UMC100.3 Technical Presentation AKG.pptx

UMC 100

1. Intelligent Motor Management System UMC100.3 Amit Kr. Ghosh, EP-PC © ABB Stotz-Kontakt June 22, 2016 | Slide 2

2. Protection Functions overload short circuit phase failure Devices Manual Motor Starters Thermal & Electronic Overload Relays Contactors Fuses ABB Solutions for Motor Feeders Standard © ABB Stotz-Kontakt June 22, 2016 | Slide 3

3. Add. Protection Functions Motor / Bearing Temperature Level Supervision Voltage / Current Level Supervison Ground Fault Detection Imbalance Phase Sequence … Supportive devices: Power supplies Current transformers T imers … Remote IO Temperature Monitoring Ground Fault-Detection Current / Voltage Monitoring Analog signal converters Interface Relays Control System PTC / PT100 / PT1000 Warning & Error Signals Commands R< ABB Solutions for Motor Feeders Advanced © ABB Stotz-Kontakt June 22, 2016 | Slide 4

4. Integrated solution Motor Control Motor Protection Motor Diagnosis Communication Control System Local IO signals PTC GF Sensor Ethernet Voltage Control ABB Solutions for Motor Feeders High Performance

5. UMC100 Intelligent Motor Protection & Control System Advanced Motor Protection Flexible Motor Control Diagnostics and Maintenance Communication for all major fieldbusses and networks © ABB Group June 22, 2016 | Slide 6

6. UMC Usage Where are UMCs used © ABB Group June 22, 2016 | Slide 7

7. UMC Usage Why are UMCs used © ABB Group June 22, 2016 | Slide 8 To avoid any sudden and unexpected motor stop by detecting upcoming problems early full information about the motor status is required Keep downtime short in case of any sudden and unexpected motor stop by getting comprehensive diagnosis to reach this b y using spare drawers This is the reason why customers invest more and use intelligent motor controllers

8. UMC100 System Overview Universal Motor Controller UMC100.3 DC 24 V DC UMC100.3 A C 110 … 240 V AC/DC UMC100.3 DC EX 24 V DC ATEX UMC100.3 A C EX 110 … 240 V AC/DC ATEX Control Panel UMC100-PAN © ABB Group June 22, 2016 | Slide 9

9. UMC100 System Overview Version 24 V DC Version 110 … 240 V AC / DC © ABB Group June 22, 2016 | Slide 10

10. UMC100 System Overview Expansion Modules Digital DX111 DX122 Voltage VI150 VI155 Analog AI111 © ABB Group June 22, 2016 | Slide 11

11. UMC100 System Overview Communication Interfaces Fieldbus Profibus DP PDP32 DeviceNet DNP31 Modbus RTU MRP31 Network Ethernet Modbus TCP MTQ22 Ethernet Profinet IO PNQ22 © ABB Group June 22, 2016 | Slide 12

12. UMC100 System Advantages UMC100 is a modular system for motor protection and control Very compact s olution due to the integrated measuring system O nly one single device independent of motor size, functionality and communication Easy to expand for more functionality Flexible communication due to separate communication interfaces © ABB Group June 22, 2016 | Slide 13

13. UMC100 How are UMCs used © ABB Group June 22, 2016 | Slide 14 Power supply 120 / 230 V AC M X5 DI 2 DI 4 DI 5 DI 3 X5 X5 X5 X5 DI 1 X5 DI X5 V V X5 UMC100.3 T1 X8 X 7 X8 DO 2 X6 X7 DO 1 DO X6 X6 T2 Cb Ca DO 3 DO C DO C X6 X6 max. 1000 V AC M M N Start Stop Local Fault PTC CEM11 Earth Fault Sensor 0V +24 V

14. UMC100 Motor Protection Overview Comprehensive motor protection for 3- and single phase motors M otor supply voltage up to 1000 V AC 50 / 60 Hz Nominal motor current 0.24 A to 63 A with integrated widerange measuring system 63 A to 850 A with external current transformer CT4L / CT5L © ABB Group June 22, 2016 | Slide 15

