IMCC Smart Motor Operator

Overview

IMCC Smart Motor Operator is a smart and robust motor operating mechanism for controlling and monitoring disconnect switches. It offers variable speed control, real time and condition based monitoring, alarm notification, IEC 61850/DNP3 communication, optical positioning, universal design and more.

iMCC provides various benefits including operation improvement, increased life of the switch, real time misalignment and blockage detection, condition based maintenance and real time notification in case of failures. It provides all the mechanical features of a conventional motor operated disconnect (MOD) that is maintenance free. It has an integrated electronic monitoring and control module called iCOD. iMCC is compatible with all disconnect switches that utilize a rotary drive shaft for ratios from 45 to 220 degrees and multiple turns, of any output torque. Using high precision gears, robust gearbox and an overrated motor, it is designed to operate for the life of the disconnect switch.

EHT’s smart motor operator has sparked interest in many parts of the world. iMCCs are currently installed in electric grids in Canada, USA, Mexico, India, Australia and Philippines.

IMCC Front Side


Features & Benefits



Maintenance Free Design

  • Cam switches replaced by optical positioning system
  • Contact oxidation resolved
  • Contactor relays replaced by solid state motor drive
  • Conventional push buttons replaced by membrane switch
  • Standard terminals replaced by spring cage terminals (optional)
  • Overcurrent detection and limitation
  • Maintenance free gearbox (no lubrication)
  • Sealed housing
  • Robust stainless steel enclosures and components
IMCC back side


IMCC Configuration


The following section provides information about various elements that can be configured on an IMCC motor mechanism to make it fully compatible with the technical specifications of your disconnect switch and your safety requirements.

Please note the information contained in this section is provided for informational purposes only. EHT is in charge of configuring the IMCC for all projects. Simply fill the technical questionnaire below and send it to a EHT representative to start a project. EHT will configure the IMCC to meet the requirements of your switch.

Click here now to see our ordering guide.

Internal Gearbox & Motor

The IMCC smart motor mechanism can be customized to operate any type of disconnect switch. There are two main classes of gearboxes, the Multiple-turn and the Single-turn. These gearboxes are then tailored to meet the torque and operating time requirements for a given disconnect switch by modifying a gear set*. To cover the various cases encountered in the market, gearboxes are mated with two different models of 0.5 HP DC motors; 1750RPM and 2500RPM. For each project, the gearbox and the motor are meticulously selected to provide the best performance.

*The gear set is designed to be easily replaceable if needed.

The selection of a gearbox performed while considering the following parameters:

  • Disconnect Switch Torque
  • External Gear Reduction Box
  • Operation time
  • Degree of rotation

The configuration tables below show a range of Motors/gearboxes to be used to meet various disconnect switch specifications. It is non-exhaustive and do not cover all cases. It aims to provide the reader with an idea of the flexibility that the sets of gearboxes & motors provide. EHT will ensure the proper selection of the gearbox and motor based on the technical data of the disconnect switch.

Single-Turn Gearboxes

Customer Specification

IMCC Specifications

External Gear Reduction Ratio Range

Disconnect Switch Torque

Disconnect Switch Rotation

Motor (RPM)

Motor (HP)

IMCC Internal Gearbox Ratio

Number of Turns of IMCC Output Shaft

IMCC Output Shaft Torque (Nm)

Operation Time (s)

None

691 – 1035

180°

1750

0.75

385:1

180°

691 – 1035

6.6

None

376 – 690

1750

0.5

385:1

376 – 690

6.6

None

306 – 375

1750

0.5

210:1

306 – 375

3.62

None

305

2500

0.5

245:1

305

2.94

None

691 – 1035

90°

1750

0.75

385:1

90°

691 – 1035

3.3

None

376 – 690

1750

0.5

385:1

376 – 690

3.3

None

306 – 375

1750

0.5

210:1

306 – 375

1.81

None

305

2500

0.5

245:1

305

1.47

 

Multiple-Turn Gearboxes

Customer Specification

IMCC Specifications

External Gear Reduction Ratio Range

Disconnect Switch Torque (Nm)

Disconnect Switch Rotation

Motor (RPM)

