Helmut Schoenfelder, ABB Stotz-Kontakt, 31.03.2015 …

UMC100.3Technical Presentation

Helmut Schoenfelder, ABB Stotz-Kontakt, 31.03.2015

© ABB Stotz-KontaktMay 18, 2015 | Slide 1

Protection Functions• overload• short circuit• phase failure

Devices• Manual Motor Starters• Thermal & Electronic Overload

Relays• Contactors• Fuses

ABB Solutions for Motor FeedersStandard

Add. Protection Functions• Motor / Bearing Temperature

Level Supervision• Voltage / Current Level

Supervison• Ground Fault Detection• Imbalance• Phase sequence• …

Supportive devices:

Power supplies

Current transformers

Timers

- …

Remote IO

Temperature Monitoring

Ground Fault-Detection

Current / Voltage Monitoring

Analog signal converters

InterfaceRelays

Control System

PTC / PT100 / PT1000

Warning & Error SignalsCommands

R<

ABB Solutions for Motor FeedersAdvanced

Integrated solution• Motor Control• Motor Protection• Motor Diagnosis• Communication

Control System

Local IO signalsPTCGF Sensor

Ethernet

VoltageControl

ABB Solutions for Motor FeedersHigh Performance

UMC100.3Intelligent Motor Protection & Control System

Advanced Motor Protection

Flexible Motor Control

Diagnostics and Maintenance

Communication for all major fieldbusses and networks

© ABB Group May 18, 2015 | Slide 5

UMC UsageWhere are UMCs used


UMC UsageWhere are UMCs used


Pulp & paper

Minerals & mining incl. cement plants

Oil & gas

Refineries

Platforms

Ships

Steel plants

Power stations

Fresh & waste water

Worldwide projects and experience

Projects with several thousand UMCs

UMC UsageWhy are UMCs used


To avoid any sudden and unexpected motor stopby 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

by using spare drawers

This is the reason why customers invest more and use intelligent motor controllers

UMC100.3 The systemOverview

Universal Motor ControllerUMC100.3 DC 24 V DC

UMC100.3 UC 110 … 240 V AC/DC

UMC100.3 DC EX 24 V DC ATEX

UMC100.3 UC EX 110 … 240 V AC/DC ATEX

Control PanelUMC100-PAN


UMC100.3 SystemOverview

Supply 24 V DC Supply 110 … 240 V AC / DCUMC100.3 UC provides 24 V DC supply for expansion modules and inputs


UMC100.3 DC UMC100.3 UC


Expansion ModulesDigital DX111

DX122

Voltage VI150

VI155

Analog AI111



Communication InterfacesFieldbus

Profibus DP PDP32

DeviceNet DNP31

Modbus RTU MRP31

NetworkEthernet Modbus TCP MTQ22

Ethernet Profinet IO PNQ22


UMC100.3 The systemAdvantages

UMC100.3 is a modular system for motor protection and control

Very compact solution due to the integrated measuring system

Only one single device independent of motor size, functionality and communication

Easy to expand for more functionality

Flexible communication due to separate communication interfaces


UMC100.3 How are UMCs used


Powersupply

120 / 230 V AC

M

X5

DI2

DI4

DI5

DI3

X5 X5 X5 X5

DI1

X5

DI0

X5

V V

X5

UMC100.3

T1X8X7 X8

DO2

X6 X7DO1

DO0

X6 X6T2 CbCa

DO3

DOC

DOC

X6 X6

max. 1000 V AC

MM

N

Start StopLocal

Fault

PTC

CEM11Earth Fault Sensor

0V +24 V

UMC100.3 Motor ProtectionOverview

Comprehensive motor protection for 3- and single phase motors

Motor 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


UMC100.3 Motor ProtectionProtection functions overview

Basic motor protectionOverload 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 With sensor CEM11 or by calculation

Too many starts per time

Advanced motor protection – with expansion moduleUnder- / Overvoltage

Phase loss / imbalance / sequence voltage based

Underload / Overload

Powerfactor

Hot motor RTD


UMC100.3 Motor ControlOverview

Most common motor starters are integrated aseasy 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 modesRemote, Local 1, Local 2


