Helmut Schoenfelder, ABB Stotz-Kontakt, UMC100.3 Technical Presentation. ABB Stotz-Kontakt May 18, 2015 Slide 1

Transcription

1 Helmut Schoenfelder, ABB Stotz-Kontakt, UMC100.3 Technical Presentation ABB Stotz-Kontakt May 18, 2015 Slide 1

2 ABB Solutions for Motor Feeders Standard Protection Functions overload short circuit phase failure Devices Manual Motor Starters Thermal & Electronic Overload Relays Contactors Fuses

3 ABB Solutions for Motor Feeders Advanced Remote IO Interface Relays Warning & Error Signals Commands Current / Voltage Monitoring Analog signal converters Ground Fault-Detection R< Control System 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 - Temperature Monitoring PTC / PT100 / PT1000

4 ABB Solutions for Motor Feeders High Performance Control System Voltage Control Ethernet Integrated solution Motor Control Motor Protection Motor Diagnosis Communication Local IO signals PTC GF Sensor

5 UMC100.3 Intelligent Motor Protection & Control System Advanced Motor Protection Flexible Motor Control Diagnostics and Maintenance Communication for all major fieldbusses and networks May 18, 2015 Slide 5

6 UMC Usage Where are UMCs used May 18, 2015 Slide 6

7 UMC Usage Where 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 May 18, 2015 Slide 7

8 UMC Usage Why are UMCs used To avoid any sudden and unexpected motor stop by 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 May 18, 2015 Slide 8

9 UMC100.3 The system Overview Universal Motor Controller UMC100.3 DC 24 V DC UMC100.3 UC V AC/DC UMC100.3 DC EX 24 V DC ATEX UMC100.3 UC EX V AC/DC ATEX Control Panel UMC100-PAN May 18, 2015 Slide 9

10 UMC100.3 System Overview UMC100.3 DC UMC100.3 UC Supply 24 V DC Supply V AC / DC UMC100.3 UC provides 24 V DC supply for expansion modules and inputs May 18, 2015 Slide 10

11 UMC100.3 The system Overview Expansion Modules Digital DX111 DX122 Voltage VI150 VI155 Analog AI111 May 18, 2015 Slide 11

12 UMC100.3 The system Overview Communication Interfaces Fieldbus Profibus DP PDP32 DeviceNet DNP31 Modbus RTU MRP31 Network Ethernet Modbus TCP MTQ22 Ethernet Profinet IO PNQ22 May 18, 2015 Slide 12

13 UMC100.3 The system Advantages 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 May 18, 2015 Slide 13

14 UMC100.3 How are UMCs used N PTC max V AC 120 / 230 V AC M M X6 DO C X6 DO C X6 DO 0 X6 DO 1 X6 X5 DO 2 X7 T1 X7 T2 X8 Ca X8 Cb UMC100.3 V V DO 3 X5 DI 0 X5 DI 1 X5 DI DI DI DI X5 X5 X5 X5 Fault CEM11 Earth Fault Sensor Power supply 0V +24 V Start Stop Local M May 18, 2015 Slide 14

15 UMC100.3 Motor Protection Overview 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 May 18, 2015 Slide 15

16 UMC100.3 Motor Protection Protection functions overview Basic motor protection Overload according to EN/IEC 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 module Under- / Overvoltage Phase loss / imbalance / sequence voltage based Underload / Overload Powerfactor Hot motor RTD May 18, 2015 Slide 16

17 UMC100.3 Motor Control Overview Most common motor starters are integrated as easy 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 modes Remote, Local 1, Local 2 May 18, 2015 Slide 17

18 UMC100.3 Motor Control Integrated Motor Starters Motor starters Direct Starter Reversing Starter Star-Delta Starter Two-Speed Starter Others Actuator mode 1/2/3/4 Open/Close Valve Control Overload Relay Standalone application without fieldbus Transparent Mode Feeder applications Softstarter mode May 18, 2015 Slide 18

19 UMC100.3 Motor Control Integrated Motor Starters Example DOL May 18, 2015 Slide 19

20 UMC100.3 Motor Control Integrated Motor Starters Example Softstarter mode May 18, 2015 Slide 20

21 UMC100.3 Motor Control Custom 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 May 18, 2015 Slide 21

22 UMC100.3 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 will be an individual starter function 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 May 18, 2015 Slide 22

23 UMC100.3 Motor Control Custom Application Editor Network View: All devices on the fieldbus UMC DTM May 18, 2015 Slide 23

24 UMC Motor Control Custom 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 (checkback supervision ) May 18, 2015 Slide 24

25 UMC100.3 Motor Control Custom Application Editor - Full application Tool Bar Function Block Library Drawing Area May 18, 2015 Slide 25

26 UMC100.3 Motor Control Control Stations and Modes Flexible definition where and when motor start/stop is allowed 4 Control Stations supported Fieldbus 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 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 May 18, 2015 Slide 26

