Daniela Lange ABB STOTZ-KONTAKT GmbH Heidelberg, Germany, daniela.lange@de.abb.com; Peter O. Mueller ABB STOTZ-KONTAKT GmbH Heidelberg, Germany, peter.o.mueller@de.abb.com
Electric motors make the industrial world go round – literally. There are millions of motors installed worldwide and around one-third of the world’s electricity is converted into motion by electric motors. The number of such motors is expected to double by 2040. How can this large installed base profit from the very substantial benefits that can be accrued from digitalization, without incurring prohibitive costs →01? ABB’s new Novolink devices supply the answer.
Novolink is the only solution to offer the highest levels of out-of-the-box digitalization using AF contactors and no specialist cabling. Novolink delivers high-grade motor protection and monitoring in the simplest, most efficient way possible. Novolink’s remote monitoring capabilities identify issues early on, keeping maintenance well ahead of any problems. By monitoring key electrical measurements, as well as significant maintenance aspects that are important for motors and general load feeders, the Novolink smart devices take Industry 4.0 digitalization strategies to a new level.
ABB Novolink
ABB Novolink modules equip traditional control gear with digital capabilities →02. The modules enable the predictive maintenance, remote control, fault diagnostics and data analytics required for the world of Industry 4.0. Novolink connects electric motors into higher-level automation and smart factory systems, giving customers the real-time data and analytics they need to implement energy-saving strategies and make an impact on their operational efficiency →03.
With Novolink, there is no need to replace existing AF contactors. The Novolink devices can be simply snapped onto any AF contactor from an AF09 up to an AF96 equipped with a 24 V DC coil. ABB’s AF contactors have an advanced, electronically controlled magnet system that covers the complete power range and are complemented by a full list of accessories.
ABB Novolink smart modules
ABB Novolink consists of two modules: the SFM1 and the SCV10.
The SFM1 Novolink contactor module monitors key maintenance statistics, including motor operating hours, contactor switching cycles and trips. The module is equipped with two X2X interfaces for incoming and outgoing connections. The module and contactor are supplied by the 24 V DC that goes to the SFM1 module. A digital input makes it possible to pick up an auxiliary signal, eg, from a device with short-circuit protection functionality, such as the ABB MO132.
The AF contactor is mechanically linked to a lever, which provides a visual feedback of the contactor position on the front of the SFM1. The lever also allows the manual operation of the contactor for test purposes. A status LED displays the operational state of the SFM1 module itself.
04a Basic solution with a MS132 for motor protection, SK1, BEA and the SFM1 smart function module for remote control. 
04b Full-featured solution consisting of a direct-online (DOL) starter with a MO132 as short-circuit protection device, AF contactor, SK1 signal contact, BEA connecting link, SFM1 smart function module and SCV10 smart current and voltage module for an encompassing motor protection.
04 Novolink modules.
The optional SCV10 Novolink smart current and voltage module provides motor protection and monitors the status of connected equipment. This module connects to the SFM1 module and measures line voltages, phase currents, power, frequency, total harmonic distortion and other important parameters →04– 05. The SFM1 module is equipped with feed-through current sensors to measure the current in all three phases of the connected load. The device also offers the option to measure the line-to-line voltage of the three phases up to 690 V AC. A ribbon cable connects the SCV10 module with the SFM1 module and it is also supplied with power from there.
The SCV10 module offers advanced protection according to IEC/EN 60947 for single- and three-phase induction motors. Relevant parameters such as the trip class and nominal current can be configured from within a programmable logic controller (PLC). For optimized control of selectable trip classes 5E-30E, an advanced thermal model calculates the actual thermal load, time to trip and time to cool. The model considers both the copper and iron parts of the motor, thus providing the best protection for the motor. Before an overload trip occurs, a warning can be generated in the PLC by monitoring the thermal load. Novolink supplies cos-phi and real power data to allow the user to monitor and protect pumps and other connected loads.