15. UMC100 Motor Protection Protection functions overview Basic Overload according to EN/ IEC 60947-4-1 tripclasses 5E, 10E, 20E, 30E, 40E Rotor blocking Phase loss / imbalance / sequence current based Under- / Overcurrent Hot motor PTC Earth fault W ith sensor CEM11 or by calculation Too many starts per time Advanced – with expansion modules Under- / Overvoltage Phase loss / imbalance / sequence voltage based Underload / Overload Powerfactor Hot motor RTD © ABB Group June 22, 2016 | Slide 16

16. UMC100 Motor Protection Overload Protection according to IEC60947-4-1 Protection based on calculated advanced thermal model Measuring current Calculating t hermal load Calculating expected time to trip After thermal overload Cooling by Time or Cooling by Thermal load Calculate remaining cooling time Configurable overload pre-warning © ABB Group June 22, 2016 | Slide 17 Five trip classes: 5E, 10E, 20E, 30E, 40E Time Current Motor overload protection Class 40E Class 30E Class 20E Class 10E Class 5E

17. UMC100 Motor Protection Locked Rotor / Long Start Protection Active during start-up Extra fast protection when rotor locked Reduces stress and protection on transmissions © ABB Group June 22, 2016 | Slide 18 Current level and delay time to be set individually start-up running Blocking Current Delay Time Motor Current

18. UMC100 Motor Protection High / Low Current Protection Active after motor start-up High Current Protection Reduce stress and protection on transmissions Early detection of overload situations Low Current Protection Detection of under-load situations E.g. detect a broken belt or a dry pump Secure the process Separate trip and warn threshold, each with individual delay time © ABB Group June 22, 2016 | Slide 19 Current levels and delay times to be set individually start-up running Trip Level Warn Level Warn Level Trip Level Motor Current

19. UMC100 Motor Protection Phase Monitoring current based Phase loss Avoid overheating of motor Phase Imbalance Detection of imbalanced currents due to voltage variations or motor problems Warning and trip threshold separately adjustable Phase Sequence Prevent wrong rotation – crusher, conveyor.. Important for mobile units Faults are detected after starting the motor © ABB Group June 22, 2016 | Slide 20 To avoid accidents and damages L1,L2 & L3 L1,L3 & L2

20. UMC100 Motor Protection Voltage / power based protection functions (VI 15X) Voltage measurement through Voltage Interface VI Phase to Phase measurement up to 690V , Suitable for 3 phase systems, no Neutral needed VI150 VI155 (for IT networks) © ABB Group June 22, 2016 | Slide 21

21. UMC100 Motor Protection With additional Voltage Module With an additional Voltage Expansion Module VI 150 or VI155 UMC100 offers more advanced motor protection functions High / Low power Powerfactor ( cosPhi ) Underload important for pump applications Under / Overvoltage All settings have warn / trip level and individual delay times © ABB Group June 22, 2016 | Slide 22

22. UMC100 Motor Protection Phase Monitoring voltage based Without Voltage module: Phase faults can only be detected based on current during motor operation With Voltage Module: P roblems are detected before starting the motor The motor can not be started Protection against Phase loss Phase imbalance Phase sequence © ABB Group June 22, 2016 | Slide 23 Check for phase faults before starting the motor

23. UMC100 Motor Protection Phase Monitoring voltage based Detection of problems in the supply network Avoid reduced motor efficiency, overheating and reduction of insulation life -> reduction of life time of the motor Motors operating with unbalance will be noisier in their operation Available Functions Overvoltage Undervoltage Voltage phase loss and imbalance Harmonic distortion (THD) Different warn - and trip levels © ABB Group June 22, 2016 | Slide 24 Recommended derating curve by NEMA. Balanced unbalanced Protection of motor and equipment

24. UMC100 Motor Protection High Temperature Protection Overload protection devices calculate the thermal load value of a motor based on the current information But they do not know the real motor temperature The motor temperature can be higher than expected due to Missing or bad cooling Motor located in high temp area To avoid this motors should be protected against high temperatures This can be done by temperature sensors in the motor windings and/or bearings © ABB Group June 22, 2016 | Slide 25

