© ABB Group August 8, 2015 | Slide 1 UMC100-FBP Technical Presentation Helmut Schönfelder, ABB...

© ABB Group April 19, 2023 | Slide 1

UMC100-FBPTechnical Presentation

Helmut Schönfelder, ABB Stotz-Kontakt, 27.08.2012


UMC100Product Overview

UMC100Universal Motor Controller

UMC100 ATEX Universal Motor Controller

UMC100-PAN Control Panel

DX111/122 Expansion Modules Digital I/O

VI150/155 Expansion Modules Voltage


UMC100Intelligent Motor Protection & Control System

Advanced Motor Protection

Flexible Motor Control

Diagnostics and Maintenance

Communication for all major fieldbusses


UMC UsageWhere are UMCs used


UMC100How are UMCs used

0V +24V Power supply

120 / 230 VAC

M

DI2

DI4

DI5

DI3

15 16 17 18

DI114

DI013

0V

24V

10 11 12

UMC100

DOC

87 9

DOC

5 6

CbCa

3 4

DO0

DO2

DO1

DO3

T2

T1

1 2

max. 1000 VAC

MM

N

Start Stop LocalFault

PTC

FieldBusPlug

CEM11Earth Fault Sensor


UMC100 Motor ProtectionOverview

Comprehensive motor protection for 3-phase motors For motor voltages up to 1000 VAC 50 / 60 Hz

Sinus wave current no drive, no softstarter

For nominal motor currents

240 mA to 63 A without accessories

> 63 A with external current transformer

Protection against Overload according to EN/IEC 60947-4-1

tripclasses 5E, 10E, 20E, 30E, 40E

Rotor blocking

Phase loss / imbalance / sequence

Under- / Overcurrent

Under- / Overvoltage

Under- / Overload overload calculated or based on powerfactor

Hot motor Thermistor

Earth fault calculation or sensor CEM11

Too many starts per time


UMC100 Motor ProtectionOverload Protection according to IEC60947-4-1

Protection based on calculated advanced thermal model

Current value

Thermal load value

Time to trip

Time to cool

Cooling after overload based on

Time or

Thermal load

Thermal overload pre-warning

Five trip classes:5E, 10E, 20E, 30E, 40E

Time

Current

Motor overload protection

Class 40EClass 30EClass 20EClass 10EClass 5E


UMC100 Motor ProtectionLocked Rotor / Long Start Protection

Active during start-up

Extra fast protection when rotor locked

Reduces stress and protection on transmissions

Current level and delay timeto be set individually

start-up running

BlockingCurrent

DelayTime

MotorCurrent


UMC100 Motor ProtectionHigh / 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 underload situations

E.g. detect a broken belt or a dry pump

Secure the process

Separate trip and warn threshold,each with individual delay timeCurrent levels and delay times

to be set individually

start-up running

Trip Level

Warn Level

Warn Level

Trip Level

MotorCurrent


To avoid accidentsand damages

UMC100 Motor ProtectionPhase Monitoring

Phase loss

Avoid overheating of motor

Phase Imbalance

Detection of imbalanced currents due to voltage variations or motor problems etc.

Warning and trip threshold separately adjustable

Phase Sequence

Prevent wrong rotation – crusher, conveyor..

Important for mobile units

Faults are detectedafter starting the motor

L1,L2 & L3L1,L3 & L2

L1/2/3


UMC100 Motor ProtectionWith additional Voltage Module

With an additional Voltage Expansion Module VI 150 or VI155 UMC100 offers some more 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


Without Voltage module:

Phase faults can only be detected basedon current during motor operation

With Voltage Module:

Detect problems early –before starting the motor

Protection against

Phase loss

Phase imbalance

Phase sequence

Check for phase faults before starting the motor

UMC100 Motor Protection with Voltage ModulePhase Monitoring


Recommended derating curve by NEMA.

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 benoisier in their operation

Available Functions

Overvoltage

Undervoltage

Voltage phase loss and imbalance

Harmonic distortion (THD)

Different warn - and trip levels

Balanced unbalanced

Protection of motor and equipment

UMC100 Motor Protection with Voltage ModulePhase Monitoring


UMC100 Motor ProtectionPTC/Thermistor High Temperature Protection

For motors with integratedPTC elements

Detects obstructed cooling

Motors located in high temp areascan be exposed to high ambient temperatures

Can not be detected by an EOL

Cable short circuit and break detection

Fault or warning configurable


Protection against earth fault due to damaged cable isolation etc.