Motor (HP)

IMCC Internal Gearbox Ratio

Number of Turns of IMCC Output Shaft

IMCC Output Shaft Torque (Nm)

Operation Time (s)

9:1 – 12:1

1000

180°

1750

0.5

64:1

4.5 – 6

120

10 – 13.5

13:1 – 15:1

2500

64:1

6.5 – 7.5

80

10 – 11.5

16:1 – 22:1

1750

35:1

8 – 11

65

10 – 13.75

23:1 – 31:1

2500

35:1

11.5 – 15.5

45

10 – 13.5

32:1 – 45:1

1750

20:1

16 – 22.5

35

10 – 14

46:1 – 63:1

2500

20:1

23 – 31.5

25

10 – 13.75

4.5:1 – 6:1

500

180°

1750

64:1

2.25 – 3

60

5 – 7

6.5:1 – 7.5:1

2500

64:1

3.25 – 3.75

40

5 – 6

8:1 – 11:1

1750

35:1

4 – 5.5

32.5

5 – 7

11.5:1 – 15.5:1

2500

35:1

5.75 – 7.75

22.5

5 – 7

16:1 – 22.5:1

1750

20:1

8 – 11.25

17.5

5 – 7

23:1 – 31.5:1

2500

20:1

11.5 – 15.75

12.5

5 – 7

9:1 – 12:1

1000

90°

1750

64:1

2.25 – 3

120

5 – 7

13:1 – 15:1

2500

64:1

3.25 – 3.75

80

5 – 6

16:1 – 22:1

1750

35:1

4 – 5.5

65

5 – 7

23:1 – 31:1

2500

35:1

5.75 – 7.75

45

5 – 7

32:1 – 45:1

1750

20:1

8 – 11.25

35

5 – 7

46:1 – 63:1

2500

20:1

11.5 – 15.75

25

5 – 7

4.5:1 – 6:1

500

90°

1750

64:1

1.125 – 1.5

60

2.5 – 3.5

6.5:1 – 7.5:1

2500

64:1

1.625 – 1.875

40

2.5 – 3

8:1 – 11:1

1750

35:1

2 – 2.75

32.5

2.5 – 3.5

11.5:1 – 15.5:1

2500

35:1

2.875 – 3.875

22.5

2.5 – 3.5

16:1 – 22.5:1

1750

20:1

4 – 5.625

17.5

2.5 – 3.5

23:1 – 31.5:1

2500

20:1

5.75 – 7.875

12.5

2.5 – 3.5

 

LITE vs PRO

Two models of IMCC are available; IMCC LITE and IMCC PRO.

iMCC LITE model addresses the needs of smaller switches with low torque requirements and minimal needs for advanced operating and monitoring functionalities. iMCC PRO model addresses the need of larger switches with long blades that require high torque to operate. IMCC PRO advanced functionalities will provide flexible control adjustment to improve the operation significantly and provides full monitoring and signaling features.

Two upgrades are available for the LITE models. The operating upgrade will unlock all the advanced operating features of the PRO models. The monitoring upgrade will unlock all the advanced monitoring and signaling features of the PRO models. These upgrades are particularly well suited for utilities interested in only one of the PRO’s set of features. It provides advanced Operating or Monitoring features at a more affordable price. The following tables presents a comparison between both models.

Operating Features

 

LITE

PRO

IMCC Operating Features

Operate any make of disconnect switches

X

X

Soft Start and Soft Stop

X

X

One parameter speed configuration

X

X

Configurable operating range

X

X

Configurable motor direction

X

X

Mechanical stress reduced at start-up

X

X

Fixed trigger blockage detection with encoder

X

X

Stop following a blockage detection

X

X

Precise and absolute positioning with optical encoder

X

X

Precise closing and opening of the disconnect switch

X

X

Easy Configuration with software

X

X

Inter-phase locking (IPL) – for inter-phase synchronization

X

X

Multi-trial ice-breaking / obstruction removal mode

X

X

DNP3 and IEC61850 remote control (with optional communication module)

X

X

Ensures optimal contact pressure

X

X

Fully configurable operating speed and torque

 

X

Removes or improves erratic behaviors during operations

 

