Helmut Schoenfelder, ABB Stotz-Kontakt, 31.03.

2015

UMC100.3
Technical Presentation

ABB Stotz-Kontakt
May 18, 2015 | Slide 1
ABB Solutions for Motor Feeders
Standard

Protection Functions
overload
short circuit
phase failure

Devices
Manual Motor Starters
Thermal & Electronic Overload
Relays
Contactors
Fuses
ABB Solutions for Motor Feeders
Advanced
Control System
Add. Protection Functions
Remote IO
Motor / Bearing Temperature
Level Supervision
Voltage / Current Level
Interface Supervison
Relays Ground Fault Detection
Warning & Error Signals Imbalance
Commands Phase sequence

Current / Voltage Monitoring

Supportive devices:
Analog signal converters
Power supplies
Current transformers

Ground Fault-Detection Timers

R< -

Temperature Monitoring
PTC / PT100 / PT1000
ABB Solutions for Motor Feeders
High Performance
Control System

Integrated solution
Motor Control
Voltage
Control
Motor Protection
Motor Diagnosis
Communication
Ethernet

Local IO signals
PTC
GF Sensor
UMC100.3
Intelligent 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 Usage
Where are UMCs used

ABB Group
May 18, 2015 | Slide 6
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

ABB Group
May 18, 2015 | Slide 7
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

ABB Group
May 18, 2015 | Slide 8
UMC100.3 The system
Overview

Universal Motor Controller

UMC100.3 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 Panel
UMC100-PAN

ABB Group
May 18, 2015 | Slide 9
UMC100.3 System
Overview
UMC100.3 DC UMC100.3 UC

Supply 24 V DC Supply 110 240 V AC / DC

UMC100.3 UC provides 24 V DC supply for expansion modules and inputs
ABB Group
May 18, 2015 | Slide 10
UMC100.3 The system
Overview

Expansion Modules
Digital DX111
DX122

Voltage VI150
VI155

Analog AI111

ABB Group
May 18, 2015 | Slide 11
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

ABB Group
May 18, 2015 | Slide 12
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

ABB Group
May 18, 2015 | Slide 13
UMC100.3
How are UMCs used N PTC max. 1000 V AC

120 / 230 V AC

M
M

X6 X6 X6 X6 X6 X5 X7 X7 X8 X8
DO DO DO DO DO T1 T2 Ca Cb
C C 0 1 2

UMC100.3

V V DO DI DI DI DI DI DI
3 0 1 2 3 4 5
X5 X5 X5 X5 X5 X5 X5

Fault
CEM11
Earth Fault Sensor

Power 0V +24 V Start Stop

supply Local
M

ABB Group
May 18, 2015 | Slide 14
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

ABB Group
May 18, 2015 | Slide 15
UMC100.3 Motor Protection
Protection functions overview

Basic motor protection

Overload 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 module

Under- / Overvoltage
Phase loss / imbalance / sequence voltage based
Underload / Overload
Powerfactor
Hot motor RTD

ABB Group
May 18, 2015 | Slide 16
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
ABB Group
May 18, 2015 | Slide 17
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

ABB Group
May 18, 2015 | Slide 18
UMC100.3 Motor Control
Integrated Motor Starters

Example DOL

ABB Group
May 18, 2015 | Slide 19
UMC100.3 Motor Control
Integrated Motor Starters
Example Softstarter mode

ABB Group
May 18, 2015 | Slide 20
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

ABB Group
May 18, 2015 | Slide 21
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

ABB Group
May 18, 2015 | Slide 22
UMC100.3 Motor Control
Custom Application Editor

Network View:
All devices on
the fieldbus

UMC DTM

ABB Group
May 18, 2015 | Slide 23
UMC100.33 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 (check-
back supervision )

ABB Group
May 18, 2015 | Slide 24
UMC100.3 Motor Control
Custom Application Editor - Full application

Tool Bar

Function Block
Library

Drawing Area

ABB Group
May 18, 2015 | Slide 25
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

ABB Group
May 18, 2015 | Slide 26
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

ABB Group
May 18, 2015 | Slide 27
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

ABB Group
May 18, 2015 | Slide 28
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
ABB Group
May 18, 2015 | Slide 29
UMC100.3 Diagnostics
Control Panel UMC100-PAN

Monitor
Status I/Os
Values Current (A, %), voltage
Faults and warnings
User defined infos
Context Context
dependent dependent
hot-key 1 hot-key 2
Operate
Start
Stop
Fault Acknowledge

Configure
All parameters can be set / changed
Optional Password Protection
USB port Scroll Stop Start
up / down Copy parameters and / or logic
buttons

ABB Group
May 18, 2015 | Slide 30
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
ABB Group
May 18, 2015 | Slide 31
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

ABB Group
May 18, 2015 | Slide 32
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

ABB Group
May 18, 2015 | Slide 33
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
ABB Group
May 18, 2015 | Slide 34
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

ABB Group
May 18, 2015 | Slide 35
UMC100.3 Expansion
I/O Modules DX111, DX122

Usable without programming Fault message displayed on

the LCD
Options
Disabled, Fault, or Warning Dis are always available in
the DCS
Autoreset
Delay
Fault text

