Mcc Panel Design

Improving Motor Reliability with Intelligent Motor Control Centers and theTesys-T

Presenter’s Name: Wayne Thygesen, Consulting Engineering Specialist December 3, 2008

Improving Motor Reliability with Intelligent MCCs and the TeSys-T

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Schneider Electric Intelligent MCC 2008

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T is the Basic Tool Used for iMCC

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TeSys T System Components Native protocol Native protocol connectivity connectivity X

X

X

MODBUS

Ethernet TCP/IP Additional Additional protection protection functions functions

Controller expansion module

or

Magelis terminal

or PC with PowerSuite External CT

Ground CT

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

Remote control Remote control and monitoring and monitoring

Control Unit Operator For up to 810A For up to 810A

Ground Fault Ground Fault Sensitivity Sensitivity

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TeSys T Motor Management System

ƒTeSys T Motor Management Controller and Control Unit Operator ƒModbus is native in the TeSys T relay plus additional communication options are available ƒCurrently designed into Model 6 iMCC

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Motor Managment Controller : LTMR „

Front view description Power Supply

6 Discrete inputs (internal powered inputs)

1 Fault relay output (NO/NC)

Plug-in terminals

Expansion module/ HMI/PC connection (modbus RS485)

Network connection (RJ45 port) Reset or Self test Button

Diagnostic Leds

3 relays outputs 5A

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Ground Temp. Network fault connection Probe (screw terminal) input

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Expansion module Assembling • Side by side or •Remote

Power Supply • Powered by Controller

Additional Motor Protection • Over / Under Voltage • Over / Under Power Factor • Over / Under Power • Load shedding • Voltage phase imbalance, lost and reversal

Additional Input • 4 discrete inputs

Input Power supply • 24 VDC or • 100-240 VAC 50/60Hz

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Measurements „

Current

Voltage

Power

Depending on the controller configuration

Functions

Measured range

Thermal capacity Motor temperature sensor Line currents Ground current

0 to 200 %

Average current Current phase imbalance Frequency Line to line voltage Line voltage imbalance Active / Reactive Power Power factor (1) Active/Reactive Energy

Controller

Controller & Exp. module

0 to 6500 Ohms 0,4 to 810 A Internal : 0 to FLC External : depend on settings 0,4 to 810 A 0 to 200 % 0 to 100 Hz 0 to 830 VAC 0 to 200 % 0 to 6553.5 KW / KVar 0 to 100 0 to 400,000 KWhr / KVarhr

(1) : Value saved on power loss

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Motor Protection functions „

Depending on the controller configuration

Functions

Current

Voltage

Power

Thermal overload (inverse & definite time) Current phase (imbalance, loss, reversal) Under/Over Current Long start, Jam Ground current Motor temperature sensor Rapid cycle lockout Voltage phase (imbalance, loss, reversal) Under/Over Voltage Voltage load shedding Under/Over Power Under/Over Power factor

Controller

Controller & expansion module

Note : All the protection functions include fault detection and most protection functions include warning detection

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Monitoring : Statistics ● Counting log for every kind of faults Tesys T records the faults statistics for the analysis of the system maintenance

● Protection faults : overload, overcurrent, … ● Diagnostics faults : HMI port com loss, internal fault, …

● Recording the motor control history ● Motor starts count and operating time ● Motor starts per hour ● Rapid cycle lockout count ● Load shedding count ● Last start record

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Monitoring : Statistics ● Recording the last 5 faults ● Fault code ● Date and time ● Value of parameters & measurements

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Monitoring : Diagnostic faults ● Internal faults Tesys T records faults which affect the ability of the controller to work properly

● Watchdog : stack over/underflow ● Temperature

● Control command checks ● Start /stop command (current checking after the command) ● Run /stop check back (current checking during the stage)

● Connection fault ● Current Transformer connection ● Voltage connection ● Temperature sensor connection

● Communication loss ● Local terminal connection ● Communication loss : HMI, Network, expansion module

