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 Intell Int ellige igent nt MCCs MCCs and the the TeSys TeSys-T -T
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Schneider Electric Intelligent MCC 2008
TeSys T is the Basic Tool Used for iMCC
TeSys T System Components Native protocol Native protocol connectivity connectivity X
X
X
MODBUS
Eth ern et TCP/IP TCP/IP Additional Additional protection protection functions functions
Controller expansion module
or
Magelis terminal
or
PC with PowerSuite External CT
Ground CT
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
TeSys T Motor Management System
TeSys T Motor Management Controller and Control Unit Operator Modbus is native in the TeSys T relay plus additional communication options are available
Currently designed into Model 6 iMCC
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
Ground Temp. Network fault connection Probe (screw terminal) input
Expansion module Assembling Power Supply
• Side by side or
• Powered by Controller
•Remote
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 o r • 100-240 VAC 50/60Hz
TeSys T Measurements
Current
Depending on the controller configuration
Functions
Measured range
Thermal capacity
0 to 200 %
Motor temperature sensor
0 to 6500 Ohms
Line currents
0,4 to 810 A
Ground current
Internal : 0 to FLC
Average current
Voltage
Current phase imbalance
0 to 200 %
Frequency
0 to 100 Hz
Line to line voltage
0 to 830 VAC
Line voltage imbalance
0 to 200 %
Active / Reactive Power Power
External : depend on settings 0,4 to 810 A
Power factor (1) Active/Reactive Energy (1) : Value saved on power loss
0 to 6553.5 KW / KVar 0 to 100 0 to 400,000 KWhr / KVarhr
Controller
Controller & Exp. module
TeSys T Motor Protection functions
Depending on the controller configuration
Functions
Thermal overload (inverse & definite time)
Controller
Controller & expansion module
Current phase (imbalance, loss, reversal) Under/Over Current Current
Long start, Jam Ground current Motor temperature sensor Rapid cycle lockout Voltage phase (imbalance, loss, reversal)
Voltage
Under/Over Voltage Voltage load shedding
Power
Under/Over Power Under/Over Power factor Note : All the protection functions include fault detection and most protection functions include warning detection
Monitoring : Statistics ●
Tesys T records the faults statistics for the analysis of the system maintenance
Counting log for every kind of faults ● ●
●
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
Monitoring : Statistics ●
Recording the last 5 faults ●
Fault code
●
Date and time
●
Value of parameters & measurements
Monitoring : Diagnostic faults ●
Tesys T records faults which affect the ability of the controller to work properly
●
●
●
Internal faults ●
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
Monitoring : Motor states ●
Tesys T records the motor states for the analysis of the device operation
●
Operating states ●
Ready
●
Start
●
Run
●
Not ready
Thermal overload status ●
Time to trip (before the fault occurs)
●
Time to reset (after a thermal overload occurs)
Control functions ●
Motor control Overview ●
Control Modes determines the device or devices that will command controller outputs : ● ●
●
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 : ●
●
Local mode : Local terminal or Local HMI Remote mode : PLC or DCS connected to the network
Ready, start, run and fault (not ready)
Fault Management determines how the controller manages faults : ●
Manual, Automatic and Remote reset
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 behaviorof ofall all controller controllerinputs inputsand andoutputs. outputs.
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
Motor Management Controller : LTMR ●
Overview
Current Rating (internal CT)
Control Power supply
• 0.4 to 8 A
• 24 VDC o r
• 1.35 to 27 A
• 100-240 VAC 50/60Hz
• 5 to 100 A
Operating mode
Motor Protection
• Overload
• Thermal Overload
• Independant
• Over/Under current
• Reverser
• Long Start / Jam
• Two-Step
• Ground current
• Two-Speed
• Motor temperature sensor
• Custom Mode
Network Communication
Inputs & Ouputs • 6 discrete inputs • 4 relay outputs • Ground fault input • Temperature sensor
• Modbus LTMR...BD/FM
• CANOpen • Profibus DP • DeviceNet • Ethernet (MB + TeSys Port)
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)
Operator Terminal: Magelis XBTN410
Configuration, Display & Control
Custom-built Touchscreen available for Water/Wastewater Applications!
