PRODUCT MANUAL MMS digital switchgear Motor control unit MC510 user guide

Transcription

1 PRODUCT MANUAL MMS digital switchgear Motor control unit MC510 user guide A reliable, available, simple, safe and powerful MNS solution MNS digital switchgear Motor control unit MC510 user guide

2 GENERAL The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental, or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB's written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. All rights reserved. Copyright 2016 Xiamen ABB Low Voltage Equipment Co., Ltd.

3 GENERAL Table of content 4-6 General 4 Target Group 4 Use of Warning, Caution, Information and Tip icon 5 Terminology 5 Related Documentation 6 Related System Version 6 Document Revision History 7 Product Overview 7 Introduction 7 Structure 10 Mounting 10 Mounting of MC Interfaces 12 Terminal Designations 16 Typical Diagram Functionality 18 Starter Types 35 Protection Functions 72 Logic Block 79 Maintenance Function 80 Metering and Monitoring 82 Using extension modules 83 Communication interface 89 Parameterization Accessories 90 MP51/MP52 Operator Panel 104 Parameterization Software: MConfig Appendix A Technical Data 106 A.1 Common Technical Data 106 A.2 Technical Data of the Basic Unit MC A.3 Technical Data of the Operation panel MP51/ A.4 Technical Data of the Loop Switch MS571

4 GENERAL General Target Group The manual is primarily intended for those requiring information on the applications of MC510 for the purpose of understanding, engineering, wiring & operation. The objective of this manual is to provide the technical functions description of MC510.This manual should be studied carefully before installing, parameterizing or operating the motor control unit. It is assumed that the user has a basic knowledge of physical and electrical fundamentals, electrical wiring practices and electrical components. This document should be used along with MC510 Parameter Description, which provides detailed information about parameters and their applications. Use of Warning, Caution, Information and Tip icon The electrical warning icon indicates the presence of a hazard that could result in electrical shock. The warning icon indicates the presence of a hazard that could result in personal injury. The caution icon indicates important information or warnings related to the concept discussed in the text. It might indicate the presence of hazard that could result on corruption of software or damage to equipment/property. The information icon alerts the reader to pertinent facts and conditions. The tip icon indicates advice on, for example, how to design your project or how to use a certain function 4/110

5 GENERAL Terminology List of the terms, acronyms, abbreviations and definitions that being used in this document. Abbreviation Term Description DCS PCS Alarm Distributed Control System Local Hardwiring Alarm is defined as status transition from any state to abnormal state. Status transition to abnormal state can be data crossing over the pre-defined alarm limit. High level distributed control system A Control Access term describing that MC510 accepts its commands from the hardwired inputs, when the Local control authority is enabled. Process Control System High level process control system MODBUS TCP Ethernet communication protocol PTC Positive Temperature Coefficient PTC thermistors are semiconductor elements with a very high positive temperature coefficient. RCU Remote Control Unit Local control unit with pushbutton and indicator to operate a device (e.g. motor) from field level. Remote Fieldbus A Control Access term describing that MC510 accepts its commands from the fieldbus inputs, when the remote control authority is enabled. TOL Thermal Overload Protection against overheated caused by overload Protection Trip A consequence of an alarm activated or an external trip command from another device to stop the motor or trip the circuit breaker. MCC Motor Control Centre Common term for a switchgear used for motor control and protection. SOE Sequence of events A record of events with time stamp. FDR Failure Device Replacement Maintenance method for failure device Related Documentation 1TNC M 1TNC M 1TNC M 1TNC M MC510 Parameter Description MC510 Modbus/TCP Protocol Implementation MConfig User Guide Extension module User Guide Related System Version The content of this document is related to MC510 products with the following hardware and firmware version release, HW FW MC510-MT-DC /110

6 GENERAL MC510-MT-AC MP MP Until further notice, this document is also applicable for future firmware versions other than those listed above. The described functions are designed but may not be fully implemented in all details. Please refer to the release notes regarding possible restrictions. Document Revision History Revision Page(s) Description of change Date M0201 Initial Edition 12/08/2016 M0202 Update extension module description 24/08/2018 6/110

7 PRODUCT OVERVIEW Product Overview Introduction MC510 is an intelligent motor control and protection device based on current and voltage measurement. It is part of low voltage system family to provide customers the intelligent system solution and supplied as part of ABB Low Voltage switchgear MNS. MC510 is microprocessor-based product providing comprehensive features. Every motor starter could be equipped with one MC510 device. By predefined parameters, MC510 will provide specific control, monitoring and protection functions in various motor applications. Providing with redundant Ethernet interface, MC510 could be integrated into industry control system and plant management system efficiently and smoothly. Every MC510 device can be accessed to get actual operating data. Fast response time for alarm and trip makes real time control of production process possible. Statistical recording of maintenance data, like running hours and number of operations, assists with predictive maintenance scheduling. For AC motor and the operated installation this means: Reliable protection Maximum utilization Continuous supervision Flexibility Structure MC510 Main unit Main unit is constructed with two parts, the electronics of the motor control unit and the integrated CT. Main unit is a one type device with the integrated CT range starting from 0.24 to 63A. For motor rating larger than 63A, interposing CTs should be selected. Main unit is designed with a mounting rail fixed to the bottom of the device for easy vertical DIN rail mounting. Screws and other mounting accessories are also provided for vertical and horizontal screw mounting. Operator panel The Operator panel is the user interface mounted on the front door or instrument plate of a drawer. 7/110

