MCC Panel Design

7/25/2019 MCC Panel Design

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Improving Motor Reliability with Intelligent Motor Control

Centers and theTesys-T

Presenters Name: Wayne Thygesen, Consulting Engineering SpecialistDecember 3, 2008


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Make the most of your

energy

Make the most of

your energySM

Add photo in this area

Improving Motor Reliability with

Intelligent MCCs and the TeSys-T


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3- Water Wastewater Competency Center Wayne Thygesen 3 December 2008Schneider Electric

Schneider Electric

Intelligent MCC

2008


4/554- Water Wastewater Competency Center Wayne Thygesen 3 December 2008Schneider Electric

TeSys T is theBasic Tool

Used for iMCC



MODBUS

Native protocol

connectivity

Native protocol

connectivity

Ethernet TCP/IP

TeSys T System Components

Ground CTGround Fault

Sensitivity

Ground Fault

Sensitivity

XX X

Controller expansion module Additionalprotection

functions

Additionalprotection

functions

External CT For up to 810AFor up to 810A

Control Unit

OperatorMagelis terminal PC with

PowerSuite

or

Remote controland monitoring

Remote control

and monitoring

or



TeSys T Motor Management Controller and Control Unit Operator

Modbus is native in the TeSys T relay plus additionalcommunication options are available

Currently designed into Model 6 iMCC

TeSys T Motor Management System



Motor Managment Controller : LTMR

Front view description

PowerSupply

6 Discrete inputs

(internal powered inputs)1 Fault relayoutput (NO/NC)

3 relaysoutputs 5A

Groundfault

input

Temp.

Probe

Networkconnection

(screw terminal)

Networkconnection(RJ45 port)

Expansion module/HMI/PC connection

(modbus RS485)Reset orSelf testButton

Plug-in terminals

Diagnostic Leds



Expansion module

Additional Motor Protection

Over / Under Voltage Over / Under Power Factor

Over / Under Power

Load shedding

Voltage phase imbalance,lost and reversal

Additional Input

4 discrete inputs

Power Supply

Powered by Controller

Assembling

Side by side or

Remote

Input Power supply

24 VDC or

100-240 VAC 50/60Hz


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TeSys T Measurements

0 to 6500 OhmsMotor temperature sensor

Measured range

0 to 830 VACLine to line voltage

0 to 400,000 KWhr / KVarhrActive/Reactive Energy

0 to 100Power factor (1)

0 to 100 HzFrequency

0 to 200 %Line voltage imbalance0 to 6553.5 KW / KVarActive / Reactive Power

Controller

0 to 200 %Current phase imbalance0,4 to 810 AAverage current

Internal : 0 to FLC

External : depend on settings

Ground current

0,4 to 810 ALine currents

Controller

& Exp.

module

Functions

0 to 200 %Thermal capacity

(1) : Value saved on power loss

Current

Voltage

Power

Depending on the controller configuration


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TeSys T Motor Protection functions

Voltage phase (imbalance, loss, reversal)

Under/Over Power factor

Under/Over Power

Rapid cycle lockout

Under/Over Voltage

Voltage load shedding

Controller

Motor temperature sensor

Ground current

Long start, Jam

Under/Over Current

Current phase (imbalance, loss, reversal)

Thermal overload (inverse & definite time)

Controller &

expansion

module

Functions

Note :All the protection functions include fault detection and most protection functions include warning detection

Current

Voltage

Power

Depending on the controller configuration


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Tesys T records thefaults statistics forthe analysis of the

system maintenance

Monitoring : Statistics

Counting log for every kind of faultsProtection faults : overload, overcurrent,

Diagnostics faults : HMI port com loss, internal

fault,

Recording the motor control historyMotor starts count and operating time

Motor starts per hour

Rapid cycle lockout count

Load shedding count

Last start record


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Monitoring : Statistics

Recording the last 5 faults Fault code

Date and time

Value of parameters & measurements


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Tesys T recordsfaults which affectthe ability of the

controller to workproperly

Monitoring : Diagnostic faults

Internal faultsWatchdog : stack over/underflow

Temperature

Control command checksStart /stop command (current checking after the command)

