Download UMC100-FBP Marketing Presentation

Helmut Schönfelder, ABB Stotz-Kontakt, 27.08.2012
UMC100-FBP
Technical Presentation
© ABB Group
April 29, 2017 | Slide 1
UMC100
Product Overview
© ABB Group
April 29, 2017 | Slide 2

UMC100
Universal Motor Controller

UMC100 ATEX Universal Motor Controller

UMC100-PAN Control Panel

DX111/122
Expansion Modules Digital I/O

VI150/155
Expansion Modules Voltage
UMC100
Intelligent Motor Protection & Control System
© ABB Group
April 29, 2017 | Slide 3

Advanced Motor Protection

Flexible Motor Control

Diagnostics and Maintenance

Communication for all major fieldbusses
UMC Usage
Where are UMCs used
© ABB Group
April 29, 2017 | Slide 5
UMC100
How are UMCs used
PTC
120 / 230 VAC
N
max. 1000 VAC
M
M
1
T
1
FieldBus
Plug
2
T
2
3
Ca
4
Cb
5
DO
C
6
DO
C
7
DO
0
8
9
DO DO
1
2
DI
1
14
DI
2
15
DI
3
16
DI
4
17
UMC100
0
V
10
24
V
11
DO
3
12
DI
0
13
DI
5
18
CEM11
Earth Fault Sensor
0V +24V
Power
Fault
supply
© ABB Group
April 29, 2017 | Slide 6
Start Stop
Local
M
UMC100 Motor Protection
Overview


© ABB Group
April 29, 2017 | Slide 7
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 Protection
Overload Protection according to IEC60947-4-1

Time
Motor overload
protection
Class 40E
Class 30E
Class 20E
Class 10E
Class 5E
Current
Five trip classes:
5E, 10E, 20E, 30E, 40E
© ABB Group
April 29, 2017 | Slide 8


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
UMC100 Motor Protection
Locked Rotor / Long Start Protection
Blocking
Current
Motor
Current
Delay
Time
start-up
running
Current level and delay time
to be set individually
© ABB Group
April 29, 2017 | Slide 9

Active during start-up

Extra fast protection when rotor locked

Reduces stress and protection on
transmissions
UMC100 Motor Protection
High / Low Current Protection
Motor
Current

Active after motor start-up

High Current Protection
Trip Level
Warn Level

Warn Level
Trip Level
start-up
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
running

Current levels and delay times
to be set individually
© ABB Group
April 29, 2017 | Slide 10

Separate trip and warn threshold,
each with individual delay time
UMC100 Motor Protection
Phase Monitoring

L1/2/3
Phase loss



L1,L3 & L2
L1,L2 & L3
To avoid accidents
and damages
© ABB Group
April 29, 2017 | Slide 11

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 detected
after starting the motor
UMC100 Motor Protection
With 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)



© ABB Group
April 29, 2017 | Slide 12
Underload important for pump applications
Under / Overvoltage
All settings have warn / trip level and individual delay
times
UMC100 Motor Protection with Voltage Module
Phase Monitoring

Without Voltage module:


With Voltage Module:


Check for phase faults
before starting the motor
© ABB Group
April 29, 2017 | Slide 13
Phase faults can only be detected based
on current during motor operation
Detect problems early –
before starting the motor
Protection against

Phase loss

Phase imbalance

Phase sequence
UMC100 Motor Protection with Voltage Module
Phase Monitoring

Balanced

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
unbalanced

Recommended derating
curve by NEMA.
Protection of motor and
equipment
© ABB Group
April 29, 2017 | Slide 14
Detection of problems in the supply network

Available Functions

Overvoltage

Undervoltage

Voltage phase loss and imbalance

Harmonic distortion (THD)
Different warn - and trip levels
UMC100 Motor Protection
PTC/Thermistor High Temperature Protection
Fault or warning
configurable
© ABB Group
April 29, 2017 | Slide 15

For motors with integrated
PTC elements

Detects obstructed cooling

Motors located in high temp areas
can be exposed to high ambient
temperatures

Can not be detected by an EOL

Cable short circuit and break detection
UMC100 Motor Protection
Earth Fault Protection with CEM11
L1 L2 L3

Protection against earth fault due to
damaged cable isolation etc.