8 PRODUCT OVERVIEW With control buttons, LED, LCD module (MP51 only), MP51/MP52 provides the functions as motor control, supervision and parameterizing. One operator panel is provided for each main unit at request. Extension modules (optional module) All extension modules are powered by the basic unit. The type of extension modules will be automatic detected by the basic unit after configured in parameter setting. DIDO module (MB550/MB551) The DIDO module MB550 provides four 24VDC digital inputs and two relay outputs. The DIDO module MB551 provides four 110/240VAC digital inputs and two relay outputs. AIAO module (MA552) The AIAO module MA552 provides two RTD inputs, one 0-10V voltage input and one 0-20mA/4-20mA current output. Hotspots monitor module (MT561) The hotspots monitor module MT561 supervises the temperature of power contacts in the drawer by infrared temperature sensor. Wireless temperature monitor module (MT564) The wireless temperature monitor module MT564 supervises the temperature of switchgear bus-bar by wireless temperature sensor WT01. Note: Max. 4 extension modules can be connected with MC510 basic unit. Material The enclosure of MC510 is made of PA6. Flammability rating of the material is UL 94 V-2 and material is halogen free. Colour of the enclosure is RAL For detail description of MP51/MP52, please refer to Chapter Accessories. 8/110

9 PRODUCT OVERVIEW Fig 1 MC510 and MP51 9/110

10 MOUNTING Mounting Mounting of MC510 Basic dimension of MC510 W X H X D = 123mm X 121mm X 72mm Typical Installation of MC510 DIN rail mounting, or screw mounting on plate Fig 1 MC510 in 8E/2 module Basic dimension of MP51 W X H X D = 91mm X 75mm X 29.3mm Mounting dimension of MP51 W X H = 84mm X 68mm Basic dimension of MP52 W X H X D = 91mm X 52mm X 29.3mm Mounting dimension of MP52 W X H = 84mm X 45mm The installation details of MC510 and MP5x, please see the related documentation installation manual. 10/110

11 INTERFACES Interfaces Terminal blocks of MC510 are located on the top of the main unit for easy access. There are 3 sets of I/O terminal blocks and 1 set of RJ12 connector as shown. Fig 3 Top View Terminal Layout Fig 4 Side View Terminal Layout 11/110

12 INTERFACES Terminal Designations Terminal name Designation Remark Plug/Contacts DI0...DI7, COM Digital inputs Cross section 2.5mm2 VL1,VL2,VL3 I0a,I0b CCA,CCB,CCI R0a,R0b,R0c,R1a,R1b Voltage input RCT input Control relay output Relay output L+,M Power supply 24V DC type L,N V AC type ETH1 Ethernet interface 1 RJ45 ETH2 Ethernet interface 1 MP Interface of MP5x RJ12 L1-T1;L2-T2;L3-T3 Current Measurement Φ 12mm Window IO-BUS Interface of extension modules Table 1 Device terminals Power Supply Depending on different product type, three types of power supply are available, i.e. 24VDC, 110VAC & 240VAC. Power supply of the device should be always derived from uninterrupted and reliable supply source. Power supply Terminal Description DC L+ 24 VDC + M 0 VDC AC L Line N Neutral Table 1 Power supply input terminals Digital Input MC510 has 8 DIs. Digital inputs are cyclically read. Functions of all digital inputs can be configured by logic block. Terminal Description DI0 Digital Input 0 DI1 Digital Input 1 DI2 Digital Input 2 DI3 Digital Input 3 12/110

13 INTERFACES DI4 Digital Input 4 DI5 Digital Input 5 DI6 Digital Input 6 DI7 Digital Input 7 COM Common input of digital inputs Table 3 Digital inputs with 24VDC supply i ) For 24VDC, it is recommended to use separate supply source for power supply and digital inputs especially in the case that DI signals are taken from the field which is located long distance from MCCs Fig 5 Illustration of DIs wiring to MC510 Residual Current Transformer MC510 supports earth fault protection through external Residual Current Transformer (RCT). Terminal I0a I0b Description Residual current transformer input A Residual current transformer input B Table 2 Residual current transformer terminals 13/110

14 INTERFACES i) Different size or types of RCT are available. Refer to MNS Digital Ordering Guide for details. ii) It is recommended to short terminals I0a and I0b to avoid potential external disturbance in case that RCT is not in use. iii) It is recommended to use STP cable for RCT circuit connections. Voltage Measurement Voltage measurement and protections are supported in MC510. Terminal VL3 VL2 VL1 Description Phase L3 voltage input Phase L2 voltage input Phase L1 voltage input Table 5 Voltage input terminals i)when single phase system is selected, voltage measurement is based on phase L1 - phase L3. Connect L to VL1 and neutral to VL3. ii)if PT is selected, according to phase sequence, connect the secondary side of PT to VL1 VL2 VL3. iii)pt type should be single-phase voltage transformer or Yy0 connection for three-phase voltage transformer. Current Measurement Terminal MC510 measures continuously three motor phase currents. The phase current data will be used by the protection functions and reported to the fieldbus. Phase currents are reported as a value relative to the motor nominal current In. Current wires are lead through current sensors from either side of the terminal. Direction can be either L->T or T->L considering that all currents must have the same direction. Motor nominal currents above 63A are not measured directly, but instead intermediate current transformer s secondary side is connected through MC510 current measurement terminal. i)when single phase system is selected, current measurement is based on phase L1. ii)the measurement range of internal CT is from 0.08A to 63A. Contactor Control Output MC510 supports various motor starter types. The control of the contactor by MC510 is via internal output relays (CCA, CCB, CCC(R1) relays) by the microprocessor. There is a interlock between CCA and CCB to avoid closing together. 14/110