25. UMC100 Motor Protection Thermistor High Temperature Protection For motors with integrated PTC elements UMC100 has a special PTC input Detection of Hot motor Cable short circuit Cable break Wiring problems and hot motor can be identified and differed © ABB Group June 22, 2016 | Slide 26 Fault or warning configurable

26. UMC100 Motor Protection RTD Temperature Protection For motors with integrated RTD elements Real temperature is measured with an analog module AI111 A module AI111 has 3 channels 2 modules AI111 can be connected Supported sensor types PT100 / 1000 KTY83 / 84 NTC Configurable Warnlevel Triplevel Delay time © ABB Group June 22, 2016 | Slide 27 Fault or warning configurable

27. UMC100 Motor Protection Earth Fault Protection internal Protection against earth fault due to damaged cable isolation, etc. Trip and warn level Active after startup or always Preconditions Ground fault current must be > 20% of Ie to be detected. Only usable in networks with low impedance to ground  only higher ground fault currents can be detected © ABB Group June 22, 2016 | Slide 28 Protection of motor and equipment

28. UMC100 Motor Protection Earth Fault Protection with sensor CEM11 Protection against earth fault due to damaged cable isolation etc. 4 sensor types available 8 threshold values for precise adjustment Threshold range size 80 … 1.700 mA 20 mm Ø 100 … 3.400 mA 35 mm Ø 120 … 6.800 mA 60 mm Ø 240 … 13.600 mA 120 mm Ø Can be used in all types of networks with higher impedance to ground small ground fault currents can be detected © ABB Group June 22, 2016 | Slide 29 Protection of motor and equipment

29. UMC100 Motor Protection Checkback Supervision Checkback supervision ensures that the motor is really running after a start command Three options for checkback Checkback current based (default) Checkback via an auxiliary contact on the main contactor. Connect auxiliary signal to DI0 of UMC Simulation: no checkback at all, for test purposes only  Checkback delay time is adjustable (default: 0,5 sec) © ABB Group June 22, 2016 | Slide 30

30. UMC100 Motor Protection Load Shedding (Voltage DIP) Application: Stop motor in case of undervoltage Automatic motor restart once voltage is back Configuration: Minimum time to detect undervoltage Maximum time for automatic restart Delay time for motor restart Undervoltage detection by External voltage monitor or Voltage expansion module VI150 / VI155 © ABB Group June 22, 2016 | Slide 31

31. UMC100 Motor Protection Load Shedding – Case A Dip Duration < Autorestart Window If the duration of the voltage dip is shorter than a time configured as ‘Autorestart Window’, the contactors will not be switched off by UMC100 -> motor keeps running © ABB Group June 22, 2016 | Slide 32

32. UMC100 Motor Protection Load Shedding – Case B Autorestart Window < Dip Duration < Max. Voltage Dip Duration If the duration of the voltage dip is longer than the ‘Auto Restart Window’, then the motor is stopped The motor will be restarted automatically after the ‘Autorestart Delay’ time © ABB Group June 22, 2016 | Slide 33

33. UMC100 Motor Control and Protection Limitation of Starts per Time © ABB Group June 22, 2016 | Slide 34 Application: Protect the motor against too many starts in a short time Limit the number of starts for a given time period Enforce a pause time between two motor starts Configurable fault / warning in case of one start left

34. UMC100 Motor Control Overview Most common motor starters are integrated as easy to parametrize control functions Direct / Reverse / Star-Delta starter Pole changing / Dahlander Actuator modes (Open / close valve control) Overload Relay Transparent mode Softstarter mode Custom Application Editor for individual control functions Support of different control stations ( DCS , Local bottons , Operation Panel ...) Support of different operation modes Remote, Local 1, Local 2 © ABB Group June 22, 2016 | Slide 35 Can I use it for single Phase motors as well?? Yes !!!!!! 