X

Reduces of Arcing Time

 

X

Reduces arc exposure to contacts which improves their lifespan

 

X

Reduces harsh harmonics injected in the grid

 

X

Improves lifespan of adjacent equipment such as Power Transformers

 

X

Reduces mechanical stress during the whole operation

 

X

Adds service life of the switch, structure, insulators and MOD

 

X

Returns to initial position (or stop) following a failure detection (e.g. blockage) –configurable option

 

X

Configurable amount of operation retries following a failure detection (e.g. blockage)

 

X

Redundancy & security operating system

 

X

CMI software – Configuration (with advance operation license), real time monitoring

 

X

Fully upgradable to PRO operational features

X

 

Monitoring and Signaling Features

 

LITE

PRO

IMCC Monitoring & Signaling features

Fixed trigger blockage detection -  configurable

X

X

10 Configurable Auxiliary Signals (possibility of a maximum of 30 signals)

X

X

DNP3 and IEC61850 Alarm notification and error codes (with optional communication module)

X

X

Temperature & humidity monitoring and control -  configurable

X

X

Temperature & humidity problem detection

X

X

Encoder failure detection

X

X

Operation time out detection -  configurable

X

X

Sensors failure detection

X

X

High current detection and limitation -  configurable

X

X

Internal interlock between motor and manual operating modes

X

X

External interlock between the disconnect switch and other equipment of the substation

X

X

System health status signal

X

X

Loss of power detection

X

X

Critical alarm signal

X

X

Non-critical alarm signal

X

X

Categorization of issues into up to 30 error codes

X

X

Three (3) operating modes (Local/Remote and manual)

X

X

Motor rotating in wrong direction detection

X

X

Fully Configurable Tolerance Limits & reference curve

 

X

Precise detection of blockages, breakages and misalignment

 

X

Fixed trigger blockage detection available in redundancy operating mode

 

X

DNP3 and IEC61850 advance real time monitoring data (with optional communication module)

 

X

Up to 400 operations recorded locally available for download

 

X

Trend analysis and diagnosis software for predictive maintenance

 

X

CMI software – Configuration (with advance monitoring license), real time monitoring and analysis modules

 

X

Fully upgradable to PRO monitoring features

X

 

Mechanical Features

 

LITE

PRO

IMCC Operating Features

SS304 Painted cabinet

X

X

Up to 34 000 in-lbs

X

X

Ultra high torque

 

X

Single-turn and multi-turn gearbox options Ce n’est pas un option, mais un choix (selection)

X

X

High quality no maintenance gearboxes

X

X

Customizable gearbox ratios

X

X

Internal three mode decoupling system (Motor, Lock, Manual)

X

X

Manual operation with hand crank or wheel

X

X

Nema 3 Cabinet

X

 

Nema 4X cabinet

 

X

Redundancy and security module

 

X

Battery & Charger Backup

A 24 volt battery set with a charger can be integrated in the IMCC motor mechanism for distribution networks (line switches), where remote cabinets are often powered by solar panels and batteries. The distribution cabinet is higher in size to provide space at the bottom for up to four 12 volt batteries. A charger is attached to the side of the cabinet as shown in the image below.

Distribution Cabinet with Batteries/Charger

  • Two 12 V batteries in series
  • Possibility of four batteries: 2 sets of 2 batteries
  • Electric Charge: 40 to 80 Ah
  • Operating Temperature: -40°C to 65°C

 

Distribution IMCC with battery backup and charger Distribution IMCC with battery backup and charger Distribution IMCC with battery backup and charger

Coupling Mechanism

EHT offers various type of coupling mechanisms, the most common being the ones below. Our couplings can be customized to meet the customer’s needs and requirements. EHT can also design coupling mechanisms based on existing ones.

