COMPLETE BREAKER

CONDITION MONITORING

Qualitrol® QBCM
Series

Next Generation Line of

Breaker Condition Monitors

Reduce unscheduled asset downtime

and maintenance costs

Qualitrol® Company LLC

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The QBCM is a one box

solution for complete
breaker condition
monitoring. Self-learning
with pattern matching
algorithms that increase
the reliability of asset
health data whilst
reducing false alarms,
the QBCM supports the
most effective condition
based maintenance
plans.”
- Shaival Desai, Product Manager
Qualitrol QBCM 3
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QBCM - The missing piece in your complete

condition based maintenance and reliability plan

Circuit breakers aren’t expensive when compared to other substation

assets, so the temptation may be to simply replace them when they
fail. But when they do fail, the damage to the rest of the system can
be catastrophic.
The Qualitrol QBCM Series is a 24/7 online monitoring system for 69kv to 1200kv
circuit breakers that pays for its modest investment by reliably detecting the smallest
issues in the circuit breaker condition. Easy to install with plug-and-play sensors, the
scalable QBCM Series increases grid reliability and safety by improving breakers
condition awareness, and greatly reduces maintenance costs while it protects the
cables and transformers in-line from over-load and damage.

Without circuit breaker monitoring, offline testing, which requires equipment to be

taken offline for up to two days, is typically performed every two to six years due to
its expense and intrusiveness. That infrequency of testing leaves large gaps of
uncertainty in which failure and property damage can occur. In addition, offline
testing doesn’t catch any SF6 leaks - or trigger coils, main contacts, motors and
heaters deterioration - critical for safe and timely breaker operation.

The new QBCM series analyzes a circuit breaker by comparing the performance data
against a reference/benchmark performance of that breaker. It is not mandatory to
know the current condition of the breakers because the QBCM monitors create a
benchmark of performance and provide a warning when it begins to degrade. This
allows users to understand the Rate of Degradation which is the key measurement for
condition based maintenance planning.
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“Installation into the existing breaker control cabinet is easy,

non-instrusive and cost effective - and typically performed
in less than one working day.”
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DRIVE OPTIMAL PERFORMANCE

Qualitrol has leveraged years of experience with monitoring devices
across the power grid to develop a solution that protects critical
assets, enhances your ability to implement proactive maintenance,
and maximizes the uptime and reliability of expensive substation
equipment. The QBCM delivers advanced features and options in 3
optimally configured models to drive the highest ROI in the market.
 Qualitrol QBCM 7

Protect Enhance Maximise

critical grid infrastructure business workflows return on investments
Circuit breakers protect other Quickly transform raw data into Grow ROI with this least invasive
critical assets in the grid network actionable insights and schedule condition monitoring solution while
- predict well in advance when maintenance operations around putting other valuable technical
they will not! the most economically viable time resources to best use

The QBCM can store up-to 10,000 operation records with full waveform signatures and can
automatically compare with a benchmark waveform signature (‘fingerprint’) for smart
warnings on breaker behavior changes during any operation. The most advanced SF6
density algorithms provide reliable and continuous monitoring of SF6, including time to reach
lock-out estimation with ±1 day precision and yearly and cumulative SF6 emissions tracking.

Simple installation • Audio-visual alarms and

warnings increase technician
• installation is non-intrusive and
awareness and safety
performed in less than one
working day, about 50% better • Simple, actionable insights
than popular options allow maintenance teams to
easily implement condition-
• A smart form factor enables
based maintenance before
installation in existing breaker
damaging events occur
control cabinets, reducing the
cost of any additional cabinets Greater Return On
‘Complete’
• No electrical or mechanical
Investments What defines a complete
modifications are needed in the • Protects multimillion-dollar grid circuit breaker monitor?
circuit breaker equipment for a small
investment Our full series of breaker
• Simplest software interface in condition monitors
the industry - semi-auto- • A smart dashboard delivers can suit almost any monitoring
commissioning capability* quick condition check with need, from essential to
maintenance tracking extensive, all as a single box
• Magnetic feet eliminate the
solution. In addition, the QBCM
need for destructive mounting • Measures SF6 gas in real-time,
even provides spare digital
in the breaker cabinet eliminating the need for manual
inputs to digitize alarms and
tracking and reducing
reduce expensive copper cable
Increased safety environmentally regulated leaks
runs. The QBCM also provides
• Smart pattern matching • Software refined with rigorous IEC 61850 capabilities for
algorithm catches critical usability testing reduces burden future smart substations.
issues with adjustable on the users to learn, operate
sensitivity and manage the devices
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MODULAR ANALYTICS
Qualitrol’s comprehensive QBCM product portfolio is
designed for flexibility to enable asset managers to
choose the right analytics mix for their maintenance
needs. With the QBCM smart dashboard providing a
trusted digital representation of the actual as-operating
state of the breaker, you’ll eliminate inefficiencies,
optimize operations, and improve profitability.