15 INTERFACES 1) Relay output R0/R1 is to be set as the function of CCC in the control circuits. 2) For external connecting contactors, spark suppression is necessary for all types of contactors except the AF types to maintain a reasonable service life of relays. Terminal CCI CCA CCB Description Contactor control voltage input Contactor control A Contactor control B Table 6 Contactor control terminals Relay Output MC510 is also equipped with two relay outputs which functions according to project specific settings. Terminal R0a R0b R0c R1a R1b Description NC terminal of SPDT NO terminal of SPDT Common terminal of SPDT NO terminal of R1 NO terminal of R1 Table 7 Relay output terminals The output status of relays may change in responding to different functions assigned. For external connecting contactors, spark suppression is necessary for all types of contactors except the AF types to maintain a reasonable service life of relays. Interface for MP51/MP52 MC510 connects with operator panel MP51/MP52 via RJ12 interface, which marked MP. Ethernet communication Interface Redundant Ethernet communication is provided, in which RJ45 interface is applied, with mark ETH1 and ETH2. 15/110

16 INTERFACES Extension module interface IO-BUS interface is used for the extension function of basic unit for more complex application. Extension functions, such as temperature measurement, analog output etc. are implemented separately in extension modules. IO-Bus interface provides the power supply of extension modules and the data exchange between MC510 and extension modules. Typical Diagram Typical wiring diagrams of different types of MC510 are shown in this section. MC V AC type Fig 6 Typical wiring diagram for MC V AC type 16/110

17 INTERFACES MC510 24V DC type Fig 7 Typical wiring diagram for MC510 24V DC type Roc is the common terminal of NO and NC contact of R0 relay, output status of NO and NC contact would change synchronously in responding to different functions assigned 17/110

18 Functionality Starter Types MC510 offers various kinds of motor starting control modes via the control of relay output. It supervises the operating state of the contactor according to the feedback of auxiliary contact, predefined feedback timeout and current. The following starting control modes are offered: Starter type NR-DOL REV-DOL NR-DOL/RCU REV-DOL/RCU Actuator NR-S/D NR-2N NR-2N Dahlander Autotransformer NR_softstater REV_softstater Contactor Feeder Contactor Feeder/RCU Table 8 Starter types supported by MC510 Starter type is selected with a dedicated parameter to match the wiring for contactor and motor control circuits. i) Pin numbers assigned for DIs in below starters are shown as per default settings and subject to be changed to meet different project engineering. ii) Spark suppression is necessary for all types of connecting contactors except AF types through MC510 output relays to maintain a reasonable service life of the output relays. Interface relays should also be considered in engineering to increase the 18/110

19 reasonable service life. Interface relay is recommended to be used for contactor type A210 and above. Fig 8 Surge Suppressors on Contactor Coils Precautious measures shall be taken in system designs to avoid potential high electromagnetic disturbance which may result in unstable network and malfunction of MC510 relays. For example, in applications that Variable Speed Drives are used in a large scale, harmonic filter devices shall be required in system design to reduce the impact to the network. NR-DOL STARTER NR_DOL starter is a basic starter type for driving motor to one direction. When start command has been received from field or local I/O, the contactor control output will be energized and remains this condition until stop command has been received or any protection function activated. Terminal Description Remark CCI CCA Contactor control voltage input Contactor control A DI5 Contactor control A feedback (F_Ca) Table 9 NR-DOL starter contactor control interface The definition of the terminal in the above list is only an example. 19/110

20 Fig 9 Control circuit for NR-DOL starter (for MC510) Operating Sequence for NR-DOL: Motor is Stopped - > Start1 - > Close CCA Motor is Running - > Stop - > Open CCA NR-DOL/RCU STARTER RCU (Remote Control Unit) is a starter type where contactors are directly controlled by a special RCU-switch located near the motor. This allows control of the motor even without MC510 Terminal Description Remark CCI CCA Contactor control voltage input Contactor control A R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) Table 10 NR-DOL/RCU starter contactor control interface The definition of the terminal in the above list is only an example. 20/110

21 Fig 10 Control circuit for NR-DOL/RCU starter Operating Sequence for NR-DOL/RCU: Motor is Stopped - > Start1 - > Close CCA for 1s and open Motor is Running - > Stop - > Close CCC (R1) for 1s and open REV-DOL STARTER REV-DOL uses contactor control output A for controlling the contactor which drives motor to direction CW and correspondingly contactor control output B is used for direction CCW. When starting motor to either direction contactor will be energized and is stopped (not energized) by command (fieldbus or local I/O) or active protection function. Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B DI5 Contactor control A feedback (F_Ca) DI6 Contactor control A feedback (F_Cb) Table 11 REV-DOL starter contactor control interface 21/110

22 The definition of the terminal in the above list is only an example. Fig 11 Control circuit for REV-DOL starter Operating Sequence for REV-DOL: Motor is Stopped - > Start1 - > Close CCA Motor is Stopped - > Start2 - > Close CCB Motor is Running - > Stop - > Open CCA&CCB REV-DOL/RCU STARTER The functionality of this starter type is according to NR-DOL/RCU starter with support for reversing use of motor. Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B R1a NO contact of R1 (CCC) R1b 22/110

23 DI5 Contactor control A feedback (F_Ca) DI6 Contactor control A feedback (F_Cb) Table 12 REV-DOL starter contactor control interface (for MC510) The definition of the terminal in the above list is only an example. Fig 12 Control circuit for REV-DOL/RCU starter Operating Sequence for REV-DOL/RCU: Motor is Stopped - > Start1 - > Close CCA for 1s and open Motor is Stopped - > Start2 - > Close CCB for 1s and open Motor is Running - > Stop - > Close CCC (R1) for 1s and open Actuator STARTER This starter type is for controlling valves and actuators by using limit switches. Limit switches cause the motor to be stopped when activated and additionally start command is allowed only to reverse direction. Torque switch is selectable by parameterization. Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B 23/110