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Monitoring : Motor states ● Operating states Tesys T records the motor states for the analysis of the device operation

● Ready ● Start ● Run ● Not ready

● Thermal overload status ● Time to trip (before the fault occurs) ● Time to reset (after a thermal overload occurs)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Control functions ● Motor control Overview ● Control Modes determines the device or devices that will command controller outputs : ● Local mode : Local terminal or Local HMI ● Remote mode : PLC or DCS connected to the network

● Operating Modes determines the behavior of the controller’s inputs and outputs (5 predefined modes and 1 custom mode) : ● Overload, Independant, Reverser, Two-Step, Two-Speed ● Custom : user customize the logical operation for the output command

● Operating States The controller provides control, monitoring and protection functions appropriate to each of the motor’s operating states : ● Ready, start, run and fault (not ready)

● Fault Management determines how the controller manages faults : ● Manual, Automatic and Remote reset

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Operating modes „ Pre-configured operating mode † Overload : The Start/Stop of the motor is realized by a mechanism other than the controller † Independant : Direct on line full voltage non reversing motor starting † Reverser : Direct on line full voltage reversing motor starting † Two-Step : Reduced voltage starting motor † Two-Speed : Two-Speed motor for motor types : Dahlander, Pole Changer

„ Custom operating mode † PowerSuite logic editor : provides logic functions (Boolean, Register, Timers, Counter,…) that manage the controller behavoir to create a user mode

• • Note Note: :The Theselected selectedoperating operatingmode modedetermine determinethe thebehavior behaviorofofall all controller inputs and outputs. controller inputs and outputs.

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Custom operating mode „

PowerSuite logic editor : 2 languages

Possibility Possibilitytotouse usean an existing logic file to existing logic file tomodify modify the logic command that the logic command that manage managecontroller controller behavior behavior

List List Language Language

Function FunctionBlock Block Diagram Diagram

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Motor Management Controller : LTMR ● Overview

Current Rating (internal CT)

Control Power supply

• 0.4 to 8 A • 1.35 to 27 A • 5 to 100 A

• 24 VDC or • 100-240 VAC 50/60Hz

Operating mode

Motor Protection

• Overload • Independant • Reverser • Two-Step • Two-Speed • Custom Mode

• Thermal Overload • Over/Under current • Long Start / Jam • Ground current • Motor temperature sensor

Network Communication

Inputs & Ouputs • 6 discrete inputs • 4 relay outputs • Ground fault input • Temperature sensor

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LTMR...BD/FM

• Modbus • CANOpen • Profibus DP • DeviceNet • Ethernet (MB + TeSys Port)

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Expansion Module : LTMEV „

Front view description 3 Phase inputs Voltage (0 to 690 VAC)

HMI/PC connection

Controller RJ45 port

Status indication LED’s

Expansion module powered by the controller 4 discrete inputs (external powered inputs)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Operator Terminal: Magelis XBTN410 „

Configuration, Display & Control

Custom-built Touchscreen available for Water/Wastewater Applications!

One to One Application

Magelis MagelisXBTN410 XBTN410

• • Local LocalControl Control • • Configures Configuresparameters parameters • • Displays real-time Displays real-timevalues values • • Alarm monitoring Alarm monitoring

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

One to Many Application

• • 24V 24VDC DCsupply supplyneeded needed • • XBTZ938 cable XBTZ938 cable • • Modbus Modbusprotocol protocolfor fordata data tranfering tranfering

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Maintenance „

Controller LED description

LED

Appearance Description

HMI Comm Power

Flashing yellow Off

- Communication - No communication

Green Flashing green Off Red Flashing red (2/s) Flashing red Off (5/s) Red

- Motor off, no internal faults - Motor on, no internal faults - Power off or internal faults - Internal or protection fault - Warning -- Load shedoror rapid No power not com.cycle Loss

Alarm

Fallback PLC Comm

Yellow Off

- Com. loss with network or HMI communication - Network - No network communication

Problems Problemscan canbe bedetected detectedusing usingthe theLED’s LED’son onthe theexpansion expansionmodule, module, Magelis terminal, PowerSuite running in a PC or PLC connected Magelis terminal, PowerSuite running in a PC or PLC connectedtotothe the controller. controller.