UMC100.3 Motor ControlIntegrated Motor Starters

Motor startersDirect Starter

Reversing Starter

Star-Delta Starter

Two-Speed Starter

OthersActuator mode 1/2/3/4 Open/Close Valve Control

Overload Relay Standalone applicationwithout fieldbus

Transparent Mode Feeder applications

Softstarter mode




Example DOL



Example Softstarter mode

UMC100.3 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 UMC100.3 inputs / outputs

Logic functions

Basic functions

Control functions

Expansion modules



2 ways how to set up a Custom Application Logic

Full flexibilityStart from zero

Build up logic step by step

result will be an individual starter function

Easy wayUse 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

UMC100.33 Motor ControlCustom Application Editor - The most basic application

Basic DI represents the digital inputs of UMC100.3 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 …)


UMC100.3 Motor ControlCustom Application Editor - Full application


Drawing Area

Function BlockLibrary

Tool Bar

Flexible definition where and when motor start/stop is allowed

4 Control Stations supportedFieldbus 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 modewhich control station is allowed to start/stop

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


UMC100.3 Motor ControlControl Stations and Modes

UMC100.3 DiagnosticsGeneral

UMC100.3 provides comprehensive information via fieldbus and LCD operator panel

Motor data

Status

3 Phase currents

3 Phase Voltages

Temperatures

Active Power

Powerfactor

Thermal Load

Start-up time and max. current

Time to trip, Time to cool


UMC100.3 DiagnosticsGeneral

Faults and WarningsShown as text on the display

Maintenance countersOperating hours of motor

Stand-still hours of motor

Number of starts

Number of overload trips

Energy

Event memory for the last 16 events


UMC100.3 DiagnosticsControl Panel UMC100-PAN

Graphical display with backlightText instead of cryptical codes

LEDs for status

MultilanguageEnglish, French, German, Italian

Polish, Portuguese, Spanish, Russian

5 User defined displays on top menue

Configurable fault texts and tag name

USB port for communication to PC with DTM software

Up-/Download parameters

Kits for mounting on the MCC front are available


UMC100.3 DiagnosticsControl Panel UMC100-PAN

MonitorStatus I/Os

Values Current (A, %), voltage

Faults and warnings

User defined infos

OperateStart

Stop

Fault Acknowledge

ConfigureAll parameters can be set / changed

Optional Password Protection

Copy parameters and / or logic


Contextdependenthot-key 1

Contextdependenthot-key 2

Scroll up / downbuttons

StartStopUSB port

UMC100.3 HardwareDigital Inputs

The UMC100.3 has 6 digital inputs DI0 ... DI5

DI0 … DI2: Configurable Multifunction inputsAlarm / Warning / CEM11 / ...

Delay time

NO/NC

Autoreset, Fault text

DI3 ... DI5: Predefined inputsStart Forward / Reverse / Stop

Jog / Inching mode

NO/NC

All inputs can be read by the DCS independent fromtheir setting


UMC100.3 HardwareDigital Inputs - Multifunction

Easy to configureSeparate settings for function and delay timeMost functions selectable as NO or NCExternal Fault with configuration of

Individual text with 2 x 8 charactersAutoresetDelay time


UMC100.3 HardwareDigital Inputs - Multifunction

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


UMC100.3 HardwareDigital Outputs

The UMC100.3 has 4 digital outputs DO0 ... DO3

3 x Relay Outputs DO0 ... DO2Switching the motor contactors

Directly set by the control function in the UMC

Free outputs can be controlled by the DCSor the UMC100.3 Customer Application

1 x 24V Transistor Output DO3Controlled 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


UMC100.3 ExpansionI/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 UMC100.3 and DX1xx

