Mitsubishi Electric Low-voltage products PLM (Product Lifecycle Management) Mitsubishi Electric Corporation

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1 Mitsubishi Electric Low-voltage products PLM (Product Lifecycle Management)

2 Suitable replacement leads to facility reliability We are surrounded by technology, and electricity is one of important social infrastructures in our life. Therefore, safe and reliable electrical system is required in order to supply stable electricity. Do you have these concerns or experiences? Concerned about the maintenance cost and the shortage of maintenance personnel Equipment is aging and worried about the lifetime of products. For continuous operation, maintenance span needs to be longer. Sudden blackout led to trouble. When old equipment was broken, it took long time to recover. Please consider to renew products and facilities. 2

3 Suitable replacement leads to facility reliability Minor failure may cause serious problem Reliability of power supply is highly-demand with information networking such as Factory Automation, Computer Integrated Manufacturing, Office Automation and Building Automation. For example, what will happen if sudden power outage occurs at your company now? How much is the loss due to power outage for 1 hour? What is the impact of unexpected shutdown of production line or calculator? The failure may spread and it may cause power outage in other areas as well. It costs and takes time to recover (Some old products can not be exchanged) Can not operate properly Aging of equipment causes these problems Switching and control device: can not make/break or trip Causes short-circuit fault Switching and control device: causes short-circuit fault due to insulation deterioration. 3

4 Suitable replacement leads to facility reliability Lifetime of product It is difficult to find an aging of equipment, however sudden failure occurs and it takes long time to recover. Therefore, preventive maintenance is very important. Initial failure Accidental failure Failure due to wear Failure rate Permissible failure rate Recommended renewal time Increase the possibility of serious accident Lifetime Time span that product can be used by conducting maintenance Year of use Environmental factors of shortening product lifetime Salty or corrosive gas environment. Insufficient air-condition with rainwater and condensation due to gaps. Fulfilled with exhaust gas. Fulfilled with nitrate ion from metal pickling and etching circuit board. 4

5 Suitable replacement leads to facility reliability Benefit of renewal Preventive maintenance ensure safety and reliability All products are aging Difficult to find deterioration Suddenly fault may occur Improvement of product performance Product performance dramatically has been improved compared to products of 30 years ago Optimize advanced products Network devices enables to measure, display and transmit the collected data. Circuit breakers and Meters with communication Air circuit breaker (AE-SW series) MDU breaker (Measuring Display Unit) MultiMeter (ME96 series) 5

6 Suitable replacement leads to facility reliability Each product Life cycle Degree Environment Actual example Guide for replacement (years) Place where air is always clean and dry Electricity room with dust-proof and air-conditioning, etc. Approx. 10 to 20 Good environment Indoors where levels of dust, etc., are low and there is no corrosive gas Independent electricity room s power distribution panel with no dust-proofing or airconditioning, and breakers installed in enclosure Approx. 7 to 15 Poor environment Place with gases containing sulfurous acid, hydrogen sulfide, salt or high levels of moisture, etc., but with low levels of dust Place with particularly high levels of corrosive gases and dust, where humans cannot stay for long periods of time Geothermal power plant, sewage treatment plant, iron and steel mill, paper mill, pulp plant, etc. Chemical plants, quarries, mines, etc. Approx. 3 to 7 Approx. 1 to 3 *Each product shall be replaced when operating cycles exceed specified number even within expected product lifetime. 6

7 Case-sample of product renewal DS VCT Wh VT Indicator VM AM VT 経年劣化 MultiMeter LA VCB V VM CT I> LBS LBS ACB CT ACB A AM A AM CT ACB MCCB MCCB MCCB MCCB MCCB MC MC MC MC MC THR THR THR THR 7

8 History of Low-voltage Power Distribution Products Now MCCB ELCB First launch of circuit breaker in Japan (1933) SCHAT series ( ) SCHAT+RU series ( ) SCRUM series ( ) SUPER-SCRUM series ( ) PSS series ( ) WS series ( ) W&WS series (since2005) WS-V series (since 2010) AE-SS series( ) ACB AE-H series ( ) AE-S series ( ) AE-SW series (since 2005) Motor stator EC series ES series ( ) ( ) EK series EM series ( ) ( ) MS series ( ) MS-A series ( ) MS-K series ( ) MS-N series (since 1994) MS-T series (since 2012) 8