24 R1a NO contact of R1 (CCC) R1b DI0 Limit position switch 1 input (Limit1) DI1 Limit position switch 2 input (Limit2) DI7 Torque switch input (Tor) DI5 Contactor control A feedback (F_Ca) DI6 Contactor control A feedback (F_Cb) Table 13 Actuator starter contactor control interface The definition of the terminal in the above list is only an example. Fig 13 Control circuit for Actuator starter Operating Sequence for Actuator: Motor is Stopped with Limit1 and Torque inactivated - > Start1 - > Close CCA for 1s and open Motor is Stopped with Limit2 and Torque inactivated - > Start2 - > Close CCB for 1s and open Motor is Running CW - > Limit1 activated or Stop - > Close CCC (R1) for 1s and open CCC (R1) Motor is Running CCW - > Limit2 activated or Stop - > Close CCC (R1) for 1s and open CCC (R1) Motor is Running - > Torque activated - > Close CCC (R1) 24/110

25 NR-S/D STARTER Motor start current is reduced in star connection to 1/3 rd of the current in delta connection, with lower torque during the same time. Start to delta starting sequence is based on the presented control logic Figure. The changeover condition is time. The following guideline applied for selecting parameter values: Changeover time < Motor startup time Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) DI6 Contactor control B feedback (F_Cb) DI7 Contactor control C feedback (F_Cc) Table 14 NR_S/D starter contactor control interface The definition of the terminal in the above list is only an example. Fig 14 Control circuit for NR-S/D starter 25/110

26 Operating Sequence for NR-S/D: Motor is Stopped - > Start1 - > Close CCB & CCC (R1) - > Changeover Time - > Open CCB & Close CCA Motor is Running - > Stop - > Open CCA & CCB & CCC (R1) NR-2N STARTER NR-2N uses two contactors control motor rotation speed, the motor contains separate windings. Rotation speed can be changed on the fly without stop command in between. Low speed (start1) could be changed to high speed (start2) immediately, and high speed could be changed to low speed after a changeover time. Current measurement for NR-2N utilizes two external current transformers measuring current from motor main supply. External current transformers can be selected separately for both speeds. The following guideline applied for selecting parameter values: Changeover time < Motor startup time Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B DI5 Contactor control A feedback (F_Ca) DI6 Contactor control A feedback (F_Cb) Table 15 NR-2N starter contactor control interface The definition of the terminal in the above list is only an example. 26/110

27 Fig 15 Control circuit for NR_2N starter, separate windings Operating Sequence in NR-2N Sending command Start1 (Low Speed N1) to close contactor CCA. Sending command Start2 (High Speed N2) to close contactor CCB. Contactors are latched Stop command opens CCA or CCB. Motor can be controlled with sequences.e.g. Stop -> Start1-> Stop Stop -> Start2 -> Stop Stop -> Start1 -> Start2 ->Stop NR-2N Dahlander STARTER NR-2N Dahlander uses three contactors control motor rotation speed where motor is equipped with a three phase winding. Rotation speed can be changed on the fly without stop command in between. Low speed (start 1) could be changed to high speed (start 2) immediately, and high speed could be changed to low speed after a changeover time. Current measurement for NR-2N Dahlander utilizes two external current transformers measuring current from motor main supply. External current transformers can be selected separately for both speeds. 27/110

28 Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) DI6 Contactor control A feedback (F_Cb) DI7 Contactor control A feedback (F_Cc) Table 16 NR-2N Dahlander starter contactor control interface The definition of the terminal in the above list is only an example. Fig 16 Control circuit for NR_2N Dahlander starter Operating Sequence in NR-2N Dahlander Sending command Speed1 to close contactor CCA. Sending command Speed2 to close contactor CCB and CCC(R1). Contactors are latched Sending stop command to open CCA or CCB + CCC(R1). 28/110

29 Motor can be controlled with sequences.e.g. Stop -> Start1-> Stop Stop -> Start2 -> Stop Stop -> Start1 -> Start2 ->Stop Stop -> Start2 -> Chang over delay-> Start1 -> Stop. AUTOTRANSFORMER STARTER This starter type is used to control autotransformer unit in order to minimize the voltage drop during motor startup. Autotransformer starter with three contactors supports motor starting with reduced voltage thus providing reduced motor startup current. The starting torque will be reduced accordingly. The following guideline applied for selecting parameter values: Changeover time < Motor startup time Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) DI6 Contactor control B feedback (F_Cb) DI7 Contactor control C feedback (F_Cc) Table 17 Autotransformer starter contactor control interface The definition of the terminal in the above list is only an example. 29/110

30 Fig 17 Control circuit for Autotransformer starter Operating Sequence for Autotransformer: Motor is Stopped - > Start1 - > Close CCB & CCC (R1) - > Changeover Time - > Open CCB & Close CCA Motor is Running - > Stop - > Open CCA & CCB & CCC (R1) NR-SOFTSTARTER Softstarter applications are for controlling motor accessory softstarter device. MC510 gives start and stop commands to the softstarter unit. The softstarter is set for adjusting motor voltage with its own parameters. More information about softstarter can be found from softstarter s manual. This starter type supports all protection functions during normal Running situation. For motor start and stop period some of the protection functions are disabled by these parameters. Terminal Description Remark CCI CCA Contactor control voltage input Contactor control A R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) Table 18 NR_Softstarter starter contactor control interface 30/110

