-to-date drawings, diagrams,
and identification tags.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each
source.
3. Wherever possible, visually verify that all
blades of the disconnecting devices are
fully OPEN or that drawout type circuit
breakers are withdrawn to the fully
disconnected position.
4. Apply lockout/tagout devices in accordance
with a documented and established policy.
5. Use an adequately rated voltage detector
to test each phase conductor or circuit part
to verify they are deenergized. Test each
phase conductor or circuit part both
phase-to-phase, and phase-to-ground.
Before and after each test, determine
that the voltage detector is operating
satisfactorily.
Informational Note: See ANSI/ISA-
61010-1 (82.02.01)/UL 61010-1, Safety
Requirements for Electrical Equipment for
Measurement, Control, and Laboratory
Use - Part 1: General Requirements,
for rating and design requirements for
voltage measurement and test instruments
intended for use on electrical systems
1000V and below.
6. Where the possibility of induced voltages
or stored electrical energy exists, ground
the phase conductors or circuit parts
before touching them. Where it could be
reasonably anticipated that the conductors
or circuit parts being deenergized
could contact other exposed energized
conductors or circuit parts, apply ground
connecting devices rated for the available
fault duty.
B. SAfety GuIdelIneS
Study this instruction bulletin and all other
associated documentation before uncrating
the controllers.
Each user has the responsibility to instruct
and supervise all personnel associated with
usage, installation, operation, and maintenance
of this equipment on all safety procedures.
Furthermore, each user has the responsibility of
establishing a safety program for each type of
equipment encountered.
The medium voltage equipment described in
this instruction bulletin is operated by a
high-energy, high-speed mechanism that
is interlocked to provide specific operating
sequences. It is mandatory that the following
rules be observed to ensure the safety of
personnel associated with usage, installation,
operation, and maintenance of these
controllers.
The safety rules in this instruction bulletin are
not intended to be a complete safety program.
The rules are intended to cover only some of the
important aspects of personnel safety related to
Circuit Breaker Monitor (CBM).

4Safety
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Circuit Breaker Monitor 01.4IB.48070A
c. GenerAl
1. Only supervised and qualified personnel
trained in the usage, installation, operation,
and maintenance of the circuit breaker
monitor shall be allowed to work on this
equipment. It is mandatory that this
instruction bulletin, any supplements, and
service advisories be studied, understood,
and followed.
2. Maintenance programs must be consistent
with both customer experience and
manufacturer’s recommendations,
including service advisories and instruction
bulletin(s). A well planned and executed
routine maintenance program is essential
for equipment's reliability and safety.
3. Service conditions shall also be considered
in the development of safety programs.
Variables include ambient temperature;
humidity; actual continuous current;
thermal cycling; number of operations;
interrupting duty; and any adverse local
conditions including excessive dust, ash,
corrosive atmosphere, vermin and insect
infestations.
d. SpecIfIc
1. DO NOT WORK ON ENERGIZED
EQUIPMENT. If work must be performed
on a circuit breaker, remove it from
service and remove it from the metal-clad
switchgear.
2. DO NOT WORK ON A EQUIPMENT WITH
THE CONTROL CIRCUIT ENERGIZED.
3. ALL COMPONENTS SHALL BE
DISCONNECTED BY MEANS OF A VISIBLE
BREAK AND SECURELY GROUNDED FOR
SAFETY OF PERSONNEL PERFORMING
MAINTENANCE OPERATIONS ON THE
EQUIPMENT.
4. Interlocks are provided to ensure the
proper operating sequences of the
equipment and for the safety of the user.
If for any reason an interlock does not
function as described, do not make any
adjustments, modification, or deform the
parts. DO NOT FORCE THE PARTS INTO
POSITION. CONTACT POWELL FOR
INSTRUCTIONS.
e. SAfety lABelS
The equipment described in this document
has DANGER, WARNING, CAUTION, and
instruction labels attached to various locations.
All equipment DANGER, WARNING, CAUTION,
and instruction labels shall be observed
when the controller is handled, operated, or
maintained.
Warning and Caution labels are located in
various places. Do NOT remove or deface any
of these warning/caution labels.
NOTICE

