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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