•• •• •• ••
One to One
One to Many
Application
Application
Magelis MagelisXBTN410 XBTN410
Local LocalControl Control Configures Configuresparameters parameters Displays real-time Displays real-timevalues values Alarm monitoring Alarm monitoring
•• •• ••
24V 24VDC DCsupply supplyneeded needed XBTZ938 cable XBTZ938 cable Modbus Modbusprotocol protocolfor fordata data tranfering tranfering
Maintenance
Controller LED description
LED
Appearance
Description
HMI Comm Power
Flashing yellow
- Communication
Of f
- N o c o m m u n i cat io n
Green
- Motor off, no internal faults
Flashing green
- Motor on, no internal faults
Of f
- P o w e r o f f o r i n t er n a l f- aIn u tl tesr n al o r p r o t ec t i o n
Alarm
Fallback PLC Comm
Red F l as h i n g r e d (2/s)
fault
F l as h i n g r e d Off
-- L o apower d s h edoronot r r ap i d c Loss y c le No com.
(5/s) Red
Yellow Of f
- W ar ni ng
- C o m . l o s s w i th n e tw o r k H M I communication -o rNetwork - N o n et w o rk communication
Problems Problemscan canbe bedetected detectedusing usingthe theLED’s LED’son onthe theexpansion expansionmodule, module, Magelis Magelisterminal, terminal,PowerSuite PowerSuiterunning runningininaaPC PCor orPLC PLCconnected connectedtotothe the controller. controller.
MCC Starter
With Configuration, Display & Control – LUCM Display
MCC Starter
With Configuration, Display & Control – LUCM Display
TeSys T Connected on Modbus OR
PLC DCS
OR
OR
Modbus
Modbus DeviceNet Modbus is good data collection system Ethern et 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
TeSys T Connected on CANopen PLC DCS
Modbus
DeviceNet Ethern et TCP/IP
CANopen is good data collection and control system 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
TeSys T Connected on Profibus PLC DCS
Modbus
DeviceNet Ethern et TCP/IP
Profibus is good data collection and control system 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
TeSys T Connected on DeviceNet PLC DCS
Modbus
DeviceNet DeviceNet Ethern et TCP/IP
DeviceNet is good control system Up to 63(?) devices for data (Practical limitation is 4 to 8 for control) Network not compromised by lost node No redundancy on DeviceNet
TeSys T Connected on Ethernet AND /OR
PLC DCS
AND
AND
/OR
/OR
Modbus
Daisy chain Ethernet (Potential ring) Ethern et TCP/IP
DeviceNet Ethern et TCP/IP
Traditional Star wired Ethernet
Ethernet is good control and data acquisition system Up to 32 devices on self-healing ring More devices on ethernet switch Network not compromised by lost node No redundancy on DeviceNet
PowerSuite Software V2.5
Programming, Configuration & Display One to One Application or O n e t o M an y A p p l i c a t i o n
•• •• •• ••
PowerSuite PowerSuiteSoftware Software Configures Configuresparameters parameters Displays real-time Displays real-timevalues values Alarm monitoring Alarm monitoring Logic Logicblock blockprogramming programming
• • RS232/485 RS232/485Converter: Converter: VW3A8106 VW3A8106 • • Direct Directethernet ethernet88pin pincable: cable: VW3A8306R10 VW3A8306R10
TeSys T with the PowerSuite
Setting menu
TeSys T with the PowerSuite
Monitoring interface
To Summarize ●
MODBUS
●
Ethern et TCP/IP ●
●
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
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
Preferred System Architecture Ethernet Network
Ethernet Switch
Ethernet Switch
Ethernet Switch located in each shipping split All motor control will have direct ethernet connection w/ IP address utilizing advanced services like “Faulty Device Replacement” and “Transparent Ready Webpages” Existing Schneider Products: ATV61/71 VFD’s; TeSys-T Overload; ATS48 w/ETG
Factory tested for correct device operation
Architecture Questions TeSys T Overload:
Should it be powered by bucket CPT? O/L and display will be OFF when disconnect is OFF Disallows daisy-chain ethernet with possible redundancy No communications issue with Modbus, DeviceNet, Profibus or CANopen Should it be remotely powered by 24 VDC? O/L and display always ON Disconnect can still be effectively “Locked Out/Tagged Out” Possible redundant ethernet communications These factors should be considered: TeSys T has realtime clock – “Clock” is stopped when power not applied
Transparent Ready Advantages Keep 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)
Note that pages are already built – no engineering costs If device is replaced or updated years from now with newer product Scada web link would still be good!