4 different types available

8 threshold values for precise adjustment
Threshold range

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
24VDC

Protection of motor
and equipment
© ABB Group
April 29, 2017 | Slide 16
size
Can be used in all types of networks

also with higher impedance to ground

also small ground fault currents can be
detected
UMC100 Motor Protection
Earth Fault Protection internal
L1 L2 L3


Protection of motor
and equipment
© ABB Group
April 29, 2017 | Slide 17
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 Protection
Checkback Supervision

Check supervision ensures that the motor is really running
after a start command

Three options for checkback

© ABB Group
April 29, 2017 | Slide 18

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 Protection
Load Shedding (Voltage DIP)



© ABB Group
April 29, 2017 | Slide 19
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 Protection
Limitation of Starts per Time

© ABB Group
April 29, 2017 | Slide 22
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 Control
Overview

Most common motor starters are integrated as
easy 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


Support of different operation modes

© ABB Group
April 29, 2017 | Slide 23
(DCS, Local bottons, Operation Panel ...)
Remote, Local 1, Local 2
UMC100 Motor Control
Integrated Motor Starters
Motor starters

Direct Starter

Reversing Starter

Star-Delta Starter

Two-Speed Starter
Others
© ABB Group
April 29, 2017 | Slide 24

Different Actuators
Open/Close Valve Control

Overload Relay
Standalone application
without fieldbus

Transparent Mode
Feeder applications
UMC100 Motor Control
Integrated Motor Starters
Example DOL

© ABB Group
April 29, 2017 | Slide 25
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
UMC100 Motor Control
Custom Application Editor

In most cases the built-in logic is flexible enough
but
© ABB Group
April 29, 2017 | Slide 26

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
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

© ABB Group
April 29, 2017 | Slide 27
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
UMC100 Motor Control
Custom Application Editor
Network View:
All devices on
the fieldbus
UMC DTM
© ABB Group
April 29, 2017 | Slide 28
UMC100 Motor Control
Custom Application Editor - The most basic application
© ABB Group
April 29, 2017 | Slide 29

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 (checkback supervision …)
UMC100 Motor Control
Custom Application Editor - Full application
Tool Bar
Function Block
Library
Drawing Area
© ABB Group
April 29, 2017 | Slide 30
UMC100 Motor Control
Hardware - Digital Inputs
Six digital inputs DI0 ... DI5



© ABB Group
April 29, 2017 | Slide 31
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 from
their setting
UMC100 Motor Control
Hardware - Multifunction Inputs
© ABB Group
April 29, 2017 | Slide 32

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 Control
Hardware - Multifunction Inputs
© ABB Group
April 29, 2017 | Slide 33

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 Control
Hardware - 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 DCS
or 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:

© ABB Group
April 29, 2017 | Slide 34
Configurable On / Off / Flashing in case of fault
UMC100 Motor Control
Control Stations
© ABB Group
April 29, 2017 | Slide 35

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 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
UMC100 Motor Control
Fault Reset
© ABB Group
April 29, 2017 | Slide 36

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
© ABB Group
April 29, 2017 | Slide 37

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
© ABB Group
April 29, 2017 | Slide 38

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

© ABB Group
April 29, 2017 | Slide 39

VI150
grounded networks

VI155
grounded networks
ungrounded netw.
altitudes >2000 m
For use with UMC100
R0101
UMC100 Motor Control
Expansion Modules Voltage VI150, VI155

Additional features with Voltage module


© ABB Group
April 29, 2017 | Slide 40
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 Diagnostics
General

Comprehensive information via fieldbus and LCD operator
panel

© ABB Group
April 29, 2017 | Slide 41
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 Diagnostics
General

Faults and Warnings



© ABB Group
April 29, 2017 | Slide 42
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 Diagnostics
Control Panel UMC100-PAN

Context
dependent
hot-key 1
Context
dependent
hot-key 2

Stop
Start
Scroll upand down
buttons
© ABB Group
April 29, 2017 | Slide 43

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
UMC100 Diagnostics
Control 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


© ABB Group
April 29, 2017 | Slide 44
2 x 8 characters
Customer defined tag name
UMC100 Diagnostics
Control Panel - Top Level Menu
…
© ABB Group
April 29, 2017 | Slide 45
…
UMC100 Diagnostics
Control Panel – Operation Mode
© ABB Group
April 29, 2017 | Slide 46

From any top level menu via left softkey

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 Diagnostics
Control Panel – Set Parameters
© ABB Group
April 29, 2017 | Slide 47

Press the right context menu button to
enter the parameter menus

From there you can enter the different
submenus

Submenues can contain further submenus

At the end one ore more parameters
can be adjusted
UMC100 Diagnostics
Control Panel - Acknowledge Faults
© ABB Group
April 29, 2017 | Slide 48

In the event of an error the left hotkey
can be used to enter the error menu

Errors are shown there

Errors can be acknowledged there
UMC100 Communication
Fieldbuses and Networks

© ABB Group
April 29, 2017 | Slide 49
UMC100 can be connected via FieldBusPlug to

Modbus TCP

PROFIBUS DP

DeviceNet

Modbus RTU

CANopen
new

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

© ABB Group
April 29, 2017 | Slide 50
Support of all relevant fieldbusses and networks