9 Renewal of low-voltage circuit breaker Renewal of low-voltage circuit breaker (example) No-fuse circuit breaker WS-V series (World Super V Series) MDU breaker (Measuring Display Unit) Earth leakage circuit breaker No-fuse circuit breaker Air circuit breaker (AE-SW series) More than 2000AF 9

10 Check your circuit breaker lifetime How long have you used your circuit breaker? Expected product lifetime of circuit breaker is approximately 10~20 years since the date of manufacturing with normal usage condition. Lifetime of circuit breaker It shall be replaced when operating cycles exceed specified number even within 10~20 years. *Low-voltage Air Circuit Breaker is required to have regular maintenance and inspection (such as lubrication) by manufacturer. And when the products are stored for long time, proper maintenance and inspection are necessary before use. Item Normal service conditions Ambient temperature From -10 to +40 and its average is less than 35 Humidity Shock and vibration Carrying current Others Relative humidity is from 45 to 85% and no condensation No abnormal shocks or vibrations The average is less than 80% of rated current No dust, smoke and corrosive gas 10

11 Regular maintenance & Renewal guidance Flowchart of regular maintenance to diagnosis Regular maintenance (Visual inspection) Mitsubishi Electric MCCBs & ELCBs RENEWAL GUIDANCE Deteriorated? Diagnosis by renewal guidance MITSUBISHI ELECTRIC FUKUYAMA WORKS 11

12 4. Appearance 3. Operating environment and conditions Self-regular maintenance of circuit breaker Diagnostic criteria Rank A (0 ~ 20 points) It is possible to use without any procedure Rank B(21 ~ 29 points ) It is still possible to use but necessary to consider renewal and be careful to use it when some parts are deteriorated. Rank C (more than 30 points) It is necessary to consider renewal Molded case circuit breaker/earth leakage circuit breaker deterioration diagnosis check list Item 1.Year of use 3 2.Number of opearating cycles (1) Ambient temparature Sample NO. Installation location Model/ Number of poles / Rating Specifications Accessaries Serial number Installation date Factor 5 4 (2) Humidity 4 (3) Corrosive gas 10 (4) Carrying current (The average) (1) Pollution (2) Dust at line side barrier area (3)Sign of overheating in terminal area 5.Insulation resistance *In the case of Earth leakage circuit brakers, insulation resistance between the right and left poles cannot be measured because the control circuit power is on Total score(factor score) Neccesity of consideration for renewal Less than 10 years Less than 15 years Less than 20 years Less than 30 years 30 years or more Conditions Less than specified operating cycles Less than double of specified opearating cycles More than double of specified opearating cycles Low( Monthly average is 30 or less) Normal( Monthly average is 35 or less) High( Monthly average exceeds 35 ) Low( Monthly average is 45% or less) Normal( Monthly average is 85% or less) High( Monthly average exceeds 85%) Not exist Exist 50% or less of rating 80% or less of rating Exceed 80% of rating Almost nothing There is dust, oilmist etc (small amount) There is dust, oilmist etc (large amount) Nothing There is soot (little) There is soot (much) There is metal powder No discoloration Slightly discolored due to overheat Remarkably discolored due to overheat Exceed 100MΩ 5~100MΩ less than 5MΩ Score Yes / No 12

13 Self-regular maintenance of circuit breaker Self-regular maintenance by user (preventive maintenance) Check item Check point Deteriorated condition Appearance Operation Accumulation of dust and metal particle. Cracking or Chipping of Molded parts. Handle operation. Nuisance trip Adherence of dust and metal particle. Cracking or Chipping of Molded parts. Unsmoothness of operation. (Handle is heavy, nuisance trip occurs) Insulation resistance Between phase, between earth (with 500V insulation resistance tester) * Cable shall be taken off 5MΩ or less Temperature Measure temperature of mold part by infrared temperature sensor or thermo-label Terminal part has nearly 60K higher than ambient temperature 13