2 TypesDX111 DIs 24 V DC

DX122 DIs 110 / 230 V AC


UMC100.3 ExpansionI/O Modules DX111, DX122

Usable without programming

OptionsDisabled, Fault, or Warning

Autoreset

Delay

Fault text

Fault message displayed on the LCD

Dis are always available inthe DCS


UMC100.3 ExpansionVoltage Modules VI150, VI155

3 voltage inputs L1, L2, L3

150 – 690 V AC

1 relay output

Flexible mounting:Up to 3m distance between UMC100.3 and VI15x

2 Types

VI150 grounded networks

VI155 all networks


UMC100.3 ExpansionVoltage Modules VI150, VI155

Additional features with Voltage moduleMotor Protection

Under / Overvoltage protection

Under / Overload protection

Power factor (cos Phi)

Voltage based phase loss / imbalance / sequence

Motor Diagnostics3 Phase voltages

Powerfactor

Voltage imbalance

Active power

Apparent power

Energy

THD Total harmonic distortion


UMC100.3 ExpansionAnalog Module AI111

3 analog inputsPT100 -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 UMC100.3


No pictures available yet

The module will be available later in 2015

UMC100.3 ExpansionAnalog Module AI111

Additional features with analog moduleTemperature mode

Same sensor / signal type for all 3 inputs

Settings are for all 3 sensor types the same

Configurable triplevel, warnlevel, delay time

Universal mode

Selectable sensor / signal type for each input

Fault / warn levels are configured by function blocks

Configurable trip / warning per input


UMC100.3 ExpansionSystem limits

UMC100.3 can be expanded with

1 Digital expansion module DX111 or DX122

1 Voltage module VI150 or VI155

2 Analog modules AI111

The complete system has then

14 Digital inputs

9 Digital outputs

1 Thermistor input

3 Phase voltage inputs

6 Analog inputs

1 Analog output


UMC100.3 CommunicationFieldbuses and Networks

Only one version of UMC100.3 for any kind of communication

Communication is done by special communication interfaces

Fieldbus communication interfaces can be mounteddirectly on the UMC100.3 or separate

Ethernet communication interfaces are mounted separately



Communication Interfaces provide connection to

FieldbusesPROFIBUS DP PDP32 PDQ22

DeviceNet DNP31

Modbus RTU MRP31

NetworksEthernet Modbus TCP MTQ22

Ethernet Profinet PNQ22

Only one version of UMC100.3 for all fieldbuses and networks

Full motor protection and control in case of a bus failure



Fieldbus communication interfaces can be mountedDirect on the UMC100.3 PDP32 DNP31 MRP31

Separate with SMK31 PDP32 DNP31 MRP31

Separate PDQ22 MTQ22 PNQ22

Network communication interfaces are alwaysmounted separate

ParametrizationController 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


UMC100.3 CommunicationFieldbus communication interfaces


PDP32 DNP31 MRP31

Profibus DP DeviceNet Modbus RTU


Fieldbus communication interfacescan be mounted in 2 ways

Direct on the UMC100.3Mechanically fixed

Powered out of the UMC100.3

On a SMK3 separate in thecable chamber of an MCC

Mounted on DIN-rail or with screws

Powered separate with 24 V DC

Similar to former CDP12 solution



Communication interface mounted direct on the UMC100.3+ 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 SMK3+ Automatic addressing when drawer is changed

+ Fast drawer replacement

+ No Droplines ensure a higher communication performance

- Extra cost


MCC installationPDP32 in drawer

Month DD, YYYY

From previousnode

Tonextnode

+ No accessories necessary- Drop lines on PROFIBUS- Address not automatically set

in case of replacements

Drop lineperdrawer

MCC installationPDP32 in cable chamber

Month DD, YYYY

From previousnode

Tonextnode

24VDC supplyof PROFIBUSnodes not shown

To drawerbackside

StandardPROFIBUScable

24 V DC Comm. interface supply

CDP18

CDP24

SMK3 +PDP32

+ Address stored in PDP32+ Fast replacement (address, parameter)+ Diagnosis to DCS if drawer withdrawn