31 The definition of the DI terminal in the above list is only an example. Fig 18 Control circuit for NR-softstarter Operating Sequence for NR-Softstarter: Motor is Stopped - > Start1 - > Close CCA - > Close CCC (R1) Motor is Running - > Stop - > Open CCC (R1) -> Ramp down time -> Open CCA REV-softstarter This starter is of similar functionality as NR-softstarter starter with additional function on supporting reversing motor. Terminal Description Remark CCI CCA CCB Contactor control voltage input Contactor control A Contactor control B R1a NO contact of R1 (CCC) R1b 31/110

32 DI5 Contactor control A feedback (F_Ca) DI6 Contactor control B feedback (F_Cb) Table 19 REV-softstarter starter contactor control interface The definition of the DI terminal in the above list is only an example. Fig 19 Control circuit for REV-Softstarter Operating Sequence for REV-Softstarter: Motor is Stopped - > Start1 - > Close CCA - > Close CCC (R1) Motor is Stopped - > Start2 - > Close CCB - > Close CCC (R1) Motor is Running - > Stop - > Open CCC (R1) -> Ramp down time -> Open CCA & CCB Contactor Feeder Contactor feeder is regarded in MC510 as a specific starter type to provide measurement, control and protection functionality to a contactor feeder circuit. When start command has been received from field or local I/O, the contactor control output will be energized and remains this condition until stop command has been received or any protection function activated. Terminal Description Remark CCI Contactor control voltage input 32/110

33 CCA Contactor control A DI5 Contactor control A feedback (F_Ca) Table 20 Contactor Feeder contactor control interface i) The definition of the terminal in the above list is only an example. ii) Power, energy and other parameters related to Power factor are NOT correct and should not be refer to! Fig 20 Control circuit for Contactor Feeder Operating Sequence for Contactor Feeder: Motor is Stopped - > Start1 - > Close CCA Motor is Running - > Stop - > Open CCA Contactor Feeder/RCU The functionality of this starter type is according to NR-DOL/RCU starter with support for contactor feeder. 33/110

34 Terminal Description Remark CCI CCA Contactor control voltage input Contactor control A R1a NO contact of R1 (CCC) R1b DI5 Contactor control A feedback (F_Ca) Table 21 Contactor Feeder/RCU contactor control interface (for MC510) i) The definition of the DI terminal in the above list is only an example. ii) Power, energy and other parameters related to Power factor are NOT correct and should not be refer to! Fig 21 Control circuit for Contactor Feeder/RCU Operating Sequence for Contactor Feeder/RCU: Motor is Stopped - > Start1 - > Close CCA for 1s and Open CCA Motor is Running - > Stop - > Close CCC (R1) for 1s and Open CCC (R1) 34/110

35 Protection Functions The module provides full protection for motor by supervising three phases voltage, three phases current, earth fault current, startup time, the state of contactors and the state of main switch. Responding of protection functions is based on the parameters given by user. The operation of separate functions is independent thus protection functions can be active at the same time but the one which indicates the situation first will give a trip for motor. According to the application, all kinds of protection can be enabled, disabled by the upper level system or MCU parameter setting tool, also the protection characteristics can be adjusted. MC510 offers the following protection and supervisory function. Thermal overload protection Stall protection Long start protection Phase failure protection Unbalance protection Unbalance protection Noload protection Under power protection Over power protection Under power factor protection Earth fault protection Undervoltage protection Overvoltage protection Phase sequence protection Start limitation protection Environment temperature protection* Hotspots temperature protection* Busbar temperature protection* Motor temeprature protection (PTC/PT100/PT1000) * Table 22 Protection Functions in MC510 * Extension module is required. 35/110

36 Thermal Overload protection Thermal overload protection (TOL) protects the motor against overheating. The motor thermal condition is simulated by a calculation. The result of the calculation is stored in a thermal register and can be reported via operator panel or fieldbus interface. Calculation is accomplished in a different motor operation conditions, principle presented below, thermal increase and decrease are simulated by TOL protection function for running and stopped motor. Fig 22 Principle picture of motor thermal simulation MC510 simulates thermal conditions in the motor for all operating modes (Running or Stopped). This permits maximum utilization of an installation and assures safe protection of the motor. Thermal overload protection simulation accounts for the temperature rise of both the stator winding and the iron mass of the motor, it gives thorough consideration on the effect of motor overheating due to three phase unbalance during the simulation calculation of motor thermal overload. There are two thermal models supported by MC510: Standard or EEx e. The standard model makes use of parameters Trip class, t6 in thermal overload calculation. The protection of explosion proof three-phase motors with type of protection increased safety EEx e is done with two special parameters, the Ia/In ratio (stall/nominal current ratio) and Te time. The following diagram offers the characteristic curve of overload protection, in which the charac-. If EEx e thermal overload protection is required, please contact ABB for detailed clarification. 36/110

37 Fig 23 Trip curve from cold condition The Maximum thermal capacity level is 100%. Maximum level is reached when motor has been running with a current 6xIn at the time t6 starting from the cold state in ambient temp. 40 C. Trip class T6 10A Table 23 IEC trip class when ambient temp. 40 C, balanced motor current If motor is in overload condition, i.e. ILmax > 1.14 x TFLC (Thermal full load current multiplier reduced by motor ambient temperature), the Overload alarm is active to indicate overload. In some applications it is beneficial to be able to bypass the TOL protection momentarily because of the process reasons. The lifetime of the motor will be shortened but it might be more costly to stop the process. MC510 provides the function of TOL bypass protection. If the TOL bypass is triggered: That is, when the motor is running, the thermal capacity value is allowed to reach 200% before a 37/110