35. UMC100 Motor Control Integrated Motor Starters Motor starters Direct Starter Reversing Starter Star-Delta Starter Two-Speed Starter Others Actuator mode 1/2/3/4 Open/Close Valve Control Overload Relay Standalone application without fieldbus Transparent Mode Feeder applications Softstarter mode © ABB Group June 22, 2016 | Slide 36

36. UMC100 Motor Control Integrated Motor Starters Easy to configure – only 3 settings for overload protection Select Starter type Set nominal motor current Set tripclass Reduced engineering effort in the DCS No further programming in the device required © ABB Group June 22, 2016 | Slide 37 Example DOL

37. UMC100 Motor Control Custom Application Editor In most cases the built-in logic is flexible enough but for special requirements an individual starter application can be created This is done with the “Custom Application Editor”, which is part of the PBDTM software package Application Editor includes a library with function blocks for UMC100 inputs / outputs Logic functions Basic functions Control functions Expansion modules © ABB Group June 22, 2016 | Slide 38

38. UMC100 Motor Control Custom Application Editor 2 ways how to set up a Custom Application Logic Full flexibility Start from zero Build up logic step by step  result is an individual starter function Easy way Use the ABB standard starter and modify it as required Advantage: use of ready and tested starter functions In most cases only small modifications will be required © ABB Group June 22, 2016 | Slide 39

39. UMC100 Motor Control Custom Application Editor © ABB Group June 22, 2016 | Slide 40 Network View: All devices on the fieldbus UMC DTM

40. UMC100 Motor Control Custom Application Editor - The most basic application Basic DI represents the digital inputs of UMC100 and the multifunction options Fault Reset allows to acknowledge protection trips Direct Starter handles all the logic to start a motor in one direction (check-back supervision …) © ABB Group June 22, 2016 | Slide 41

41. UMC100 Motor Control Custom Application Editor - Full application © ABB Group June 22, 2016 | Slide 42 Drawing Area Function Block Library Tool Bar

42. Flexible definition where and when motor start/stop is allowed 4 Control Stations supported Fieldbus cyclic (I/O communication) Fieldbus acyclic ( Profibus only) Push buttons on DIs Operator Panel 3 Control modes: Local 1, Local 2, Auto Individually to configure for each mode which control station is allowed to start/stop Depending on busfault , force local 2 and the autobit one of the 3 modes is active © ABB Group June 22, 2016 | Slide 43 UMC100 Motor Control Control Stations and Modes

43. UMC100 Diagnostics General UMC100.3 provides comprehensive information via fieldbus and LCD operator panel Motor data Status Current all 3 phases Phase Voltages Active Power Power factor Thermal Load Start-up time and max. current Time to trip, Time to cool © ABB Group June 22, 2016 | Slide 44

44. UMC100 Diagnostics General Faults and Warnings Shown as text on the display Maintenance counters Operating hours of motor Number of starts Number of overload trips Energy Event memory for the last 16 events © ABB Group June 22, 2016 | Slide 45

45. UMC100 Diagnostics Control Panel UMC100-PAN D isplay with backlight Text instead of cryptically codes LEDs for status Multilanguage English, French, German, Italian Polish, Portuguese, Spanish, Russian 5 User defined displays on top menu Configurable fault texts and tag name USB port for communication to PC Up-/Download parameters Kits for mounting on the MCC front are available © ABB Group June 22, 2016 | Slide 46

46. UMC100 Diagnostics Control Panel UMC100-PAN Monitor Status I/ Os Values Current (A, %), voltage Faults and warnings U ser defined infos Operate Start Stop Fault Acknowledge Configure All parameters can be set / changed Optional Password Protection Copy parameters and / or logic © ABB Group June 22, 2016 | Slide 47 Context dependent hot-key 1 Context dependent hot-key 2 Scroll up / down buttons Start Stop USB port

47. UMC100 Hardware Digital Inputs The UMC100 has 6 digital inputs DI0 ... DI5 DI0 … DI2: Configurable Multifunction inputs Alarm / Warning / CEM11 / ... Delay time NO/NC Autoreset , Fault text DI3 ... DI5: Predefined inputs Start Forward / Reverse / Stop Jog / Inching mode NO/NC All inputs can be read by the DCS independent from their setting © ABB Group June 22, 2016 | Slide 48

48. UMC100 Hardware Digital Inputs - Multifunction Easy to configure Separate settings for function and delay time Most functions selectable as NO or NC External Fault with configuration of Individual text with 2 x 8 characters Autoreset Delay time © ABB Group June 22, 2016 | Slide 49

