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
© ABB Group May 18, 2015 | Slide 6
UMC UsageWhere are UMCs used
© ABB Group May 18, 2015 | Slide 7
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
© ABB Group May 18, 2015 | Slide 8
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
© ABB Group May 18, 2015 | Slide 9
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
© ABB Group May 18, 2015 | Slide 10
UMC100.3 DC UMC100.3 UC
UMC100.3 The systemOverview
Expansion ModulesDigital DX111
DX122
Voltage VI150
VI155
Analog AI111
© ABB Group May 18, 2015 | Slide 11
UMC100.3 The systemOverview
Communication InterfacesFieldbus
Profibus DP PDP32
DeviceNet DNP31
Modbus RTU MRP31
NetworkEthernet Modbus TCP MTQ22
Ethernet Profinet IO PNQ22
© ABB Group May 18, 2015 | Slide 12
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
© ABB Group May 18, 2015 | Slide 13
UMC100.3 How are UMCs used
© ABB Group May 18, 2015 | Slide 14
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
© ABB Group May 18, 2015 | Slide 15
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
© ABB Group May 18, 2015 | Slide 16
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
© ABB Group May 18, 2015 | Slide 17
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
© ABB Group May 18, 2015 | Slide 18
UMC100.3 Motor ControlIntegrated Motor Starters
© ABB Group May 18, 2015 | Slide 19
Example DOL
UMC100.3 Motor ControlIntegrated Motor Starters
© ABB Group May 18, 2015 | Slide 20
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
© ABB Group May 18, 2015 | Slide 21
UMC100.3 Motor ControlCustom Application Editor
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
© ABB Group May 18, 2015 | Slide 22
UMC100.3 Motor ControlCustom Application Editor
© ABB Group May 18, 2015 | Slide 23
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 …)
© ABB Group May 18, 2015 | Slide 24
UMC100.3 Motor ControlCustom Application Editor - Full application
© ABB Group May 18, 2015 | Slide 25
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
© ABB Group May 18, 2015 | Slide 26
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
© ABB Group May 18, 2015 | Slide 27
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
© ABB Group May 18, 2015 | Slide 28
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
© ABB Group May 18, 2015 | Slide 29
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
© ABB Group May 18, 2015 | Slide 30
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
© ABB Group May 18, 2015 | Slide 31
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
© ABB Group May 18, 2015 | Slide 32
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
© ABB Group May 18, 2015 | Slide 33
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
© ABB Group May 18, 2015 | Slide 34
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
© ABB Group May 18, 2015 | Slide 35
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
© ABB Group May 18, 2015 | Slide 36
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
© ABB Group May 18, 2015 | Slide 37
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
© ABB Group May 18, 2015 | Slide 38
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
© ABB Group May 18, 2015 | Slide 39
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
© ABB Group May 18, 2015 | Slide 40
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
© ABB Group May 18, 2015 | Slide 41
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
© ABB Group May 18, 2015 | Slide 42
UMC100.3 CommunicationFieldbuses and Networks
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
© ABB Group May 18, 2015 | Slide 43
UMC100.3 CommunicationFieldbuses and Networks
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
© ABB Group May 18, 2015 | Slide 44
UMC100.3 CommunicationFieldbus communication interfaces
© ABB Group May 18, 2015 | Slide 45
PDP32 DNP31 MRP31
Profibus DP DeviceNet Modbus RTU
UMC100.3 CommunicationFieldbus communication interfaces
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
© ABB Group May 18, 2015 | Slide 46
UMC100.3 CommunicationFieldbus communication interfaces
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
© ABB Group May 18, 2015 | Slide 47
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
© ABB Group May 18, 2015 | Slide 51
Application with PDQ22in a Drawer System
UMC100.3 CommunicationCommunication interfaces for Ethernet
© ABB Group May 18, 2015 | Slide 52
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
© ABB Group May 18, 2015 | Slide 53
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
© ABB Group May 18, 2015 | Slide 54
UMC100.3 CommunicationEthernet – Network topologies
© ABB Group May 18, 2015 | Slide 55
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
© ABB Group May 18, 2015 | Slide 57
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
© ABB Group May 18, 2015 | Slide 58
UMC100.3 CommunicationEthernet application
Simple connection fromEthernet interface to drawers
Ready made cables available
Or make own cables
Terminal blocks available separately
© ABB Group May 18, 2015 | Slide 59
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
© ABB Group May 18, 2015 | Slide 60
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
© ABB Group May 18, 2015 | Slide 61
Fast installation
Communication via ready made cable CDP23
No special Ethernet connectors required
UMC100.3 CommunicationEthernet – MTQ22 setup
© ABB Group May 18, 2015 | Slide 62
PC tool for configuration
Standard Micro USB interface
Online / Offline
UMC100.3 CommunicationMonitoring Data: UMC100.3 -> Control System
© ABB Group May 18, 2015 | Slide 63
UMC100.3 CommunicationCommand Data: Control System -> UMC100.3
© ABB Group May 18, 2015 | Slide 64
UMC100.3 CommunicationDiagnosis Data: UMC100.3 -> Control System
© ABB Group May 18, 2015 | Slide 65
UMC100.3 CommissioningEngineering Workflow
© ABB Group May 18, 2015 | Slide 66
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
© ABB Group May 18, 2015 | Slide 67
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
© ABB Group May 18, 2015 | Slide 68
UMC100.3 CommunicationConfiguration via PC
Using the open FDT/DTM standard
Point to point connection via UTF21
Profibus connectionvia UTP22
© ABB Group May 18, 2015 | Slide 69
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
© ABB Group May 18, 2015 | Slide 70