27 UMC100.3 Diagnostics General 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 May 18, 2015 Slide 27

28 UMC100.3 Diagnostics General Faults and Warnings Shown as text on the display Maintenance counters Operating hours of motor Stand-still hours of motor Number of starts Number of overload trips Energy Event memory for the last 16 events May 18, 2015 Slide 28

29 UMC100.3 Diagnostics Control Panel UMC100-PAN Graphical display with backlight Text instead of cryptical codes LEDs for status Multilanguage English, 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 May 18, 2015 Slide 29

30 UMC100.3 Diagnostics Control Panel UMC100-PAN Monitor Status I/Os Values Current (A, %), voltage Faults and warnings Context dependent hot-key 1 Context dependent hot-key 2 User defined infos Operate Start Stop Fault Acknowledge Configure All parameters can be set / changed USB port Scroll up / down buttons Stop Start Optional Password Protection Copy parameters and / or logic May 18, 2015 Slide 30

31 UMC100.3 Hardware Digital Inputs The UMC100.3 has 6 digital inputs DI0... DI5 DI0 DI2: Configurable Multifunction inputs Alarm / Warning / CEM11 /... 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 May 18, 2015 Slide 31

32 UMC100.3 Hardware Digital Inputs - Multifunction 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 May 18, 2015 Slide 32

33 UMC100.3 Hardware Digital 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 May 18, 2015 Slide 33

34 UMC100.3 Hardware Digital Outputs The UMC100.3 has 4 digital outputs DO0... DO3 3 x Relay Outputs DO0... DO2 Switching the motor contactors Directly set by the control function in the UMC Free outputs can be controlled by the DCS or the UMC100.3 Customer Application 1 x 24V Transistor Output DO3 Controlled 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 May 18, 2015 Slide 34

35 UMC100.3 Expansion I/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 Types DX111 DIs 24 V DC DX122 DIs 110 / 230 V AC May 18, 2015 Slide 35

36 UMC100.3 Expansion I/O Modules DX111, DX122 Usable without programming Options Disabled, Fault, or Warning Autoreset Delay Fault text Fault message displayed on the LCD Dis are always available in the DCS May 18, 2015 Slide 36

37 UMC100.3 Expansion Voltage Modules VI150, VI155 3 voltage inputs L1, L2, L V AC 1 relay output Flexible mounting: Up to 3m distance between UMC100.3 and VI15x 2 Types VI150 VI155 grounded networks all networks May 18, 2015 Slide 37

38 UMC100.3 Expansion Voltage Modules VI150, VI155 Additional features with Voltage module Motor Protection Under / Overvoltage protection Under / Overload protection Power factor (cos Phi) Voltage based phase loss / imbalance / sequence Motor Diagnostics 3 Phase voltages Powerfactor Voltage imbalance Active power Apparent power Energy THD Total harmonic distortion May 18, 2015 Slide 38

39 UMC100.3 Expansion Analog Module AI111 No pictures available yet The module will be available later in analog inputs PT ºC ºC PT ºC KTY C KTY C NTC C V ma ma PT100/PT1000 sensors with 2 or 3-wires 2 modules AI111 can be connected to a UMC100.3 May 18, 2015 Slide 39

40 UMC100.3 Expansion Analog Module AI111 Additional features with analog module Temperature 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 May 18, 2015 Slide 40

41 UMC100.3 Expansion System limits UMC100.3 can be expanded with Digital expansion module DX111 or DX122 Voltage module VI150 or VI155 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 May 18, 2015 Slide 41

42 UMC100.3 Communication Fieldbuses 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 mounted directly on the UMC100.3 or separate Ethernet communication interfaces are mounted separately May 18, 2015 Slide 42

43 UMC100.3 Communication Fieldbuses and Networks Communication Interfaces provide connection to Fieldbuses PROFIBUS DP PDP32 PDQ22 DeviceNet DNP31 Modbus RTU MRP31 Networks Ethernet 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 May 18, 2015 Slide 43

44 UMC100.3 Communication Fieldbuses and Networks Fieldbus communication interfaces can be mounted Direct on the UMC100.3 PDP32 DNP31 MRP31 Separate with SMK31 PDP32 DNP31 MRP31 Separate PDQ22 MTQ22 PNQ22 Network communication interfaces are always mounted separate Parametrization Controller 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 May 18, 2015 Slide 44

45 UMC100.3 Communication Fieldbus communication interfaces PDP32 DNP31 MRP31 Profibus DP DeviceNet Modbus RTU May 18, 2015 Slide 45

46 UMC100.3 Communication Fieldbus communication interfaces Fieldbus communication interfaces can be mounted in 2 ways Direct on the UMC100.3 Mechanically fixed Powered out of the UMC100.3 On a SMK3 separate in the cable chamber of an MCC Mounted on DIN-rail or with screws Powered separate with 24 V DC Similar to former CDP12 solution May 18, 2015 Slide 46

47 UMC100.3 Communication Fieldbus communication interfaces Communication interface mounted direct on the UMC 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 May 18, 2015 Slide 47