4 different 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 also with higher impedance to ground

also small ground fault currents can be detected

L1 L2 L3

24VDC

Protection of motorand equipment

UMC100 Motor ProtectionEarth Fault Protection with CEM11


L1 L2 L3

Protection of motorand equipment

UMC100 Motor ProtectionEarth 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


UMC100 Motor ProtectionCheckback Supervision

Check 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


UMC100 Motor ProtectionLoad 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


UMC100 Motor Control and ProtectionLimitation of Starts per Time

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


UMC100 Motor ControlOverview

Most common motor starters are integrated aseasy to parametrize control functions

Direct / Reverse / Star-Delta starter

Pole changing / Dahlander

Actuator mode (Open / close valve control)

Overload Relay

Transparent mode for feeders

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


UMC100 Motor ControlIntegrated Motor Starters

Motor starters

Direct Starter

Reversing Starter

Star-Delta Starter

Two-Speed Starter

Others

Different Actuators Open/Close Valve Control

Overload Relay Standalone applicationwithout fieldbus

Transparent Mode Feeder applications


UMC100 Motor ControlIntegrated Motor Starters

Easy to configure – only 3 settings for overload protection

1. Select Starter type

2. Set nominal motor current

3. Set tripclass

Reduced engineering effort in the DCS

No further programming in the device required

Example DOL


UMC100 Motor ControlCustom 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



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



Network View:All devices onthe fieldbus

UMC DTM


UMC100 Motor ControlCustom 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 …)


UMC100 Motor ControlCustom Application Editor - Full application

Drawing Area

Function BlockLibrary

Tool Bar


UMC100 Motor ControlHardware - Digital Inputs

Six digital inputs DI0 ... DI5

DI0 ... DI2: Configurable Multifunction inputs

Alarm / Warning / ...

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 fromtheir setting


UMC100 Motor ControlHardware - Multifunction Inputs

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


UMC100 Motor ControlHardware - Multifunction Inputs

Off

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


UMC100 Motor ControlHardware - Digital Outputs

3 x Relay Outputs DO0 ... DO2 Switching the motor contactors

Directly controlled by the control function in the UMC

Free outputs can be controlled by the DCSor the UMC100 Customer Application

DO2 can be configured as fault output

1 x 24V Transistor Output DO3 Configurable as fault output

or controlled by DCS

or controlled by Customer Application Logic

Fault Output: Configurable On / Off / Flashing in case of fault


UMC100 Motor ControlControl Stations

Flexible definition where and when motor start/stop is allowed

4 Control Stations

Fieldbus (cyclic, acyclic)

Push buttons on DIs

LCD Operator Panel

3 modes: Local 1, Local 2, Auto

Individually to configure for each modewhich control station is allowed to start/stop

Depending on busfault, force local 2 and the autobit one of the 3 modes is active


UMC100 Motor ControlFault Reset

Fault reset via Bus, LCD Panel or Digital Input

Manual reset of protection faults

Manual or automatic fault reset of faults coming from the multifunction inputs or inputs of the digital IO module


UMC100 Motor Control Expansion Modules I/O DX111, DX122

8 galvanic isolated DIs

4 relay outputs

1 Analog output (0/4-20mA, 0-10V)to drive current meter or to a DCS

2 separate roots for the relay outputs and the DI

Flexible mounting:Up to 3m distance between UMC100 and DX1xx

2 Types

DX111 DIs 24 V DC

DX122 DIs 110 / 230 V AC


UMC100 Motor Control Using the Digital I/O Expansion

Usable without programming

Options

Disabled, Fault, or Warning

Autoreset

Delay

Fault text

Fault message displayed on the LCD

DI always available in the DCS


UMC100 Motor Control Expansion Modules Voltage 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 grounded networksungrounded netw.altitudes >2000 m

For use with UMC100 R0101


UMC100 Motor ControlExpansion Modules Voltage VI150, VI155

Additional features with Voltage module Protection

Under / Overvoltage protection

Under / Overload protection

Power factor (cos Phi)

Voltage based phase loss / imbalance / sequence

Diagnostics 3 Phase voltages

Powerfactor

Voltage imbalance

Active power

Apparent power

Energy

THD Total harmonic distortion


UMC100 DiagnosticsGeneral

Comprehensive information via fieldbus and LCD operator panel

Motor data

Status

Current

3 Phase Voltages

Active Power

Powerfactor

Thermal Load

Start-up time and max. current

Time to trip, Time to cool


UMC100 DiagnosticsGeneral

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


UMC100 DiagnosticsControl Panel UMC100-PAN

Monitor DIO

Current (A, %)