Run /stop check back (current checking during the stage)

Connection fault

Current Transformer connection

Voltage connection

Temperature sensor connection

Communication loss Local terminal connection

Communication loss : HMI, Network, expansion module


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Monitoring : Motor states

Tesys T records themotor states for the

analysis of thedevice operation

Operating statesReady

Start

Run

Not ready

Thermal overload status

Time to trip (before the fault occurs)

Time to reset (after a thermal overload occurs)


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Control functionsMotor control Overview

Control Modesdetermines the device or devices that will command controlleroutputs :

Local mode : Local terminal or Local HMI

Remote mode : PLC or DCS connected to the network

Operating Modesdetermines the behavior of the controllers inputs and outputs (5predefined modes and 1 custom mode) :

Overload, Independant, Reverser, Two-Step, Two-Speed

Custom : user customize the logical operation for the output command

Operating StatesThe controller provides control, monitoring and protection functionsappropriate to each of the motors operating states :

Ready, start, run and fault (not ready)

Fault Managementdetermines how the controller manages faults :

Manual, Automatic and Remote reset


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Operating modes

Pre-configured operating mode Overload : The Start/Stop of the motor is realized by a mechanism other

than the controller

Independant : Direct on line full voltage non reversing motor starting

Reverser : Direct on line full voltage reversing motor starting

Two-Step : Reduced voltage starting motor

Two-Speed : Two-Speed motor for motor types : Dahlander, Pole

Changer

Note : The selected operating mode determine the behavior of all

controller inputs and outputs.

Note : The selected operating mode determine the behavior of all

controller inputs and outputs.

Custom operating mode

PowerSuite logic editor : provides logic functions (Boolean, Register,

Timers, Counter,) that manage the controller behavoir to create a user

mode


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Custom operating mode

PowerSuite logic editor : 2 languages

Function Block

Diagram

Function Block

Diagram

List

Language

List

Language

Possibility to use an

existing logic file to modify

the logic command that

manage controller

behavior

Possibility to use an

existing logic file to modify

the logic command thatmanage controller

behavior


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Current Rating (internal CT)

0.4 to 8 A

1.35 to 27 A

5 to 100 A

Motor Management Controller : LTMR

Control Power supply

24 VDC or

100-240 VAC 50/60Hz

Operating mode

Overload

Independant

Reverser Two-Step

Two-Speed

Custom Mode

Motor Protection

Thermal Overload

Over/Under current

Long Start / Jam

Ground current

Motor temperature sensor

Inputs & Ouputs 6 discrete inputs

4 relay outputs

Ground fault input

Temperature sensor

Network Communication

Modbus

CANOpen

Profibus DP

DeviceNet

Ethernet (MB + TeSys Port)

LTMR...BD/FM

Overview

i d l


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Expansion Module : LTMEV

Front view description3 Phase inputs Voltage

(0 to 690 VAC)

Controller

RJ45 port

HMI/PC

connection

4 discrete inputs

(external powered inputs)

Expansion modulepowered by the

controller

Status indication

LEDs


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Operator Terminal: Magelis XBTN410

Configuration, Display & Control

One to Many

Appl icat ion

One to One

Appl icat ion

Magelis XBTN410 Local Control

Configures parameters

Displays real-time values

Alarm monitoring

Magelis XBTN410 Local Control

Configures parameters


Alarm monitoring

24V DC supply needed

XBTZ938 cable

Modbus protocol for datatranfering

24V DC supply needed

XBTZ938 cable

Modbus protocol for datatranfering

Custom-built

Touchscreen available

for Water/Wastewater

Applications!


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Controller LED description

DescriptionAppearanceLED

Problems can be detected using the LEDs on the expansion module,

Magelis terminal, PowerSuite running in a PC or PLC connected to the

controller.