14 Renewal of motor starter Renewal of motor starter (example) S-N10 S-T10 S-N50 S-T50 S-K220 S-N220 14

15 Check your motor starter lifetime How long have you used your motor starter? Life time of motor starter Expected product lifetime of motor starter is approximately 10 years since the date of first- use of product with normal usage condition. It shall be replaced when operating cycles exceed specified number even within 10 years. *The degree of deterioration changes depending on environmental conditions or conditions of use such as frequent opening and closing operations, inching operations and continuous energization etc. Mechanical durability [Unit: 10,000 cycles] Electrical durability [Unit: 10,000 cycles] ( Category AC3) N10~N35/T10~T50 N10~N65/ T10~T65 N50~N800/T65~T N80~N300/ T80~T100 N400~N

16 How to check deterioration of motor starter Factors and signs that lead deterioration and failure Possible cause Environmentally Electrically Mechanically Other factors Fault sign Rust Abnormal heating Deformation /Damage Abnormal odor and noise Frequent thermal trip Possible Failure Bad electrical continuity Welding Insulation problem Operation problem Coil layer Short circuit Damage to equipment Electric shock Stop Production line 16

17 How to check manufacture date N series K series A series Check here Year: 2000 ex)00 2S February *The last two digits of years and the number of month are described. October to December are represented alphabetically as below. ex) Sep 9, Oct X, Nov Y, Dec Z Year:1990 ex)90 9S September ex)2 06A Showa year: 52 (Japanese calendar) = Year:1997 June *K, A series may have been manufactured in Showa-period.(Japanese calendar). If so, the year are described by the last one digit of Showa year and month. If the lifetime (10 years) has passed, we recommend you to upgrade it. Since it is highly likely that the lifetime (10 years) has passed, we recommend you to upgrade it 17

18 Life time of contactor (motor starter) <End of life of contact due to wear> Severe application requires frequent operations to start and stop the load (motor), such as conveyor and crane control that need frequent making and breaking operations and crane that need inching operations. As opening and closing operations increase, wear particles are generated and it accelerates contact wear. When the thickness of contact (Part A) becomes 50% of new contact, we judge that it is end of life of contact. contact contact alloy alloy < Movable contact side > < Fixed contact side > 18

19 Life time of contactor (motor starter) <End of life of coil due to aging (more than 35A)> When ambient temperature is high (high humidity),and the product is installed closely, and control (operation) voltage is over voltage, and for continuous energization use, temperature rise of coil fluctuates (rise) and it accelerates coil aging (insulation deterioration) due to heating. < Example: S-N180 type > Coil tape is peeled off due to heating Fixed iron core 19

20 Renewal of indicator Renewal of indicator (example) VT CT V indicator Active Energy W indicator PF indicator W transducer PF transducer V transducer A transducer A indicator VT Integrate 9 kinds of measurement devices into 1 device CT ME96SS series has 9 functions and they enable to improve performance and reduce cost. ELECTRONIC MULTI-MEASURING INSTRUMENT ME96SS Series 20

21 Renewal of indicator Mechanical Measuring Instrument Electronic Multi Measuring Instrument ME96SS series Easy to check data with high visibility liquid crystal display Easy to collect data with multiple communication function < MODBUS RTU is equipped as standard > (MODBUS TCP, CC-Link is optional) Able to collect data by SD memory card (Optional) Concerned about aging device Want to save meter-reading power Electronic Multi Measuring Instrument ME96NS series (old type) < Example of MODBUS TCP system configuration > EcoWebServerⅢ LAN CH2 Ethernet MODBUS TCP ME96SS Ver.A Series HUB Ethernet MODBUS TCP EcoMonitorLight ME96SS Ver.A Series Low visibility 10 years since installation Need more measuring items Need MODBUS TCP communication MODBUS TCP RTU Convertor: MOXA MGATE MB3170 and etc. RS-485 MODBUS RTU 21 21

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