49. UMC100 Hardware Digital Inputs - Multifunction O ff Stop (NO/NC) Ext. Fault always (NO/NC) Ext. Fault Motor on (NO/NC) Prep. emerg. Start (NO/NC) Testposition (NC/NC) Force local 2 (NO/NC) Fault reset (NO/NC) Voltage DIP (NO/NC) CEM11 Warning always CEM11 Warning after startup CEM11 Fault always CEM11 Fault after startup Delay time configurable © ABB Group June 22, 2016 | Slide 50

50. UMC100 Hardware Digital Outputs The UMC100 has 4 digital outputs DO0 ... DO3 3 x Relay Outputs DO0 ... DO2 Switching the motor contactors Directly set by the control function in the UMC Free outputs can be controlled by the DCS or the UMC100 Customer Application 1 x 24V Transistor Output DO3 Controlled by DCS or controlled by Customer Application Logic Fault Output: DO2 or DO3 can be configured as Fault Output Configurable On / Off / or Flashing in case of fault © ABB Group June 22, 2016 | Slide 51

51. UMC100 Expansion I/O Modules DX111, DX122 8 galvanic isolated DIs 4 relay outputs 1 Analog output (0/4-20mA, 0-10V) to drive an instrument or to a DCS 2 separate roots for the relay outputs and the inputs Flexible mounting: Up to 3m distance between UMC100 and DX1xx 2 Types DX111 DIs 24 V DC DX122 DIs 110 / 230 V AC © ABB Group June 22, 2016 | Slide 52

52. UMC100 Expansion I/O Modules DX111, DX122 Usable without programming Options Disabled, Fault, or Warning Autoreset Delay Fault text Fault message displayed on the LCD Dis are always available in the DCS © ABB Group June 22, 2016 | Slide 53

53. UMC100 Expansion Voltage Modules VI150, VI155 3 voltage inputs L1, L2, L3 150 – 690 V AC 1 relay output Flexible mounting: Up to 3m distance between UMC100 and VI15x 2 Types VI150 grounded networks VI155 all networks © ABB Group June 22, 2016 | Slide 54

54. UMC100 Expansion Voltage Modules VI150, VI155 Additional features with Voltage module Motor Protection Under / Overvoltage protection Under / Overload protection Power factor (cos Phi) Voltage based phase loss / imbalance / sequence Motor Diagnostics 3 Phase voltages Powerfactor Voltage imbalance Active power Apparent power Energy THD Total harmonic distortion © ABB Group June 22, 2016 | Slide 55

55. UMC100 Expansion Analog Module AI111 3 analog inputs PT100 -50…+400 ºC -50… +70 ºC PT1000 -50…+ 400 ºC KTY83 -50...+175 °C KTY84 -40...+300 °C NTC +80...+160 °C 0... 10 V 0... 20 mA 4... 20 mA PT100/PT1000 sensors with 2 or 3-wires 2 modules AI111 can be connected to a UMC100 © ABB Group June 22, 2016 | Slide 56 NEW

56. UMC100 Expansion Analog Module AI111 Additional features with A nalog module Temperature mode Analog mode Configurable trip level, warn level, delay time Protection © ABB Group June 22, 2016 | Slide 57 (available from Q3 2015)

57. UMC100 Expansion System maximum UMC100 can be expanded with 1 Digital expansion module DX111 or DX122 1 Voltage module VI150 or VI155 2 Analog m odules AI111 The complete system has then 14 Digital inputs 8 Digital outputs 1 Thermistor input 3 Phase voltage inputs 6 Analog inputs 1 Analog output Additional features with a nalog module Temperature mode Configurable triplevel , warnlevel , delay time Protection Analog mode ölklök © ABB Group June 22, 2016 | Slide 58

58. UMC100 Communication Field busses and Networks Only one version of UMC100 for any kind of communication Communication is done by special communication interfaces Fieldbus communication interfaces can be mounted directly on the UMC100 or separate Ethernet communication interfaces are mounted separately © ABB Group June 22, 2016 | Slide 59 Nice.. This means, I can chose the communication protocol at ease!!