Problems can be detected using the LEDs on the expansion module,

Magelis terminal, PowerSuite running in a PC or PLC connected to the

controller.

Maintenance

- Communication

- No commun icat ion

Flashing yellow

Off

HMI

Comm

- Motor off, no internal faults

- Motor on, no internal faults

- Power of f or internal

faul ts

Green

Flashing green

Off

Power

- In ternal or protect ion

faul t

- Warni ng

- Load shed or rap id cyc le

Red

Flashin g red

(2/s)

Flashin g red

(5/s)

Alarm

- No power or not com. Loss

- Com. loss wi th network

or HMI

Off

Red

Fallback

- Network communication- No network

communica t ion

YellowOff

PLCComm


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MCC Starter With Configuration, Display & Control LUCM Display


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MCC Starter With Configuration, Display & Control LUCM Display

d db


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TeSys T Connected on Modbus

PLC

DCS

DeviceNet

Modbus

Ethern et TCP/IP

Modbus

Modbus is good data collection systemUp to 32 devices for data (Practical limitation is lower for control)

Network not compromised by lost node

Redundancy is not standard or easy to implement with Modbus

OR OR OR


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TeSys T Connected on CANopen

PLC

DCS

DeviceNet

Modbus

Ethern et TCP/IP

CANopen is good data collection and control system

Up to 63 devices for data (Practical limitation is ??? for control)


No redundancy on CANopen

Similar network to DeviceNet


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TeSys T Connected on Profibus

PLC

DCS

DeviceNet

Modbus

Ethern et TCP/IP

Profibus is good data collection and control system

Up to xx devices for data (Practical limitation is 4 to 8 for control)


Multi-masters is available on Profibus


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TeSys T Connected on DeviceNet

PLC

DCS

DeviceNet

Modbus

Ethern et TCP/IP

DeviceNet is good control system

Up to 63(?) devices for data (Practical limitation is 4 to 8 for control)


No redundancy on DeviceNet

DeviceNet


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TeSys T Connected on Ethernet

PLC

DCS

DeviceNet

Modbus

Ethern et TCP/IP

Ethernet is good control and data acquisition system

Up to 32 devices on self-healing ring

More devices on ethernet switch


No redundancy on DeviceNet

AND

/OR

AND

/OR

AND

/OR

Ethern et TCP/IP

Daisy chain Ethernet (Potential ring

Traditional Star wired Ethernet

P S it S ft V2 5


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PowerSuite Software V2.5

Programming, Configuration & Display

One to One Appl icat ion or

One to Many Appl icat ion

PowerSuite Software Configures parameters


Alarm monitoring

Logic block programming

PowerSuite Software Configures parameters Displays real-time values

Alarm monitoring

Logic block programming

RS232/485 Converter:

VW3A8106

Direct ethernet 8 pin cable:

VW3A8306R10

RS232/485 Converter:

VW3A8106

Direct ethernet 8 pin cable:

VW3A8306R10

TeSys T with the PowerSuite


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Setting menu




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Monitoring interface

To Summarize


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To Summarize

Controller integrated design: 1 single product Main protection and control features integrated into the controller

Current sensing integrated from factory up to 100 A

Most common Operating Mode ready to use

Full functionality and protection even when bus system failCommunication

5 main protocols

Double network connectivity

MODBUS

Ethern et TCP/IP

Customization Custom operating mode: truth table and logic block

User map: rearrange register table for faster communicating

Flexible cabling layout: removable and changeable terminal strips

Optional enhancement

Voltage and Power protection

Voltage, Power and Energy consumption monitoring

Preferred System Architecture


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Ethernet

Switch

Ethernet

Switch

Preferred System ArchitectureEthernet Network

Ethernet Switch located in each shipping splitAll motor control will have direct ethernet connection w/ IP addressutilizing advanced services like Faulty Device Replacement andTransparent Ready Webpages

Existing Schneider Products:ATV61/71 VFDs; TeSys-T Overload; ATS48 w/ETG

Factory tested for correct device operation

Architecture Questions


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TeSys T Overload: Should it be powered by bucket CPT?