38 trip occur. Or when the motor has been tripped due to thermal overload protection, the motor is required to start urgently when the heat capacity is below 200%. TOL bypass protection may cause overheating and even fire. This function can be used only if the customer is clear about the load, even if the motor is required to operate under overload conditions. Otherwise, it may cause equipment damage, serious injuries or even death. Function Setting range 0=Disabled 1=Enabled 4=Protection bypass1 5=Enabled, and disable during motor startup Default value 1 Step value 1 Thermal model Setting range 0=Standard model 1=EEX e Default value 0 Step value 1 T6 2 Setting range 3-40s Default value 6s Step value 1 Ia/In3 Setting range Default value 5.0 Step value 0.1 Te3 Setting range 5-40s Default value Step value 5s 1s Cool coe. Setting range 1-10 Default value 4 Step value 1 TOL Alarm Level Setting range % Default value 90% 38/110

39 Step value 1% TOL Trip Level Setting range % Default value 100% Step value 1% TOL Reset Level Setting range 10-60% Default value 50% Step value 1% TOL bypass Setting range 0=Disabled 1=Enabled Default value 0 Trip Reset Mode Setting range 1=Auto 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Ambient Temperature Setting range 0-80 C Default value 40 C Step value 5 C Table 24 TOL protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. 2 When Standard thermal model is selected 3 When EEx e thermal model is selected Stall Protection Stall protection is used to protect the driven mechanical system from jams and excessive overload. Stall protection function uses I max as the criterion. There are other parameters to be determined as followed. 39/110

40 Function Setting range 0=Disable 1=Enable 4=Protection bypass Default value 0 Step value 1 Trip Level Setting range % Default value 400% Step value 10% Trip Delay Setting range s Default value 0.5s Step value 0.1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 25 Stall protection parameters The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 24 Stall protection 40/110

41 Stall function activates after motor nominal startup time has elapsed. The highest measured phase current (I Lmax) is compared against the Trip level. When I Lmax remains over the trip level at a time longer than Trip delay, a Stall alarm is issued and the contactor tripped. Long Start protection The long start protection protects motor against locked or stalled rotor in starting state. MC510 detects the current after a start command, and signals a fault when current continuously exceeds a separately set threshold of the period of start time. Fig 25 Long start protection Function Enable/Disable Setting range 0=Disable 1=Enable 4=Protection bypass Default value 0 Step value 1 Locked rotor Level Setting range % Default value 120% Step value 10% Locked Rotor Delay Setting range 0-250s Default value Step value 10s 1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local 41/110

42 Default value Step value 4 1 Table 26 Long Start protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Long Start protection activates during motor nominal startup time and disables automatically after predefined startup time. The highest measured phase current (I Lmax) is compared against the Locked rotor level. When I Lmax remains over the trip level at a time longer than Locked Rotor delay, a Long Start alarm is issued and the contactor tripped. Phase failure protection MC510 protects the motor against phase current loss condition. Phase failure protection function uses I Lmin/I Lmax (the ratio of lowest I Lmin and highest measured phase value I Lmax) as the criterion. Function is suppressed by parameters Motor startup time, Number of phases and Softstart ramp time. Function Setting range 0=Disable 1=Enable 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range 10-90% Default value 80% Step value 1% Trip Level Setting range 5-90% Default value 70% Step value 1% Trip Delay Setting range 0-60s Default value Step value 10s 1s Trip Reset Mode 42/110

43 Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 27 Phase failure parameters The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 26 Phase failure protection I Lmin/I Lmax is compared against the phase failure Alarm level. When I Lmin/I Lmax decreases below the Alarm level, a Phase failure alarm alarm is issued. I Lmin/I Lmax is compared against the phase failure Trip level. When I Lmin/I Lmax remains below the Trip level at a time longer the Trip delay, a Phase failure trip alarm is issued and the contactor tripped. Unbalance protection MC510 protects the motor against unbalance condition. Unbalance protection function also uses I Lmin/I Lmax as the criterion. Function is suppressed by parameters Motor startup time, Number of phases and softstart ramp time. Function Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass 43/110

44 Default value 0 Step value 1 Alarm Level Setting range 50-90% Default value 90% Step value 1% Trip Level Setting range 50-90% Default value 85% Step value 1% Trip Delay Setting range 0-60s Default value Step value 10s 1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 28 Unbalance protection parameters The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 27 Unbalance protection 44/110

45 I Lmin/I Lmax is compared against the unbalance Alarm level. When I Lmin/I Lmax decreases below the Alarm level, a Unbalance alarm alarm is issued. I Lmin/I Lmax is compared against the unbalance Trip level. When I Lmin/I Lmax remain below the Trip level at a time longer the Trip delay, an Unbalance Trip alarm is issued and the contactor tripped. Underload protection MC510 protects the motor against underload condition. Underload protection function uses I Lmax/I n (the ratio of highest measured phase value I Lmax and the rated current of the motor I n) as the criterion. There are other parameters to be determined, such as alarm level, trip level and trip delay. The protection characteristic is as follows: Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range 20-90% Default value 30% Step value 1% Trip Level Setting range 5-90% Default value 20% Step value 1% Trip Delay Setting range s Default value Step value 10s 1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 29 Underload protection parameters 45/110

46 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 28 Underload protection The ILmax/In is compared against the Underload Alarm level. When ILmax/In decreases below the Alarm level an Underload alarm alarm is issued. The ILmax/In is compared against the Underload trip level. When ILmax/In remains below the Trip level at a time longer than underload Trip delay, a Underload trip alarm is issued and the contactor tripped. Noload protection MC510 protects the motor against no load condition. Practically no load protection is the same function as underload protection. The function also uses I Lmax/I n as the criterion. Function Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range 5-50% Default value 20% Step value 1% Trip Level 46/110