QBCM-LT
Provides essential condition monitoring for gang operated circuit breakers
(GOB).

QBCM-ST
Provides extensive condition monitoring for gang operated circuit
breakers (GOB).

QBCM-IP
Provides advanced condition monitoring for independent pole operated
circuit breakers (IPOB).

Smart System Dashboard

For LT/ST/IP monitors. Provides real-time access to breaker misoperation
data for the most informed decision making.
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Monitors essential parameters:

• SF6 pressure, density and humidity
• Coil currents and voltages
• Phase currents
• Digital inputs
• Virtual contacts velocity monitoring

Field ungradable from the QBCM LT

model with all the essential features
plus:
• Mechanism heaters monitoring
• Mechanism motors monitoring
• Extra digital inputs for alarms
digitization

Flagship model with a full feature set

for IPOB condition monitoring in a
single compact footprint, greatly
reducing installation time and effort.

QBCM smart dashboard is an

essential tool where data is
transformed into easy to read
tracking visuals, helping operators
understand data changes and
deliver faster maintenance
decisions.
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TECHNICAL SPECIFICATIONS - POWER SUPPLY QBCM

Universal power supply
Input range 100 - 240 V AC, 125 - 250 V DC
Line frequency 50/60 Hz

TECHNICAL SPECIFICATIONS - INPUTS

Analog inputs
3-phase currents 3 channels, 0-1 V AC or 0-333mV AC split-core CTs
Close coils 1-3 channels, 0-1 V DC shunt or hall effect sensor
Trip coils and B/U trip coils 2-6 channels, 0-1 V DC, shunt or hall effect sensor
Battery voltage 2 universal analog voltage inputs up to 299 V AC/DC
Auxiliary voltages 1 universal analog voltage input up to 299 V AC/DC
SF6 gas density/pressure/humidity/dewpoint 1-3 channel, 4-20mA for analog sensors (can also be used
for hydraulic pressure)
1 channel, RS 485 for daisy-chained modbus sensors
Anti-condensation heaters 3 channels, 0-1 V AC or 0-333mV AC split-core CTs
Mechanism heaters 3 channels, 0-1 V AC or 0-333mV AC split-core CTs
Motor currents AC/DC 0-3 channels, 0-1 V AC or 0-333 mVAC split-core CT, shunts
or Hall Effect DC sensor

Travel transducer
Mechanism travel stroke. And velocity (optional) 3 x RS 422 channels on mother board, stroke measured in mm,
inches or degrees. Velocity calculated in meters/sec, feet/sec
or degrees/sec

Digital inputs
Trip initiation A, B, C 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
Backup trip initiation A, B, C 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
Close initiation A, B, C 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
52A auxiliary breaker contact status A, B, C 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
52B auxiliary breaker contact status A, B, C 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
Motor run timers 1, 2, 3 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
Heater status 1, 2, 3 1-3 channels, up to 250 V DC / 240 V AC, minimum 90 V
Spare for alarms digitization 2-7 channels configurable option
All digital inputs are polarity free with special pitch terminal blocks offering easy mistake proof installation

TECHNICAL SPECIFICATIONS - OUTPUTS

Relays
BCM failure alarm (Relay #1) Dry contact 10 A at 250 V AC / 0.2 A at 125 V DC
Breaker failure alarm (Relay #2) Dry contact 10 A at 250 V AC / 0.2 A at 125 V DC
User configurable alarm (Relay #3) Dry contact 10 A at 250 V AC / 0.2 A at 125 V DC
 Qualitrol QBCM 11