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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MCC Starter „

With Configuration, Display & Control – LUCM Display

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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MCC Starter „

With Configuration, Display & Control – LUCM Display

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Connected on Modbus OR

PLC DCS

OR

OR

Modbus

Modbus DeviceNet Modbus is good data collection system Ethernet TCP/IP

Up to 32 devices for data (Practical limitation is lower for control) Network not compromised by lost node Redundancy is not standard or easy to implement with Modbus

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Connected on CANopen PLC DCS

Modbus

DeviceNet

CANopen is good data collection and control system

Ethernet TCP/IP

Up to 63 devices for data (Practical limitation is ??? for control) Network not compromised by lost node No redundancy on CANopen Similar network to DeviceNet

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Connected on Profibus PLC DCS

Modbus

DeviceNet

Profibus is good data collection and control system

Ethernet TCP/IP

Up to xx devices for data (Practical limitation is 4 to 8 for control) Network not compromised by lost node Multi-masters is available on Profibus

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Connected on DeviceNet PLC DCS

Modbus

DeviceNet DeviceNet

DeviceNet is good control system

Ethernet TCP/IP

Up to 63(?) devices for data (Practical limitation is 4 to 8 for control) Network not compromised by lost node No redundancy on DeviceNet

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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TeSys T Connected on Ethernet AND /OR

PLC DCS

AND

AND

/OR

/OR

Modbus

Daisy chain Ethernet (Potential ring) Ethernet TCP/IP

Traditional Star wired Ethernet

DeviceNet

Ethernet is good control and data acquisition system

Ethernet TCP/IP

Up to 32 devices on self-healing ring More devices on ethernet switch Network not compromised by lost node No redundancy on DeviceNet

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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PowerSuite Software V2.5 „

Programming, Configuration & Display One to One Application or One to Many Application

PowerSuite PowerSuiteSoftware Software

• • Configures Configuresparameters parameters • • Displays real-time Displays real-timevalues values • • Alarm monitoring Alarm monitoring • • Logic Logicblock blockprogramming programming

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

• • RS232/485 RS232/485Converter: Converter: VW3A8106 VW3A8106 • • Direct Directethernet ethernet88pin pincable: cable: VW3A8306R10 VW3A8306R10

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TeSys T with the PowerSuite „

Setting menu

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TeSys T with the PowerSuite „

Monitoring interface

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To Summarize ● Controller integrated design: 1 single product ● Main protection and control features integrated into the controller ● Current sensing integrated from factory up to 100 A ● Most common Operating Mode ready to use ● Full functionality and protection even when bus system fail MODBUS

Ethernet TCP/IP

● Communication ● 5 main protocols ● Double network connectivity

● Customization ● Custom operating mode: truth table and logic block ● User map: rearrange register table for faster communicating ● Flexible cabling layout: removable and changeable terminal strips

● Optional enhancement ● Voltage and Power protection ● Voltage, Power and Energy consumption monitoring

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Preferred System Architecture Ethernet Network

Ethernet Switch

Ethernet Switch

ƒ Ethernet Switch located in each shipping split ƒ All motor control will have direct ethernet connection

w/ IP address utilizing advanced services like “Faulty Device Replacement” and “Transparent Ready Webpages” ƒ Existing Schneider Products: ATV61/71 VFD’s; TeSys-T Overload; ATS48 w/ETG

ƒ Factory

tested for correct device operation

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Architecture Questions ƒ TeSys

T Overload:

ƒ Should it be powered by bucket CPT? ƒO/L and display will be OFF when disconnect is OFF ƒDisallows daisy-chain ethernet with possible redundancy ƒNo communications issue with Modbus, DeviceNet, Profibus ƒ Should it be remotely powered by 24 VDC? ƒO/L and display always ON ƒDisconnect can still be effectively “Locked ƒPossible redundant ethernet communications ƒ These factors should be considered: ƒTeSys T has realtime clock – “Clock”

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

or CANopen

Out/Tagged Out”

is stopped when power not applied

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Transparent Ready Advantages ƒKeep

in mind that ethernet web pages can be accessed without using I/O Points in the Scada System. (See costs on List Price sheet below)

ƒNote

that pages are already built – no engineering costs

ƒIf

device is replaced or updated years from now with newer product Scada web link would still be good!