47 Setting range 5-50% Default value 15% Step value 1% Trip Delay Setting range s Default value Step value 5s 1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 30 Noload protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 29 Noload protection The I Lmax/I n is compared against the Noload Alarm level. When I Lmax/I n decreases below the Alarm level a Noload alarm alarm is issued. The I Lmax/I n is compared against the Noload trip level. When I Lmax/I n remains below the Trip level at a time longer than Noload Trip delay, a Noload trip alarm is issued and the contactor tripped. 47/110

48 Earth fault protection There are two ways of earth fault protection in MC510 protects the motor against the earth fault condition. Direct measurement of zero sequence current through an external RCT Calculation of zero sequence current by internal calculation through measurement current values The function is by default suppressed by parameters Motor startup time and Softstarter ramp up time to avoid nuisance tripping due to harmonics caused by saturation of the current transformers. In some cases, it may be required to be switched on during startup in specific project requirements. This protection is neither intended to be used for pre-emptive isolation supervision nor for personnel protection against electrical shock. For these applications ABB recommends the usage of external protection devices (PRCDs / RCDs). Earth fault protection uses parameters as in the following table. Function Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass 3 Default value 0 Step value 1 Protection based on Setting range 0=External RCT 1=Internal Calculation Default valuez 0 Step value 1 Earth Fault Primary Setting range Default value 1000mA, 5000mA 1000mA Step value - Alarm Level Setting range mA (Earth Fault Primary = 1A) mA (Earth Fault Primary = 5A) 1 20%-50% In 2 Default value 500mA1 20%In 2 Step value 100mA 1 0.1%In 2 Trip Level Setting range mA (Earth Fault Primary = 1A) mA (Earth Fault Primary = 5A) 1 48/110

49 20%-80% In 2 Default value 800mA 1 50%In 2 Step value 100mA 1 0.1%In 2 Trip Delay Setting range s Default value 10.0s Step value 0.1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Earth fault protection is activated during motor startup time Setting range 0=Disabled 1=Enabled Default value 0 Step value 1 Table 31 Earth fault protection parameters 1 When Protection based on = External RCT is selected 2 When Protection based on = Internal Calculation is selected 3 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Fig 30 Earth fault protection (I 0 = Measured Earth Fault Current) 49/110

50 I 0 is compared against the earth fault current fault Alarm level. When I 0 exceeds above the Alarm level, an Earth fault alarm alarm is issued. I 0 is compared against the earth fault current Trip level. When I 0 remains above the earth fault current Trip level at a time longer than Trip delay, an Earth fault trip alarm is issued and the contactor tripped. Undervoltage protection MC510 protects the motor against undervoltage condition as voltage dip. The undervoltage protection function uses ULmin as the criterion. There are other parameters to be determined, such as alarm level, trip level and trip delay, reset voltage level. The protection characteristic is as follows: 3 Fig 31 Undervoltage protection The lowest measured main line voltage (U Lmin) is compared against the undervoltage alarm level. When U Lmin decreases below the undervoltage alarm level, an Undervoltage alarm alarm is issued. The lowest measured main line voltage (U Lmin) is compared against the undervoltage Trip level and voltage restore level. When U Lmin recovers above undervoltage Restore level before Trip delay expires and motor continues running. If U Lmin remains below the restore level at a time longer than Trip delay, Undervoltage trip is issued and contactor will be opened. When Autorestart function is active, Undervoltage trip delay will be same as Max. power down time automatically. Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 50/110

51 Step value 1 Alarm Level Setting range % Default valuez 80% Step value 1% Trip Level Setting range % Default value 65% Step value 1% Trip Delay Setting range s Default value 1.0s Step value 0.1s Reset Level Setting range % Default value 90% Step value 1% Trip Reset Mode Setting range 1=Auto 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 32 Undervoltage protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Overvoltage protection MC510 protects the motor against overvoltage condition. The overvoltage protection function uses ULmax as the criterion. There are other parameters to be determined, such as alarm level, trip level and trip delay, reset voltage level. The protection characteristic is as follows: 51/110

52 Fig 32 Overvoltage protection The maximum measured main line voltage (U Lmax) is compared against the overvoltage alarm level. When U Lmax increases bigger than the overvoltage alarm level, an Overvoltage alarm alarm is issued. The maximum measured main line voltage (U Lmax) is compared against the overvoltage Trip level and voltage restore level. When U Lmax recovers below overvoltage Restore level before Trip delay expires and motor continues running. If U Lmax remains bigger than the restore level at a time longer than Trip delay, Overvoltage trip is issued and contactor will be opened. Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range % Default valuez 100% Step value 1% Trip Level Setting range % Default value 120% Step value 1% Trip Delay Setting range s Default value 1.0s Step value 0.1s Reset Level Setting range % Default value 100% Step value 1% 52/110

53 Trip Reset Mode Setting range 1=Auto 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 33 Overvoltage protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Under power protection MC510 protects the motor against under power condition. Under power protection function uses P/Pn (the ratio of measured power value P and the rated power the motor Pn) as the criterion. (P / Pn) Alarm level Trip level Trip delay warning 2. start trip delay 3. clear trip delay 4. start trip delay trip 6. trip reset t Fig 33 Under power protection The P/P n is compared against the Alarm level. When P/P n decreases below the Alarm level a Under power alarm alarm is issued. The P/P n is compared against the trip level. When P/P n remains below the Trip level at a time longer than Trip delay, a Under power trip alarm is issued and the contactor tripped. There are other parameters to be determined, such as alarm level, trip level and trip delay. The protection characteristic is as follows: 53/110

54 Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range % Default valuez 50% Step value 1% Trip Level Setting range % Default value 30% Step value 1% Trip Delay Setting range s Default value 1.0s Step value 0.1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 34 Under power protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Over power protection MC510 protects the motor against over power condition. Over power protection function uses P/P n (the ratio of measured power P and the rated power of the motor P n) as the criterion. 54/110