Swing Handle Coupling

  • Coupling of the disconnect switch (DS) by use of a lever handle
  • Ensures proper recoupling alignment
  • Lockable handle (Engaged and Disengaged Positions)
  • Easy alignment by use of the swing handle with a standard pipe 2″IPS
  • DS is mechanically blocked in the disengaged position (open or closed)
  • Very high torque capacity (Over 1000Nm Nominal Capacity)

 

Swing Handle Coupling for Disconnect Switches Swing Handle Coupling for Air Break Switches Swing Handle Coupling for Isolators

Flange Coupling

  • Very high torque capacity (Over 1000Nm Nominal Capacity)
  • Easy Installation
  • Compact design optimized for space limited installation
  • Galvanized Steel
  • U-bolts and Set Screw ensure optimized torque transfer
  • Very robust

 

Flange Coupling for Disconnect Switches Flange Coupling for Disconnect Switches Flange Coupling for Disconnect Switches

Mounting Bracket

  • Fully customizable
  • Robust Galvanized Steel Brackets
  • Drilled to match the existing mounting layout
  • Horizontally adjusted for proper alignment with the drive shaft
  • Optional adjustable blocker plates for swing handle coupling with decoupling lever handle

 

Flange Coupling for Disconnect Switches Flange Coupling for Disconnect Switches

Safety Interlocks

EHT can integrate Interlock keys, such as Kirk Keys or Castel Keys to meet customers’ safety requirements. The positions and modes can be locked. For example, a first interlock could be used to lock the open position and a second one could be used to lock the LOCK mode when the motor is decoupled and de-energized. The customer’s existing keys and interlocks can be reused or new interlocks can be used. The integration is done in accordance to the customer’s specifications to ensure full compliance of the safety procedures.

Safety Interlocks
Safety Interlocks

External Gearbox

In some cases, EHT can replace damaged external gearboxes on multi-turn disconnect switches, or completely remove them and replace the multi-turn motor mechanism by a single-turn. In other cases, there are motor mechanisms made out of special designs. For example, some motor mechanisms have a horizontal output shaft on the side of the cabinet that operates the drive shaft linearly. In such cases, EHT can design a custom made external gearbox to transfer the shaft direction from vertical to horizontal and provide the linear shaft movement.

Optional Cam Switch

Some utilities require traditional electro-mechanical style cam switches for signaling as may be required by Protection and Control. In this case, a cam switch can be added to the encoder shaft as shown in the below images.

  • Robust Aluminum Cams
  • High quality switches
  • Efficient one collar per cam attachment mechanism for easy adjustment

 

EHT optional cam switches EHT optional cam switches EHT optional cam switches

Electrical Specification

Control & Motor Specifications

Supply Voltage (V)

Control

Motor

Transformer Ratio

24Vdc

V28

24Vdc

-

48Vdc

V48

48Vdc

-

125Vdc

V110

90Vdc

-

120Vac

V150

-

220Vac; 250Vdc

V250

180Vdc

-

460Vac

V150

90Vdc

460 : 115

Heater Specifications

Supply Voltage (V)

Power (W)

Temperature Range

120Vac to 230Vac

180W

-10°C to 65°C

120Vac

250W

-40°C to 65°C

230Vac

250W

-40°C to 65°C

Communication & Signaling

Auxiliary Signalling Module (ASM)

Auxiliary Signaling Module

Hard Copper Wire Signaling Board

Number of outputs 10 per stage
Consumption 4.1W per stage
Contact rating REL-DC Resistive DC = 2A @ 125Vdc
Inductive DC(2) = 0.2mA @ 125Vdc
REL-AC Resistive AC = 12A @ 250Vac
Inductive AC(2) = 3A @ 250Vac

(2) High inductive load => L/R = 20ms
Wire gauge 0.5 to 6 mm2 (20 to 10 AWG)

DNP3 / IEC 61850 Board

Protocol COMM-IEC IEC61850 Ed. 1.0
COMM-DNP DNP3.0
RS485 Option Connexion RS485, half duplex, full duplex
Speed Up to 115200 Baud rate
RJ45 option Connexion RJ45
Speed 100Mps
Optical fiber option Connexion Duplex ST
Speed 100 base Fx

DNP3 / IEC61850 Communication Board

Find Out More About the IMCC Benefits

IMCC PROVIDES MONITORING DATA IMCC IMPROVES OPERATIONS
IMCC DETECTS FAILURES AND NOTIFIES IMCC ONE SIZE FITS ALL – FROM 25KV TO 1200KV