MCC installationPDP32 in cable chamber with DSUB-9

Month DD, YYYY

From previousnode

Tonextnode

24VDC supplyof PROFIBUSnodes not shown

To drawerbackside

StandardPROFIBUSconnectorand cable

24 V DC Comm.interface supply

CDP18

CDP24

SMK3+PDP32

+ Easier wiring+ Fast replacement (address, parameter)+ Info to DCS if drawer withdrawn+ Termination at each node possible

UMC100.3 CommunicationSeparation of Busnode and Device


Application with PDQ22in a Drawer System

UMC100.3 CommunicationCommunication interfaces for Ethernet


MTQ22 Modbus TCP PNQ22 Profinet IO

Up to four UMC100.3 connectable

Support different network topologiesStar

Bus

Redundant Ring

Integrated Ethernet switch

UMC100.3 connected via simple cables

Din-rail mounting


UMC100.3 CommunicationEthernet communication

UMC100.3 CommunicationEthernet communication interfaces

MTQ22 Modbus TCPUMC100, UMC22, PST, PSE selectable

Up to 4 masters can be configured

Master supervision with timeout

Micro USB port for configuration via PC

PNQ22 Profinet IOStandard integration via GSDML

Integrated into AC800xA

Time stamped events (with AC800)

Sequence of events SOE


UMC100.3 CommunicationEthernet – Network topologies


UMC100.3 CommunicationEthernet – Redundant ring topology

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 56

UMC100.3 CommunicationEthernet – Competitor’s solution

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


UMC100.3 CommunicationEthernet – ABB Solution

Other Ethernet interfaces andUMC100.3 are always reachable

If drawer withdrawn

If an interface is not reachablebecause of a cable break

No special Ethernet connectorsfor drawers needed

No need to link 100MBit into drawers


UMC100.3 CommunicationEthernet application

Simple connection fromEthernet interface to drawers

Ready made cables available

Or make own cables

Terminal blocks available separately


Network – SwitchSupply for switch,MTQ22 / PNQ22

For a ring goback to switch

24 V DC Supply

To next MTQ22 / PNQ22

To drawers

From switch

UMC100.3 CommunicationEthernet – Withdrawable solution


Fast installation through ready made cables CDP18

No issues in withdrawable systemsEthernet not inside the drawer!

No special Ethernet connectors required when using in a MCC

UMC100.3 CommunicationEthernet – Fix solution


Fast installation

Communication via ready made cable CDP23

No special Ethernet connectors required

UMC100.3 CommunicationEthernet – MTQ22 setup


PC tool for configuration

Standard Micro USB interface

Online / Offline

UMC100.3 CommunicationMonitoring Data: UMC100.3 -> Control System


UMC100.3 CommunicationCommand Data: Control System -> UMC100.3


UMC100.3 CommunicationDiagnosis Data: UMC100.3 -> Control System


UMC100.3 CommissioningEngineering Workflow


Configure UMC100.3 withLCD Panel

GSD, EDS, GSDML

HWD

DTM

No Programming

Customer Requirements

Predefined logicsufficient 80% / 20% Programming

required

Change control logic with function block editor

Download / test application

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

UMC100.3 CommissioningVia Device Description Files (GSD, EDS, GSDML)

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

Custom applications can’t be changed

Configuration from the controller

PROFIBUS GSD

DeviceNet EDS

Profinet GSDML

Latest device desription files arealways available on the internet side


PROFIBUS Example

UMC100.3 CommissioningConfiguration 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


UMC100.3 CommunicationConfiguration via PC

Using the open FDT/DTM standard

Point to point connection via UTF21

Profibus connectionvia UTP22


UMC100.3Summary

UMC100.3 integratesAdvanced Motor Protection

Flexible Motor Control

Diagnostics and Maintenance Data

Communication for fieldbusses and networks

Perfect solution for Motor Control Centers

Can be adapted to almost all customer requirementsBuilt-in logic -> just configure

Customer specific logic -> logic editor

Powerful LCD panel for monitoring, parameterization and control

Expansion modules for flexible I/O handling


Helmut Schoenfelder, ABB Stotz-Kontakt, 31.03.2015 …

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Transcript of Helmut Schoenfelder, ABB Stotz-Kontakt, 31.03.2015 …