ABB Group
May 18, 2015 | Slide 36
UMC100.3 Expansion
Voltage 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 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

ABB Group
May 18, 2015 | Slide 38
UMC100.3 Expansion
Analog Module AI111

No pictures available yet 3 analog inputs

The module will be PT100 -50+400 C
available later in 2015 -50 +70 C
PT1000 -50+400 C
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
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

ABB Group
May 18, 2015 | Slide 40
UMC100.3 Expansion
System 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 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

ABB Group
May 18, 2015 | Slide 42
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

ABB Group
May 18, 2015 | Slide 43
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

ABB Group
May 18, 2015 | Slide 44
UMC100.3 Communication
Fieldbus communication interfaces

PDP32 DNP31 MRP31

Profibus DP DeviceNet Modbus RTU

ABB Group
May 18, 2015 | Slide 45
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

ABB Group
May 18, 2015 | Slide 46
UMC100.3 Communication
Fieldbus 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 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

MCC installation
PDP32 in cable chamber
From
previous
node

CDP18

To drawer
backside

CDP24
24 V DC Comm.
interface supply
SMK3 +
PDP32

Standard
PROFIBUS
cable

To
next
node

24VDC supply
of PROFIBUS
+ Address stored in PDP32 nodes not shown

Month DD, YYYY

+ Fast replacement (address, parameter)
+ Diagnosis to DCS if drawer withdrawn
MCC installation From
previous
node

PDP32 in cable chamber with DSUB-9

CDP18

To drawer
backside

CDP24
24 V DC Comm.
interface supply

SMK3+
PDP32

Standard
PROFIBUS
connector
and cable

To
next
node

+ Easier wiring 24VDC supply

+ Fast replacement (address, parameter) of PROFIBUS
nodes not shown

Month DD, YYYY

+ Info to DCS if drawer withdrawn
+ Termination at each node possible
UMC100.3 Communication
Separation of Busnode and Device

Application with PDQ22

in a Drawer System

ABB Group
May 18, 2015 | Slide 51
UMC100.3 Communication
Communication interfaces for Ethernet

MTQ22 Modbus TCP PNQ22 Profinet IO

ABB Group
May 18, 2015 | Slide 52
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

ABB Group
May 18, 2015 | Slide 53
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

ABB Group
May 18, 2015 | Slide 54
UMC100.3 Communication
Ethernet Network topologies

ABB Group
May 18, 2015 | Slide 55
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 62439-2

ABB
March 2012 | Slide 56
UMC100.3 Communication
Ethernet Competitors 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

ABB Group
May 18, 2015 | Slide 57
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

ABB Group
May 18, 2015 | Slide 58
UMC100.3 Communication
Network Switch
Ethernet application Supply for switch,
MTQ22 / PNQ22

To drawers

From switch
To next MTQ22 /
PNQ22
24 V DC Supply

Simple connection from

Ethernet interface to drawers
Ready made cables available
Or make own cables
For a ring go
Terminal blocks available separately back to switch

ABB Group
May 18, 2015 | Slide 59
UMC100.3 Communication
Ethernet Withdrawable solution

Fast installation through ready made cables CDP18

No issues in withdrawable systems
Ethernet not inside the drawer!

ABB Group
No special Ethernet connectors required when using in a MCC
May 18, 2015 | Slide 60
UMC100.3 Communication
Ethernet Fix solution

Fast installation
Communication via ready made cable CDP23
No special Ethernet connectors required

ABB Group
May 18, 2015 | Slide 61
UMC100.3 Communication
Ethernet MTQ22 setup

PC tool for configuration

Standard Micro USB interface
Online / Offline

ABB Group
May 18, 2015 | Slide 62
UMC100.3 Communication
Monitoring Data: UMC100.3 -> Control System

ABB Group
May 18, 2015 | Slide 63
UMC100.3 Communication
Command Data: Control System -> UMC100.3

ABB Group
May 18, 2015 | Slide 64
UMC100.3 Communication
Diagnosis Data: UMC100.3 -> Control System

ABB Group
May 18, 2015 | Slide 65
UMC100.3 Commissioning
Engineering Workflow

Customer Requirements

Predefined logic Programming

sufficient 80% / 20% required

Configure UMC100.3 with Change control logic with

LCD Panel function block editor

GSD, EDS, GSDML Download / test application

HWD Change function block
DTM parameters and protection
parameters simply via
No Programming configuration (like left side)
ABB Group
May 18, 2015 | Slide 66
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.
Custom applications cant be changed
PROFIBUS
Example
Configuration from the controller
PROFIBUS GSD
DeviceNet EDS
Profinet GSDML
Latest device desription files are
always available on the internet side

ABB Group
May 18, 2015 | Slide 67
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

ABB Group
May 18, 2015 | Slide 68
UMC100.3 Communication
Configuration via PC

Using the open FDT/DTM

standard
Point to point connection
via UTF21
Profibus connection
via UTP22

ABB Group
May 18, 2015 | Slide 69
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

ABB Group
May 18, 2015 | Slide 70