PROFIBUS DP V0/V1
PDP22, PDQ22

Modbus RTU
MRP21

Ethernet Modbus TCP
MTQ22

DeviceNet
DNP21

CANopen
COP21
new
UMC100 Communication
Separation of Busnode and Device
LCD Control Panel
a) Drawer mounted
b) or remote mounting
Fits in very space limited installations!
UMC100
FBP Interface
Cable
Panel Extension
Cable
© ABB Group
April 29, 2017 | Slide 51
UMC100 Communication
Separation of Busnode and Device
Application with FBP
in a Drawer System
© ABB Group
April 29, 2017 | Slide 52
UMC100 Communication
Separation of Busnode and Device
© ABB Group
April 29, 2017 | Slide 53

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
UMC100 Communication
Separation of Busnode and Device
Application with PDQ22
in a Drawer System
© ABB Group
April 29, 2017 | Slide 54
UMC100 Communication
Ethernet – Modbus TCP with MTQ22
© ABB Group
April 29, 2017 | Slide 55

Ethernet connectivity for
up to four UMC100

Modbus TCP protocol

Supports different
network topologies

Star

Bus

Ring with redundancy
new

Easy to use

Easy to setup

No special Ethernet connectors
requried in MCCs
UMC100 Communication
Ethernet – Network topologies
© ABB Group
April 29, 2017 | Slide 56
new
UMC100 Communication
Ethernet – Redundant ring topology

© ABB
March 2012 | Slide 57
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

new


UMC100 Communication
Ethernet – Competitor’s solution
© ABB Group
April 29, 2017 | Slide 58
new

In ring or line setup the devices are
not reachable if just two drawers
are 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 can
occure because of missing devices

General problem: 10/100MBit
communication inside a drawer
UMC100 Communication
Ethernet – Solution with MTQ22

© ABB Group
April 29, 2017 | Slide 59
new
Other UMCs / MTQs are always
reachable

If drawer withdrawn

If MTQ not reachable because
of a cable break

No special Ethernet connectors
for drawers needed

No need to link 100MBit into drawers
UMC100 Communication
Ethernet – Modbus TCP with MTQ22
Network – Switch
Supply for switch,
MTQ22
To drawers
To switch
To next MTQ22
24 V DC
MTQ22 Supply

Simple connection from
MTQ22 to drawers

Ready made cables available

Or make own cables

© ABB Group
April 29, 2017 | Slide 60
Terminal blocks available separately
For a ring go
back to switch
UMC100 Communication
Ethernet – Modbus TCP with MTQ22

© ABB Group
April 29, 2017 | Slide 61
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
UMC100 Communication
Ethernet – MTQ22 and withdrawable solution

Fast installation through
ready made cables


© ABB Group
April 29, 2017 | Slide 62
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 fixed setup

Fast installation

Communication via
ready made cable


© ABB Group
April 29, 2017 | Slide 63
CDP17
No special Ethernet
connectors required
UMC100 Communication
Ethernet – MTQ22 setup
© ABB Group
April 29, 2017 | Slide 64

PC tool for configuration

Standard Micro USB interface

Online / Offline
UMC100 Communication
Monitoring Data: UMC100 -> Control System
© ABB Group
April 29, 2017 | Slide 65
UMC100 Communication
Command Data: Control System -> UMC100
© ABB Group
April 29, 2017 | Slide 66
UMC100 Communication
Diagnosis Data: UMC100 -> Control System
© ABB Group
April 29, 2017 | Slide 67
UMC100 Communication
Engineering Workflow

Customer Requirements
Predefined logic
sufficient

Configure UMC100 with
LCD
EDS
HWD
DTM
© ABB Group
April 29, 2017 | Slide 68
No Programming
Predefined logic
not sufficient

Change control logic with
function block editor

Download / test application

Change function block
parameters and protection
parameters simply via
configuration (like left side)
Panel
GSD,

80% / 20%

UMC100 Communication
Configuration via Device Description Files (GSD, EDS)
PROFIBUS
Example

Table based configuration within the
control system. Download of parameters
during bus start / engineering time.

Custom applications can’t be changed

PROFIBUS:


CANopen / DeviceNet


© ABB Group
April 29, 2017 | Slide 69
Separate GSD files for PDP22 and
PDQ22
EDS files for each bus
Latest GSD and EDS files are always
available on the internet side
UMC100 Communication
Configuration via Device Type Manager (DTM)
© ABB Group
April 29, 2017 | Slide 70

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
© ABB Group
April 29, 2017 | Slide 71

Using the open FDT/DTM
standard

Point to point connection
via UTF21

Profibus connection
via UTP22
UMC100 Product Assortment
© ABB Group
April 29, 2017 | Slide 73

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 package
Includes the Custom Application Logic Editor
UMC100 Product Assortment
Ethernet communication
© ABB Group
April 29, 2017 | Slide 74
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
UMC100
Summary


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

© ABB Group
April 29, 2017 | Slide 75
UMC100 integrates

Built-in logic -> just configure

Customer specific logic -> logic editor
Powerful LCD panel for monitoring, parameterization and
control