Embedded Webpages in TeSys T!
Embedded Webpages in TeSys T!
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
Controller Controlleraccept accept5A 5Aand and1A 1A secondary signal from external secondary signal from externalCT CT
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
Motor protection
Accuracy limit factor
5
P
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.
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)
Architecture : TeSys T connected on the Modbus
network PLC DCS
DeviceNet Ethern et TCP/IP
TeSys TeSysTTon onthe thenetwork network: : • • Remote RemoteControl Control • • Configures Configures&&sets setsup upthe the functions functions • Monitoring • Monitoring
• • Network NetworkConnection ConnectionPort Porton on the front (picture shows RJ45 the front (picture shows RJ45 for forModbus) Modbus) • • Terminal TerminalStrip Strip (For DeviceNet, (For DeviceNet,only onlyterminal terminal strip stripisispresented) presented)
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
44 Ground Groundfault faultcurrent current transformer transformer 55 PTC PTCthermistor thermistor(binary (binaryoror analog) analog)
6
3
7
8
Controller
Expansion module
4 5
Control wiring 66logic logicinput input- -Internal Internal supplied power supplied power
44logic logicinput inputrequire requireexternal external power power isolated isolatedwith withinput inputon onthe thecontroller controller
22control controlrelay relay output output
Warning Warningrelay relay output output
Fault Faultrelay relayoutput output 97-98: 97-98:NO NO; ;95-96: 95-96:NC NC
Control modes
Local mode : Terminal or HMI C o n t r o l T h r o u g h T e r m i n a l St r i p s C o n t r o l T h r o u g h T e r m i n a l St r i p s
M o n i t o r Th r o u g h M o n i t o r Th r o u g h Network Network C o n t r o l Th r o u g h M a g e l i s H MI C o n t r o l T h r o u g h M a g e l i s H MI
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 regardlessof ofthe thecontrol controlmode mode
Control modes
Remote mode T er m i n a l S t r i p s o n l y f o r S i g n a l In p u t T er m i n a l S t r i p s o n l y f o r S i g n a l In p u t
Control Comm and Control Comm and Through Network Through Network M a g e li s H M I o n l y f o r M o n i t o r i n g M a g e li s H M I o n l y f o r M o n i t o r i n g
Network
• • Control ControlRemote Remotemode modeselection selectionisisdefined definedby byinput inputI.6: I.6:1= 1=Remote Remotemode mode • • The Thebumpless bumplessparameter parameterdetermines determinesthe thebehavior behaviorof ofoutputs 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 positionwhen whenthere thereisisaachanging changingcontrol controlmode. mode. • • Local LocalStop StopCommand Commandwill willalways alwaysbe beresponded respondedregardless regardlessof ofthe thecontrol controlmode mode
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)
Current Transformer wiring
External CT
Measuring phase currents up 810 A
Controller Controlleraccept accept5A 5Aand and1A 1Asecondary secondaryfrom from external externalcurrent. current.The Therecommended recommendedcontroller controller model modelfor forthese thesecurrent currentisis0.4 0.4toto8A 8A(Ref. (Ref. LTMR08xxx) LTMR08xxx)
Current Transformer wiring
External ground fault CT
Precise ground protection
Z1 Z2
The Thecontroller controllerhas has22terminals terminals(Z1 (Z1&&Z2) Z2)toto connect an external ground CT. The ground connect an external ground CT. The ground CT CTmeasure measureground groundsensitivity sensitivityas aslevel level significantly lower then internal ground significantly lower then internal groundfault fault (sensibility : 20 ma to 10 A) (sensibility : 20 ma to 10 A)
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.
Setting
Configuration & Setting via HMI/PC or Remote PLC/DCS
HMI/PC connection HMI
Network connection PLC/DCS
XBTN410
Or PC Network
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 SM your energy
To summarize ●
Controller integrated design: 1 single product Main protection and control features integrated into the controller
●
MODBUS
●
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
Communication
Ethern et TCP/IP ●
●
●
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