5
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01.4IB.48070A
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6Equipment Description
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Circuit Breaker Monitor 01.4IB.48070A
Ch 3 Equipment Description
A. overvIeW
The Circuit Breaker Monitoring System
(Figure 4) is comprised of three main modules:
1) Circuit Breaker Monitor (CBM)
The CBM (Figure 1) is an industrial
multi-channel Data Acquisition Module.
It provides four (4) analog and two (2)
digital input channels, pre-configured and
dedicated to the connected devices. The
module is ruggedized and designed to
withstand shock, vibration (IEC 60068-2-
6), temperature extremes (-40°C to +70°C)
and relative humidity (5 to 95%). The
module is designed to be embedded within
the control housing of a circuit breaker,
adjacent to the devices it monitors. The
module is dedicated to monitoring the
standard electromechanical devices which
provide the major functions of charging,
closing and tripping of a spring operated
circuit breaker mechanism as well as the
contacts which indicate circuit breaker
state and spring charge state. The circuit
board, battery and housing are designed
to last for approximately 25 years when
operated within the specified vibration,
shock, temperature and relative humidity.
With the onboard memory and embedded
processing, signal data is analyzed for
circuit breaker performance profile and
compared to required performance values
for basic alarm function. The performance
values and raw analog curves for up to 1000
operations are retained in a battery
backed-up memory. The data
communications from the CBM is via a built
in IR transceiver.
Figure 1 Circuit Breaker Monitor (CBM)
2) Infrared Interface Module (IRIM)
The IRIM (Figure 2) is an infrared to RS-485
Modbus transceiver mounted inside the
circuit breaker compartment. It is placed
such that the Circuit Breaker Monitor
infrared transceiver can communicate
its data to the IRIM. The IRIM permits
multipoint two (2) wire RS-485 Modbus
connection to additional IRIM units.
Modbus and power connections for this
unit are via an 8-pin Phoenix connector.
Additionally, the IRIM has an RJ-45 (8P8C)
connector for cable connections to the
External Indication Module (EIM).
Figure 2 Infrared Interface Module (IRIM)

7
Equipment Description Powered by Safety®
01.4IB.48070A
3) External Indication Module (EIM)
The EIM (Figure 3) is connected to the IRIM via RJ-45 connection and has an isolated USB
connection for use by a laptop along with three LEDs behind a white lens for displaying circuit
breaker condition. LED colors are GREEN (slow pulse - satisfactory condition), AMBER (slow pulse
- warning), and RED (slow pulse - alarm). A laptop can be connected to the EIM via USB mini-B
port connection.
Figure 3 External Indication Module (EIM)
Figure 4 Circuit Breaker Monitoring System Overview
Interior of Switchgear
Circuit Breaker
Computer
Application
LED and
USB
Bus Bar
Bus Bar
BS
Fibers
CBM
Hall Eect
Sensor
IR
Transceiver
IR
Transceiver IRIM
RS485 HMI or
Sentry

8Equipment Description
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Circuit Breaker Monitor 01.4IB.48070A
B. HAll effect SenSor
The Hall Effect Sensor module is mounted within the wire bundle directly behind the circuit breaker's
secondary disconnect. In order to provide a consistent polarity signal the positive (+) polarity leads
for the charging motor, close coil and trip coil are placed within the sensor (Figure 5).
The lead from the sensor is to be laced to the existing wire bundle. The lead will traverse the breaker
frame from right to left with the wire bundle that passes from near the secondary disconnect where
the sensor is attached to the upper left side of the frame where the
Circuit Breaker Monitor is mounted.
Figure 5 Hall Effect Sensor Module Wires
Figure 6 Hall Effect Sensor Module Installed

9
Equipment Description Powered by Safety®
01.4IB.48070A
c. InputS And IndIcAtorS
Table A Main Input Connections
Pin Number Description Function
1 +ve Supply to Charge Motor Analog Voltage Input
2 -ve Return from Charge Motor
3 +ve Supply to Close Coil Analog Voltage Input
4 -ve Return from Close Coil
5 +ve Supply to Trip Coil Analog Voltage Input
6 -ve Return from Trip Coil
7 Digital Input A for LCS Contact Digital Sense Input
8 Digital Input B for LCS Contact
9 Digital Input A for 52A Contact Digital Sense Input
10 Digital Input B for 52A Contact
11 Chassis Ground Local Chassis Ground
12 +ve Supply to CBM Supply Voltage
13 -ve Return from CBM
Figure 7 Circuit Breaker Monitor (CBM) Input Connections
a. Temperature Sensor
b. Main Inputs
c. Hall Effect Sensor Connection
d. BriteSpot®Inputs
a
b
c
d
1 2 3 4 5 6 7 8 9 10 11 12 13
1 2 3 4
1 2 3