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Embedded Webpages in TeSys T!

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Embedded Webpages in TeSys T!

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Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Measure of the current Internal CT for current range up to 100A

External CT to expand the current range up to 810A

External load CT LT6CT... or LUTC… or Customer Choice

33windows windowswith withembedded embeddedCT CTfor for measuring the phase current measuring the phase current

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

Controller Controlleraccept accept5A 5Aand and1A 1A secondary signal from external secondary signal from externalCT CT

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External Current transformers „

Characteristics of the external CT

Protection CT provides a good accuracy at high current and has a higher precision limit (linearity zone) . Requirement for the CTs (standard IEC 60044-1) Accuracy class 5

Motor protection P

Accuracy limit factor 10 or 15

Accuracy class : define the current error at the nominal current and at the accuracy limit current ( example : accuracy class = 5, the current error is +/- 1% if current ≤ 2x I nominal and +/-5% at the Accuracy limit current) Accuracy limit factor : define the maximum error at the accuracy limit current (example accuracy class=5 and accuracy limit factor=10, the maximum error is +/5% at 10xIn.

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Measure of ground fault External ground CT for precise ground sensitivity

Ground GroundCT CTmeasures measuresground groundfault faultas aslevel level significantly lower then internal ground significantly lower then internal groundfault fault (controller sensibility : 20 mA to 10 A) (controller sensibility : 20 mA to 10 A)

Ground fault CT (current =0 => no ground fault)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Architecture : TeSys T connected on the Modbus

network

PLC DCS

DeviceNet Ethernet TCP/IP

TeSys TeSysTTon onthe thenetwork network: : • • Remote RemoteControl Control • • Configures Configures&&sets setsup upthe the functions functions • • Monitoring Monitoring

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

•• Network NetworkConnection ConnectionPort Porton on the thefront front(picture (pictureshows showsRJ45 RJ45 for Modbus) for Modbus) •• Terminal TerminalStrip Strip (For DeviceNet, (For DeviceNet,only onlyterminal terminal strip is presented) strip is presented)

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Main power circuit 11 Circuit Circuitbreaker breaker 22 Contactor Contactor

1

33 Control Controlpower powersupply supply (24VDC / 100-240VAC) (24VDC / 100-240VAC) 2

66 HMI HMIororPowerSuite PowerSuiteport port connection connection 77 Cable Cableconnection connection (controller (controller&&expansion) expansion) 88 Network Networkport port

6

3

7

8

Controller

Expansion module

44 Ground Groundfault faultcurrent current transformer transformer 55 PTC PTCthermistor thermistor(binary (binaryoror analog) analog)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

4 5

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Control wiring 66logic logicinput input- -Internal Internal supplied power supplied power

44logic logicinput inputrequire requireexternal external power power

22control controlrelay relay output output

Fault Faultrelay relayoutput output 97-98: 97-98:NO NO; ;95-96: 95-96:NC NC

Warning Warningrelay relay output output

isolated isolatedwith withinput inputon onthe thecontroller controller

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Control modes „

Local mode : Terminal or HMI Control ControlThrough ThroughTerminal TerminalStrips Strips

Monitor MonitorThrough Through Network Network Control ControlThrough ThroughMagelis MagelisHMI HMI

Network

• • Control Controllocal localmode modeselection selectionisisdefined definedby byinput inputI.6: I.6:00==Local Localmode mode • • Control Controllocal localchannel channelsetting: setting:00==Local LocalTerminal, Terminal,11==Local LocalHMI HMI • • Local LocalStop StopCommand Commandwill willalways alwaysbe beresponded respondedregardless regardlessofofthe thecontrol controlmode mode