O/L and display will be OFF when disconnect is OFFDisallows daisy-chain ethernet with possible redundancyNo communications issue with Modbus, DeviceNet, Profibus or CANopen

Should it be remotely powered by 24 VDC?O/L and display always ONDisconnect can still be effectively Locked Out/Tagged OutPossible redundant ethernet communications

These factors should be considered:TeSys T has realtime clock Clock is stopped when power not applied

Architecture Questions

Transparent Ready Advantages


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Transparent Ready AdvantagesKeep in mind that ethernet web pages can be accessed without using I/OPoints in the Scada System. (See costs on List Price sheet below)

Note that pages are already built no engineering costs

If device is replaced or updated years from now with newer productScada web link would still be good!


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Embedded Webpages in TeSys T!


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Embedded Webpages in TeSys T!


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Measure of the current


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Measure of the current

External CT to expand the

current range up to 810A

External load CT

LT6CT... or

LUTC orCustomer Choice

Controller accept 5A and 1A

secondary signal from external CT

Controller accept 5A and 1A

secondary signal from external CT

Internal CT for current

range up to 100A

3 windows with embedded CT for

measuring the phase current

3 windows with embedded CT for

measuring the phase current

External Current transformers


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External Current transformers

Characteristics of the external CT

Accuracy

class

Motor

protection

Accuracy limit

factor

5 P 10 or 15

Protection CT provides a good accuracy at high current and has a higher

precision limit (linearity zone) .

Requirement for the CTs (standard IEC 60044-1)

Accuracy class : define the current error at the nominal current and at the

accuracy limit current ( example : accuracy class = 5, the current error is +/- 1% if

current 2x I nominal and +/-5% at the Accuracy limit current)

Accuracy limit factor: define the maximum error at the accuracy limit current

(example accuracy class=5 and accuracy limit factor=10, the maximum error is +/-

5% at 10xIn.

Measure of ground fault


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Measure of ground fault

Ground CT measures ground fault as level

significantly lower then internal ground fault

(controller sensibility : 20 mA to 10 A)

Ground CT measures ground fault as level

significantly lower then internal ground fault

(controller sensibility : 20 mA to 10 A)

External ground CT for

precise ground sensitivity

Ground fault CT

(current =0 => noground fault)

Architecture : TeSys T connected on the


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Architecture : TeSys T connected on the

networkPLCDCS

DeviceNet

Modbus

Ethern et TCP/IP

TeSys T on the network : Remote Control Configures & sets up the

functions

Monitoring

TeSys T on the network : Remote Control

Configures & sets up thefunctions

Monitoring

Network Connection Port on

the front (picture shows RJ45for Modbus)

Terminal Strip

(For DeviceNet, only terminal

strip is presented)

Network Connection Port on

the front (picture shows RJ45for Modbus)

Terminal Strip

(For DeviceNet, only terminal

strip is presented)

Main power circuit


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6 HMI or PowerSuite port

connection

7 Cable connection

(controller & expansion)

8 Network port

6 HMI or PowerSuite port

connection

7 Cable connection

(controller & expansion)

8 Network port

p

23

4

5

76 8

Expansion module

Controller

11 Circuit breaker2 Contactor

3 Control power supply

(24VDC / 100-240VAC)

1 Circuit breaker

2 Contactor

3 Control power supply

(24VDC / 100-240VAC)

4 Ground fault currenttransformer

5 PTC thermistor (binary or

analog)

4 Ground fault current

transformer

5 PTC thermistor (binary or

analog)

Control wiring


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g

6 logic input - Internalsupplied power

6 logic input - Internal

supplied power Fault relay output97-98: NO ; 95-96: NC

Fault relay output

97-98: NO ; 95-96: NC

4 logic input require external

power

isolated with input on the controller

4 logic input require external

power

isolated with input on the controller

2 control relay

output

2 control relay

outputWarning relay

output

Warning relay

output


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Control modes


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Remote mode

Control Remote mode selection is defined by input I.6: 1= Remote mode

The bumpless parameter determines the behavior of outputs O1 & O2 when

changing control mode. If this parameter is enable the outputs remain the same

position when there is a changing control mode.