48 MCC installation PDP32 in drawer From previous node Drop line per drawer + No accessories necessary - Drop lines on PROFIBUS - Address not automatically set in case of replacements To next node Month DD, YYYY

49 MCC installation PDP32 in cable chamber From previous node CDP18 To drawer backside SMK3 + PDP32 CDP24 24 V DC Comm. interface supply Standard PROFIBUS cable To next node Month DD, YYYY + Address stored in PDP32 + Fast replacement (address, parameter) + Diagnosis to DCS if drawer withdrawn 24VDC supply of PROFIBUS nodes not shown

50 MCC installation PDP32 in cable chamber with DSUB-9 From previous node CDP18 To drawer backside CDP24 24 V DC Comm. interface supply SMK3+ PDP32 Standard PROFIBUS connector and cable Month DD, YYYY + Easier wiring + Fast replacement (address, parameter) + Info to DCS if drawer withdrawn + Termination at each node possible To next node 24VDC supply of PROFIBUS nodes not shown

51 UMC100.3 Communication Separation of Busnode and Device Application with PDQ22 in a Drawer System May 18, 2015 Slide 51

52 UMC100.3 Communication Communication interfaces for Ethernet MTQ22 Modbus TCP PNQ22 Profinet IO May 18, 2015 Slide 52

53 UMC100.3 Communication Ethernet communication Up to four UMC100.3 connectable Support different network topologies Star Bus Redundant Ring Integrated Ethernet switch UMC100.3 connected via simple cables Din-rail mounting May 18, 2015 Slide 53

54 UMC100.3 Communication Ethernet communication interfaces MTQ22 Modbus TCP UMC100, UMC22, PST, PSE selectable Up to 4 masters can be configured Master supervision with timeout Micro USB port for configuration via PC PNQ22 Profinet IO Standard integration via GSDML Integrated into AC800xA Time stamped events (with AC800) Sequence of events SOE May 18, 2015 Slide 54

55 UMC100.3 Communication Ethernet Network topologies May 18, 2015 Slide 55

56 UMC100.3 Communication Ethernet 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 ABB March 2012 Slide 56

57 UMC100.3 Communication Ethernet Competitor s solution 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 May 18, 2015 Slide 57

58 UMC100.3 Communication Ethernet ABB Solution Other Ethernet interfaces and UMC100.3 are always reachable If drawer withdrawn If an interface is not reachable because of a cable break No special Ethernet connectors for drawers needed No need to link 100MBit into drawers May 18, 2015 Slide 58

59 UMC100.3 Communication Ethernet application Network Switch Supply for switch, MTQ22 / PNQ22 To drawers 24 V DC Supply From switch To next MTQ22 / PNQ22 Simple connection from Ethernet interface to drawers Ready made cables available Or make own cables Terminal blocks available separately For a ring go back to switch May 18, 2015 Slide 59

60 UMC100.3 Communication Ethernet Withdrawable solution Fast installation through ready made cables CDP18 No issues in withdrawable systems Ethernet not inside the drawer! May 18, 2015 Slide 60 No special Ethernet connectors required when using in a MCC

61 UMC100.3 Communication Ethernet Fix solution Fast installation Communication via ready made cable CDP23 No special Ethernet connectors required May 18, 2015 Slide 61

62 UMC100.3 Communication Ethernet MTQ22 setup PC tool for configuration Standard Micro USB interface Online / Offline May 18, 2015 Slide 62

63 UMC100.3 Communication Monitoring Data: UMC > Control System May 18, 2015 Slide 63

64 UMC100.3 Communication Command Data: Control System -> UMC100.3 May 18, 2015 Slide 64

65 UMC100.3 Communication Diagnosis Data: UMC > Control System May 18, 2015 Slide 65

66 UMC100.3 Commissioning Engineering Workflow Customer Requirements Predefined logic sufficient 80% / 20% Programming required Configure UMC100.3 with LCD Panel GSD, EDS, GSDML HWD DTM No Programming Change control logic with function block editor Download / test application Change function block parameters and protection parameters simply via configuration (like left side) May 18, 2015 Slide 66

67 UMC100.3 Commissioning Via Device Description Files (GSD, EDS, GSDML) Table based configuration within the control system. Download of parameters during bus start / engineering time. PROFIBUS Example Custom applications can t be changed Configuration from the controller PROFIBUS GSD DeviceNet Profinet EDS GSDML Latest device desription files are always available on the internet side May 18, 2015 Slide 67

68 UMC100.3 Commissioning Configuration 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 May 18, 2015 Slide 68

69 UMC100.3 Communication Configuration via PC Using the open FDT/DTM standard Point to point connection via UTF21 Profibus connection via UTP22 May 18, 2015 Slide 69

70 UMC100.3 Summary UMC100.3 integrates Advanced 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 requirements Built-in logic -> just configure Customer specific logic -> logic editor Powerful LCD panel for monitoring, parameterization and control Expansion modules for flexible I/O handling May 18, 2015 Slide 70

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