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Control modes „

Remote mode Terminal TerminalStrips Stripsonly onlyfor forSignal SignalInput Input

Control ControlCommand Command Through ThroughNetwork Network Magelis MagelisHMI HMIonly onlyfor forMonitoring Monitoring

Network

• • Control ControlRemote Remotemode modeselection selectionisisdefined definedby byinput inputI.6: I.6:1= 1=Remote Remotemode mode • • The Thebumpless bumplessparameter parameterdetermines determinesthe thebehavior behaviorofofoutputs outputsO1 O1&&O2 O2when when changing control mode. If this parameter is enable the outputs remain the changing control mode. If this parameter is enable the outputs remain thesame same position when there is a changing control mode. position when there is a changing control mode. • • Local LocalStop StopCommand Commandwill willalways alwaysbe beresponded respondedregardless regardlessofofthe thecontrol controlmode mode

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Current Transformer wiring „ Internal CT † Measuring phase currents direct from 0.4 to 100 A Wiring Wiringthrough throughthe thewindows(Ø windows(Ø18mm) 18mm)

Wiring Wiringusing usingMulti-turns Multi-turns

Wiring Wiringusing usingLug-Lug Lug-Lugkit kit

1

2 4

3

11: :Lug Lugshroud shroud(ref. (ref.31172-005-01) 31172-005-01) 22: :Lug Lug (ref. (ref.: :31154-023-50) 31154-023-50)

33: :L1 L1&&L3 L3bus busterminals terminals(ref. (ref.: :31172-017-01) 31172-017-01) 44: :L2 L2bus busterminal terminal(ref. (ref.: :31172-018-01) 31172-018-01)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Current Transformer wiring „ External CT † Measuring phase currents up 810 A

Controller Controlleraccept accept5A 5Aand and1A 1Asecondary secondaryfrom from external current. The recommended controller external current. The recommended controller model modelfor forthese thesecurrent currentisis0.4 0.4toto8A 8A(Ref. (Ref. LTMR08xxx) LTMR08xxx)

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Current Transformer wiring „ External ground fault CT † Precise ground protection

Z1 Z2

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

The Thecontroller controllerhas has22terminals terminals(Z1 (Z1&&Z2) Z2)toto connect connectan anexternal externalground groundCT. CT.The Theground ground CT measure ground sensitivity as level CT measure ground sensitivity as level significantly significantlylower lowerthen theninternal internalground groundfault fault (sensibility : 20 ma to 10 A) (sensibility : 20 ma to 10 A)

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Temperature sensor wiring „ Types of sensor can be used † PTC binary, PTC or NTC Analog (Set up the sensor parameter)

T1 T1and andT2 T2returns returnsthe thetemperature temperature value measured by resistance value measured by resistance sensor. sensor.

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Setting „

Configuration & Setting via HMI/PC or Remote PLC/DCS

HMI/PC connection HMI

Network connection PLC/DCS

XBTN410

Or PC Network

Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Setting with the PowerSuite „

Monitoring menu

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Make the most of SM your energy

Setting with the PowerSuite „

Parameters menu

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Make the most of your energy

Make the most of SM your energy

To summarize ● Controller integrated design: 1 single product ● Main protection and control features integrated into the controller ● Current sensing integrated from factory up to 100 A ● Most common Operating Mode ready to use ● Full functionality and protection even when bus system fail MODBUS

Ethernet TCP/IP

● Communication ● 5 main protocols ● Double network connectivity

● Customization ● Custom operating mode: truth table and logic block ● User map: rearrange register table for faster communicating ● Flexible cabling layout: removable and changeable terminal strips

● Optional enhancement ● Voltage and Power protection ● Voltage, Power and Energy consumption monitoring Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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Schneider Electric - Water Wastewater Competency Center – Wayne Thygesen – 3 December 2008

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