Alarms

Display user defined values

Operate Start

Stop

Fault Acknowledge

Configure All parameters can be set

Optional Password Protection

Copy parameters and / or logic

Contextdependenthot-key 1

Contextdependenthot-key 2

Scroll up-and downbuttons

StartStop


UMC100 DiagnosticsControl Panel UMC100-PAN

Graphical display

Shows up to 4 lines

Text instead of cryptical codes

Backlight

Multilanguage

English, French, German

Italian, Portuguese, Spanish, Russian

5 User defined displays on top menue

Customer defined fault texts

2 x 8 characters

Customer defined tag name


UMC100 DiagnosticsControl Panel - Top Level Menu

… …


UMC100 Diagnostics Control Panel – Operation Mode

From any top level menu via left soft-key Direction: For/FFor/Rev/FRev

(depending on control function) Key-Up/Down changes the direction

selection Dedicated keys for Start / Stop Icons in the bottom line show current

output status Rem / Loc is shown in the bottom line

depending on mode Option: password protection


UMC100 DiagnosticsControl Panel – Set Parameters

Press the right context menu button to enter the parameter menus

From there you can enter the different submenus

Submenues can contain further sub-menus

At the end one ore more parameters can be adjusted


UMC100 Diagnostics Control Panel - Acknowledge Faults

In the event of an error the left hotkeycan be used to enter the error menu

Errors are shown there

Errors can be acknowledged there


UMC100 Communication Fieldbuses and Networks

UMC100 can be connected via FieldBusPlug to

Modbus TCP new

PROFIBUS DP

DeviceNet

Modbus RTU

CANopen

Only one version of UMC100 for all fieldbuses and networks

Full motor protection and control in case of a bus failure

Fieldbus interface and UMC can be mounted separately - perfect for withdrawable MCC applications

Parameterization via device description files (GSD, EDS) or Operator Panel or PC Configuration Tool


UMC100 Communication Fieldbuses and Networks

Example with PROFIBUS

Support of all relevant fieldbusses and networks

PROFIBUS DP V0/V1 PDP22, PDQ22

Modbus RTU MRP21

Ethernet Modbus TCP MTQ22 new

DeviceNet DNP21

CANopen COP21


UMC100 Communication Separation of Busnode and Device

FBP InterfaceCable

LCD Control Panela) Drawer mountedb) or remote mounting

UMC100

Panel ExtensionCable

Fits in very space limited installations!



Application with FBPin a Drawer System



Robust solution to connect fieldbus with motor controller inside a drawer: No trunklines!

Busnode stays alive while drawer gets exchanged All required accessories available: control panel extension,

inside and outside passive cable and fixing bracket



Application with PDQ22in a Drawer System


UMC100 CommunicationEthernet – Modbus TCP with MTQ22 new

Ethernet connectivity forup to four UMC100

Modbus TCP protocol

Supports differentnetwork topologies

Star

Bus

Ring with redundancy

Easy to use

Easy to setup

No special Ethernet connectorsrequried in MCCs

UMC100 Communication Ethernet – Network topologies new


The ring topology offers cable redundancy on Ethernet side

A managed switch supporting MRP and acting as MRP manager must be used in this case

The implemented media redundancy protocol (MRP) is according to EN/IEC 62439-2

© ABBMarch 2012 | Slide 57

UMC100 Communication Ethernet – Redundant ring topology new

In ring or line setup the devices arenot reachable if just two drawersare withdrawn

Complex and expensive Ethernet connectors are required to short-cut Ethernet lines when drawers are withdrawn to overcome the above mentioned problem

Problems with long timeouts canoccure because of missing devices

General problem: 10/100MBit communication inside a drawer

UMC100 Communication Ethernet – Competitor’s solution new


UMC100 Communication Ethernet – Solution with MTQ22 new


Other UMCs / MTQs are always reachable

If drawer withdrawn

If MTQ not reachable becauseof a cable break

No special Ethernet connectorsfor drawers needed

No need to link 100MBit into drawers

UMC100 CommunicationEthernet – Modbus TCP with MTQ22

To drawer4x

2x

Network – SwitchSupply for switch,MTQ22

Network – SwitchSupply for switch,MTQ22

For a ring goback to switchFor a ring goback to switch

24 V DC

MTQ22 Supply

To next MTQ22

To drawers

To switch

Simple connection fromMTQ22 to drawers

Ready made cables available

Or make own cables

Terminal blocks available separately


UMC100 Communication Ethernet – Modbus TCP with MTQ22 new

Advantages

Multimaster functionality – up to 4 masters supported

Supports MRP protocol EN/IEC 62439-2 for redundancy

No Ethernet inside a drawer – no need to bring in 100 Mbit/s

Simple connection between MTQ22 and UMC100 –No special Ethernet connectors required