These two Novolink devices help detect load, supply, or feeder issues, making problem-solving faster.
Reduced engineering effort
Installation of Novolink modules is fast and simple, thanks to less wiring and fewer components than the traditional approach. The SFM1 snaps on to the existing 24 V DC coil contactors of ABB’s AF range without increasing the effective width of the contactor. Novolink devices are compatible with 24 V DC coil contactors – from AF09 up to AF96 in screw versions and from AF09 up to AF38 in push-in spring versions. Because standard AF contactors can be used, retrofitting existing solutions is simple – in many cases only the control wiring needs to be changed.
Data from the contactors, the motor and connected loads is taken into the B&R Automation Studio integrated software development environment (see below) via the Novolink device’s X2X bus. X2X provides some very useful features not available in other bus systems. For example, is it not necessary to set any bus address on the module as bus addresses are automatically set by the system. This configuration feature removes a lot of pitfalls often encountered during commissioning or module replacement. It is also possible to update the firmware of the X2X modules via the bus, thus ensuring the system stays in a known state. Programming is simple, with all the data available from a single feeder node, making it easy to customize protection functions to the needs of the application.
Standard controls are ready to use out of the box without additional engineering and there is no need for expensive specialist cabling or further training. Through the integrated connectivity and integration into B&R solutions, valuable information can be derived readily from raw data. Integration into other systems is catered for via B&R’s OPC UA server and other gateways. Novolink’s modules allow the remote control and monitoring of AF contactors via the B&R X20 bus from within a B&R PLC, reducing costs and increasing overall uptime.
Novolink devices can be connected in a daisy chain with multiple devices working in a sequence using standard Ethernet cables →06.
Data from the Novolink devices can be used directly with a wide range of B&R system applications, including those that facilitate supervisory control and data acquisition (SCADA), human-machine interfaces (HMIs), audit trail, enterprise resource planning (ERP) systems, manufacturing execution systems (MESs) and cloud infrastructure functions.
From corrective to predictive maintenance
Getting ahead of faults and problems is key to preserving uptimes, maintaining the longevity of equipment and ensuring the uninterrupted flow of production. With Novolink, it is possible to set thresholds and receive warnings of incipient equipment failure so that operational parameters can be adjusted to accommodate the changed situation while optimizing production and reducing energy consumption – all with the next maintenance window in mind.
Advanced diagnostic capabilities make it simple to optimize performance by, for instance, switching off idle processes. The user can combine real-time diagnostics with long-term data trend analysis to unlock new service models.
The Novolink diagnostic capabilities allow operatives to immediately isolate problem areas (such as a malfunctioning load) without initiating a system-wide shutdown and arrive more quickly at a solution, thus minimizing disruption. For ease of use, all control, monitoring and diagnostic signals are fully visible and there is clear fault localization indication.
With B&R PLCs, monitoring can be carried out from a remote location via cloud connectivity, eliminating the need for maintenance personnel to conduct regular on-site checks.
Novolink’s fully digitalized approach means that data trends can be analyzed over the long term so processes can be adapted to maximize performance.
The B&R Automation Studio
The B&R Automation Studio offers an integrated software development environment with tools for every project phase, including a wide range of diagnostics for system optimization. The user can access extensive target system information via the Web with the System Diagnostics Manager. The controller, drive, communication and visualization are all configurable in one environment, reducing integration time and maintenance costs.
The future of motor digitalization
Novolink is the only solution to offer such high levels of functionality using AF contactors and no specialist cabling. Novolink – which is fully integrated into the B&R automation system – delivers high-grade motor protection and monitoring in a very simple way. Remote monitoring enables early identification of issues, prompting maintenance and ensuring equipment lasts longer. By monitoring the principal electrical parameters and maintenance aspects, Novolink smart devices take Industry 4.0 digitalization strategies into new areas. Data-driven functions, including predictive maintenance, remote control, real-time optimization, instant fault diagnosis and predictive analytics, will help factories by improving operational performance, reliability and long-term costs.