10 Equipment Description
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Circuit Breaker Monitor 01.4IB.48070A
Table B Hall Effect Input Connections
Pin Number Description
1 +5V Power for HE
2 Ground for HE
3 Digital HE Signal
4 Shield for HE
Table C CBM LED Indicators
Color Description
Green Flashing - Operating as Expected
Red Interacting with Flash, DO NOT POWER OFF
Figure 8 IR Transceiver Window and LED Indicator Location
ab
a. IR Transceiver Window
b. LED Indicator
Table D Hall Effect Module LED Indicators
Color Description
Green Operating as Expected
Red Initializing or Calibration Mode

11
Equipment Description Powered by Safety®
01.4IB.48070A
d. cIrcuIt BreAker MonItor (cBM) operAtIon
The CBM, when powered and properly
connected to the devices on a circuit breaker,
will provide direct or indirect measurement of
parameters for the following:
1. Primary contact touch time.
2. Primary contact part time.
3. Spring charge time.
4. Close coil armature time (via algorithms in
BreakerView).
5. Trip coil armature time (via algorithms in
BreakerView).
6. Supply voltage values and fluctuations.
7. Phase temperatures on lower primaries
near sliding contact.
8. CBM internal ambient temperature.
The CBM will directly provide for basic alerts for
those parameters not requiring BreakerView
algorithms. These alerts will be visually
indicated by the EIM's LED color.
The CBM measures the parameters of voltages,
currents (charging motor and coils), contact
timing, and temperatures then performs
calculations to determine the circuit breaker
health.
e. IrIM operAtIon
The IRIM (Infrared Interface Module) is the
interface between the CBM's proprietary
infrared communications link to ModBus RTU
(RS-485) and USB communications interfaces.
It also indicates the circuit breaker health
through the EIM LED.
1) Infrared Communication Interface
Infrared (IR) communication is used to
connect the IRIM and CBM. This is a "line-
of-sight" interface that avoids the need
for additional wiring in the circuit breaker
control plug for communication purposes.
It uses an adaptive IR protocol to ensure
reliable, high speed communication
over distances varying from 1 inch
and approximately 18 inches. If the
communication link between the IRIM and
CBM is interrupted the EIM, connected to
the IRIM, will indicate this.
2) IRIM Operation
Figure 9 shows a block diagram of the circuit
breaker, CBM, associated components
and two communication interfaces. The
IRIM and EIM combination provides an
isolated RS-485 interface for Modbus RTU
communication and a mini USB connector
for direct USB communication to a local
computer. The IR communication between
the IRIM and CBM is shared between these
two interfaces with the USB taking priority.
3) Communication Interfaces
a. RS-485 Interface - This interface
supports the Modbus RTU protocol.
The "GND ISO" (pin 3) should be
connected to the RS-485 cable shield
and not a local ground. Refer to RS-485
wiring details for more information.
The default interface parameters are
Modbus ID #1, 115200 baud, 8 data
bits, no parity and 1 stop bit. The
Modbus ID and baud rate can be
adjusted using Powell's IRIM production
assistant software. The IRIM supports
the following baud rates: 9600, 19200,
38400, or 115200.
b. USB Interface - This is used to make
a direct connection between the CBM
and a local Microsoft®Windows based
computer running Powell's software
(eg. BreakerView). A USB driver
may be required for this interface,
this can be downloaded from
breakerview.powellind.com. Once
installed this driver is automatically
configured.

12 Equipment Description
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Circuit Breaker Monitor 01.4IB.48070A
Figure 9 CBM System Block Diagram
IRIM to RS485
Modbus Converter
Sentry or HMI
Modbus RS485
Isolated USB
and Indicator
USB
Computer w/ USB
Optical Wireless
IRIM
Hall Eect
Sensor
Core Module
CBM on Breaker
Ambient
Temperature
and Humidity
Isolation
TM4C129x
MCU
Flash Memory
Infrared
Transceiver
Communications
Module Optional Module
G2.1 Temperature
Sensors (3ch)
4 Position
Connector
13 Position
Connector
52A
LCS
Trip Voltage
Close Voltage
Spring Charging
Motor Voltage
Supply Voltage
Split Core Hall
Eect Sensor
Charging Motor
Close Coil
Trip Coil