Redundancy even works with several drawers taken out

All types of UMCs are supported – easy system upgrade

Micro USB port for configuration via PC



Fast installation through ready made cables

CDP18, CDP19

No issues in withdrawable systems

Ethernet not inside the drawer!

No special Ethernet connectors required when using in a MCC

UMC100 Communication Ethernet – MTQ22 and withdrawable solution


Fast installation

Communication via ready made cable

CDP17

No special Ethernet connectors required

UMC100 Communication Ethernet – MTQ22 and fixed setup


PC tool for configuration

Standard Micro USB interface

Online / Offline

UMC100 Communication Ethernet – MTQ22 setup


UMC100 Communication Monitoring Data: UMC100 -> Control System


UMC100 Communication Command Data: Control System -> UMC100


UMC100 Communication Diagnosis Data: UMC100 -> Control System


UMC100 CommunicationEngineering Workflow

Configure UMC100 with

LCD Panel

GSD, EDS

HWD

DTM

No Programming

Customer Requirements

Predefined logicsufficient 80% / 20%

Predefined logicnot sufficient

Change control logic with function block editor

Download / test application

Change function block parameters and protection parameters simply via configuration (like left side)


UMC100 CommunicationConfiguration via Device Description Files (GSD, EDS)

Table based configuration within the control system. Download of parameters during bus start / engineering time.

Custom applications can’t be changed

PROFIBUS:

Separate GSD files for PDP22 and PDQ22

CANopen / DeviceNet

EDS files for each bus

Latest GSD and EDS files are always available on the internet side

PROFIBUS Example


UMC100 CommunicationConfiguration via Device Type Manager (DTM)

Very comfortable way to configure all parameters and functions of the UMC

Explanation of parameters through images …

Custom applications can be created and downloaded into the UMC100

Offline engineering of devices and whole bus lines

Online monitoring and diagnosis on PROFIBUS

Same tool and PC communication adapter as used by ABB Instrumentation


UMC100 Communication Configuration via PC-Adapters

Using the open FDT/DTM standard

Point to point connection via UTF21

Profibus connectionvia UTP22


UMC100 Product Assortment

UMC100-FBP Universal Motor Controller

UMC100-FBP Universal Motor Controller ATEX

DX111 I/O Expansion module Inputs 24 V DC

DX122 I/O Expansion module Inputs 110 / 230 V AC

VI150 Voltage Expansion module Grounded networks

VI155 Voltage Expansion module Un-/Grounded networks

UMC100-PAN Operating panel

UMCIO Cable UMC100 – expansion module

IOIO Cable expansion module – exp. module

PBDTM DTM software packageIncludes the Custom Application Logic Editor


UMC100 Product AssortmentEthernet communication new

MTQ22-FBP.0 Ethernet Modbus TCP Interface

CDP17-FBP.150 Cable MTQ22 – UMC100 Length 1,5 m

CDP18-FBP.150 Cable MTQ22 – drawer outside Length 1,5 m

CDP19-FBP.100 Cable UMC100 – drawer inside Length 1 m

CDP11-FBP.0 Passive cable fixing bracket 50 pcs

CDP11-FBP.4 Passive cable fixing bracket 4 pcs

ETHTB-FBP.4 Terminal blocks 4 pcs

ETHTB-FBP.50 Terminal blocks 50 pcs


UMC100Summary

UMC100 integrates

Advanced Motor Protection

Flexible Motor Control

Diagnostics and Maintenance Data

Fieldbus Communication for all major busses

Perfect solution for Motor Control Centers

Can be adapted to almost all customer requirements

Built-in logic -> just configure

Customer specific logic -> logic editor

Powerful LCD panel for monitoring, parameterization and control

© ABB Group August 8, 2015 | Slide 1 UMC100-FBP Technical Presentation Helmut Schönfelder, ABB...

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Transcript of © ABB Group August 8, 2015 | Slide 1 UMC100-FBP Technical Presentation Helmut Schönfelder, ABB...