Local Stop Command will always be responded regardless of the control mode

Control Remote mode selection is defined by input I.6: 1= Remote mode

The bumpless parameter determines the behavior of outputs O1 & O2 when

changing control mode. If this parameter is enable the outputs remain the same

position when there is a changing control mode.

Local Stop Command will always be responded regardless of the control mode

Magelis HMI on ly for Moni tor ing

Magelis HMI on ly for Mon i tor ing

Terminal Str ips on ly for Signal Inp utTerminal Str ips on ly for Signal Inpu t

Network

Contro l Command

Through Network

Contro l Command

Through Network

Current Transformer wiring


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g

Internal CT

Measuring phase currents direct from 0.4 to 100 A

Wiring through the windows( 18mm)Wiring through the windows( 18mm) Wiring using Multi-turnsWiring using Multi-turns

1 : Lug shroud (ref. 31172-005-01)

2 : Lug (ref. : 31154-023-50)

3 : L1 & L3 bus terminals (ref. : 31172-017-01)

4 : L2 bus terminal (ref. : 31172-018-01)

1 : Lug shroud (ref. 31172-005-01)

2 : Lug (ref. : 31154-023-50)

3 : L1 & L3 bus terminals (ref. : 31172-017-01)

4 : L2 bus terminal (ref. : 31172-018-01)

Wiring using Lug-Lug kitWiring using Lug-Lug kit

12

3

4



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Controller accept 5A and 1A secondary from

external current. The recommended controllermodel for these current is 0.4 to 8A (Ref.

LTMR08xxx)

Controller accept 5A and 1A secondary from

external current. The recommended controller

model for these current is 0.4 to 8A (Ref.LTMR08xxx)

External CT

Measuring phase currents up 810 A



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The controller has 2 terminals (Z1 & Z2) to

connect an external ground CT. The ground

CT measure ground sensitivity as levelsignificantly lower then internal ground fault

(sensibility : 20 ma to 10 A)

The controller has 2 terminals (Z1 & Z2) to

connect an external ground CT. The ground

CT measure ground sensitivity as level

significantly lower then internal ground fault(sensibility : 20 ma to 10 A)

External ground fault CT

Precise ground protection

Z1 Z2

Temperature sensor wiring


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T1 and T2 returns the temperature

value measured by resistance

sensor.

T1 and T2 returns the temperature

value measured by resistancesensor.

Types of sensor can be used

PTC binary, PTC or NTC Analog (Set up the sensor parameter)

Setting


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Configuration & Setting via HMI/PC or Remote PLC/DCS

PLC/DCS

Network

Network connection

Or

HMI/PC connection

XBTN410

HMI

PC

Setting with the PowerSuite


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energy

Make the most ofyour energy

SM


Monitoring menu

Setting with the PowerSuite


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energy

Make the most ofyour energy

SM


Parameters menu

To summarize


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Controller integrated design: 1 single product

Main protection and control features integrated into thecontroller

Current sensing integrated from factory up to 100 A

Most common Operating Mode ready to use

Full functionality and protection even when bus system failCommunication

5 main protocols

Double network connectivity

MODBUS

Ethern et TCP/IP

Customization

Custom operating mode: truth table and logic block

User map: rearrange register table for faster communicating

Flexible cabling layout: removable and changeable terminalstrips

Optional enhancement

Voltage and Power protection

Voltage, Power and Energy consumption monitoring


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MCC Panel Design

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