59. UMC100 Communication Field busses and Networks Communication Interfaces provide connection to Fieldbuses PROFIBUS DP PDP32 Device Net DNP31 Modbus RTU MRP31 Networks Ethernet Modbus TCP MTQ22 Ethernet Profinet PNQ22 Only one version of UMC100 for all fieldbuses and networks Full motor protection and control in case of a bus failure © ABB Group June 22, 2016 | Slide 60

60. UMC100 Communication Field busses and Networks Fieldbus communication interfaces can be mounted D irect on the UMC100.3 PDP32 DNP31 MRP31 Separate with SMK31 PDP32 DNP31 MRP31 Separate PDQ22 MTQ22 PNQ22 Network communication interfaces are always mounted separate Parametrization Controller Panel Software Software Bus via Panel Profibus DP x x x x DeviceNet x x x Modbus RTU x x Modbus TCP x x Profinet x x x © ABB Group June 22, 2016 | Slide 61

61. UMC100 Communication Fieldbus communication interfaces © ABB Group June 22, 2016 | Slide 62 PDP32 DNP31 MRP31 Profibus DP DeviceNet Modbus RTU

62. UMC100 Communication Fieldbus communication interfaces Fieldbus communication interfaces can be mounted in 2 ways Direct on the UMC100 Mechanically fixed Powered out of the UMC100 On a SMK31 separate in the cable chamber of an MCC Mounted on DIN-rail or with screws Powered separate with 24 V DC © ABB Group June 22, 2016 | Slide 63

63. UMC100 Communication Fieldbus communication interfaces Communication interface mounted direct on the UMC100 + Behaves like an integrated communication port (competitor solution) + simple and cheap - Droplines reduce communication performance - Address setting required when drawer is changed Communication interface mounted separate on a SMK31 + Automatic addressing when drawer is changed + Fast drawer replacement + No Droplines ensure a higher communication performance - Extra cost © ABB Group June 22, 2016 | Slide 64

64. MCC installation PDP32 in drawer Month DD, YYYY From previous node To next node + No accessories necessary - Drop lines on PROFIBUS - Address not automatically set in case of replacements Drop line per drawer

65. MCC installation PDP32 in cable chamber Month DD, YYYY From previous node To next node 24VDC supply of PROFIBUS nodes not shown To drawer backside Standard PROFIBUS cable 24 V DC Comm . interface supply CDP18 CDP24 SMK31 + PDP32 + Address stored in PDP32 + Fast replacement ( address , parameter ) + Diagnosis to DCS if drawer withdrawn

66. MCC installation PDP32 in cable chamber with DSUB-9 Month DD, YYYY From previous node To next node 24VDC supply of PROFIBUS nodes not shown To drawer backside Standard PROFIBUS connector and cable 24 V DC Comm . interface supply CDP18 CDP24 SMK31+ PDP32 + Easier wiring + Fast replacement ( address , parameter ) + Info to DCS if drawer withdrawn + Termination at each node possible

67. UMC100 Communication Separation of Busnode and Device © ABB Group June 22, 2016 | Slide 68 Application with PDQ22 in a Drawer System

68. UMC100 Communication Communication interfaces for Ethernet © ABB Group June 22, 2016 | Slide 69 MTQ22 Modbus TCP PNQ22 Profinet IO NEW

69. Up to four UMC100 connectable Support different network topologies Star Bus Redundant Ring Integrated Ethernet switch UMC100 connected via simple cables Din-rail mounting © ABB Group June 22, 2016 | Slide 70 UMC100 Communication Ethernet communication

70. UMC100 Communication Ethernet communication interfaces MTQ22 Modbus TCP UMC100, UMC22, PST , PSE selectable Up to 4 masters can be configured Master supervision with timeout Micro USB port for configuration via PC PNQ22 Profinet IO Standard integration via GSDML I ntegrated into AC800xA Time stamped events (with AC800) Sequence of events SOE © ABB Group June 22, 2016 | Slide 71

71. UMC100 Communication Ethernet – Network topologies © ABB Group June 22, 2016 | Slide 72