TECHNICAL SPECIFICATIONS - PERFORMANCE QBCM

LEDs / audible alarms
Power (Green) BCM power OK
Warning (Amber) Automatic warnings as compared with fingerprint
Alarm (Red) Hard limit alarms as configured
3 kHz buzzer For warnings, alarms and notifications - can be muted from UI

Recording
Resolution User selectable for 32 / 64 / 128 samples per cycle

Storage
Data storage memory 8 GB microSDHC standard (up to 10,000 operations records)

Reporting
SF6 emission Days to reach lock-out level, total emission and year-to-date
emission reporting
Breaker operation analysis report A standard report with detailed analysis for every breaker operation.
Includes comparison with stored reference fingerprint operation
record. Mechanism operation time, auxiliary contact time, current
interruption time, motor run time, peak motor current,
restrike detection, travel transducer sensor data

Communications
Hardware media types 1 x 10/100Base RJ-45, 1 x 100Base-FX with ST connector,
1 x USB 2.0 port, 1 x RS 485 copper port
Protocols DNP3.0, IEC 61850, Modbus
Time sync inputs NTP Standard or optional IEEE 1588 PTP

Environmental
Ambient operating temperature -40° C to +75° C [-40° F to +165° F]
Storage temperature -55° C to +85° C [-67° F to +185° F]
Humidity 5 - 97%, non-condensing
Enclosure rating IP20 (for installations inside breaker control cabinet)
Optional IP67 enclosure for external mounting
Seismic IEC 60255-21-3
Low temp, dry heat and damp heat BS-EN60068-2-1; BS-EN60068-2-2; BS-EN60068-2-56
Vibration and shock test compliance BS-EN60068-2-6; BS-EN60068-2-27

Immunity
EMC test compliance Conforms to relevant specifications for monitoring / control
equipment in HV substations: BS-IEC-EN 61000-6-5:2015;
BS-IEC-EN 61 000-3-2,3; BS-IEC-EN 61000-4-2, 3, 4, 5, 6, 8, 9, 10, 11,
12, 16, 17, 18, 19, 29; IEEE-ANSI C37.90.1; IEC 810-2
Others BS-EN60255-27:2013 Safety; BS-EN 60255-5 sections 6 and 7
dielectric tests; IEC 60255-22-1
1 MHz burst immunity to noise, 2.5 kV EMI / RFI immunity

Mechanical
Dimensions 381mm x 140mm x 70/89/115mm (H) [15" x 5.5" x 2.75"/3.5"/4.5"]
Weight ~0.8kg - 1.5 kg [~1.76lbs. - 3.3 lbs.)
SYSTEM SENSORS
Our sensors are key components of the QBCM breaker condition
monitoring system. Specifically designed for ease of installation, they
send all signals to the QBCM data acquisition system for interpretation.
Support for 3rd party or OEM provided sensors is also available.

AC current sensor: DC Hall effect sensor: SF6 sensors: Travel transducers:

The CT can be mounted to The DC hall effect sensor The QBCM supports analog A rotary travel transducer
existing panels to measure is a solid core high and Modbus sensors. is available for installation
or monitor AC current. accuracy and very short Analog sensors provide on breaker mechanism
These split-core CTs can response time solution to one parameter, while shafts. Standard 8mm and
be mounted without capture the coil signatures Modbus sensors provide 10mm flexible couplings
removing existing cables with maximum details and multiple parameters. are available for the
for ease of installation. reliability. This sensor Sensors are available in installation. Linear
The CTs are available in provides a reliable, non- density only versions, transducers may be
different measuring ranges intrusive solution for density/pressure/temp. available as a customer
to be used for phase retrofit applications. The versions and special solution.
current, motor currents output of the sensor is density/pressure/temp./
and heater currents. 0-1V. OEM installed shunts dew-point versions.
can substitute these Adapters for DN8 and
sensors for new breakers. DN20 are also available for
installation.

Qualitrol Company LLC

1385 Fairport Road, Fairport Phone: +1 585.643.3717 Visit our website for more information and a
New York 14450, USA Email: [email protected] complete portfolio at www.qualitrolcorp.com