55 Fig 34 Over power protection The P/P n is compared against the alarm level. When P/P n increases above the Alarm level an Over power alarm alarm is issued. The P/P n is compared against the trip level. When P/P n remains above the Trip level at a time longer than Trip delay, a Over power trip alarm is issued and the contactor tripped. There are other parameters to be determined, such as alarm level, trip level and trip delay. The protection characteristic is as follows: Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range % Default valuez 100% Step value 1% Trip Level Setting range % Default value 150% Step value 1% Trip Delay Setting range s Default value 0.2s 55/110

56 Step value 0.1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default value 4 Step value 1 Table 35 Over power protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Under power factor protection MC510 protects the motor against underload condition based on power factor. Under power factor protection function uses measured power factor as the criterion. The protection is masked by motor startup time or softstarter start time. There are other parameters to be determined, such as alarm level, trip level and trip delay. The protection characteristic is as follows: Function Enable/Disable Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection bypass Default value 0 Step value 1 Alarm Level Setting range 1-100% Default valuez 60% Step value 1% Trip Level Setting range 1-100% Default value 50% Step value 1% Trip Delay Setting range 0-60s Default value Step value 10s 1s Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local 56/110

57 Default value 4 Step value 1 Table 36 Under power factor protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Power factor Alarm level Trip level Trip delay warning 2. start trip delay 3. clear trip delay 4. start trip delay trip 6. trip reset t Fig 35 Under power factor protection The power factor is compared against the Alarm level. When power factor decreases below the Alarm level a Under power alarm alarm is issued. The power factor is compared against the trip level. When it remains below the Trip level at a time longer than Trip delay, a Under power trip alarm is issued and the contactor tripped. Phase sequence protection MC510 protects the motor against wrong phase sequence condition. The protection bases on the sequence of voltage input while motor is stopped. And while motor is started, it bases on the sequence of current. The predefined phase sequence as following, Voltage: V L1,V L2, V L3 Current: I L1, I L2, I L3 While the protection is enabled, there will be a trip while the measured phase sequence is different from the predefined sequence. The function is by default suppressed by parameters Motor startup time and Softstarter ramp up time to avoid nuisance tripping due to harmonics caused by saturation of the current transformers. In some cases, it may be required to be switched on during startup in specific project requirements. 57/110

58 Function Enable/Disable Setting range 0=Disabled 1=Enabled 4=Protection bypass Default value 0 Step value 1 Trip Reset Mode Setting range 2=Local 3=Remote 4=Remote&Local Default valuez 4 Step value 1 Table 37 Phase sequence protection parameters 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Start limitation Start limitation helps to protect the motor and also the process against excess number of starts in a given interval. When the number of starts is reached and the motor is switched off, a new start is prevented. The time interval starts from the first start. After the elapse of the time interval the counter is reset to the pre-set value. The permissible motor starts per hour can be obtained from the manufacturers motor and apparatus data sheet. However, the minimum waiting time between two starts shall be complied. The parameterization of the protection function can be the number of starts per time interval or the time between two consecutive starts. In the first case the user must wait after the trip for the reset to take place before making a start. Independent of this function, the motor is protected by TOL function and a start is possible only if the thermal capacity is below the startup inhibit level. If motor data specifies the number of starts during a certain time span the advantage of this protection function can be taken of supervising the number of starts. On some other cases process may put requirements for the motor start number thus this protection can be employed. Functionality is presented in the following example. Fig. 36 presents the start limitation protection with 3 starts allowed. 1) Normal situation, after stop command motor can be started normally, Start 2. Every start activates an internal timer for the time defined by time interval parameter. The number of active timers are reviewed after every stop command and compared to value of number of starts parameter. Stop command can thus exist during active or elapsed timer. 2) Two timers are still active, thus stop command generates alarm message "Start limitation alarm" and one more start Start 3 is allowed. 58/110

59 3) The 3rd start has been executed. A contactor trip and trip message "Start Limitation Trip" alarm will follow when motor is stopped while there are two active timers, here starting from Start 1. 4) Trip can be automatically reset when the first timer from Start 1 is finished. Motor start is possible when all pending trips are reset. Supervision continues with a new timer from Start 4 Fig 36 Start limitation protection Function Enable/Disable Setting range 0=Disable 1=Enable 4=Protection bypass Default value 0 Step value 1 Time interval Setting range Default valuez 1-600min 1min Step value 1 Number of starts Setting range Default value 2 Step value 1 Trip Reset Mode Setting range 1=Auto Default value 1 Step value 1 Table 38 Start limitation parameters 59/110

60 1 The user can trigger the protection bypass command through the input of the digital or the command from the fieldbus. Then all the options allow the protection bypass are actived, even if the trip level is reached, MC510 still only sends out the corresponding alarm information and does not execute the trip command. Loop environment Temperature protection MC510 extends the module hotspots module MT561 to monitor the ambient temperature inside the drawer and prevent the drawer components from being too high, thus causing the drawer to burn down. MC510 monitors the temperature of drawer environment to decide whether to trigger environmental temperature protection alarm. For details, please refer to the hotspots module MT561 section of the extended module user guide. When MT561 is only used for loop environment temperature protection, there is no need to configure hotspots temperature sensor. Hotspots temperature protection By extending the module hotspots module MT561, MC510 monitors the temperature of the inserting in the drawer to prevent the temperature of the drawer from being too high, which leads to the burnout of the drawer. The single insertion temperature measurement is realized by inserting a fixed temperature infrared sensor IR. MC510 monitors the temperature of one primary connector to decide whether to trigger a temperature protection. Fig 37 Hotspots temperature protection 60/110

61 For details, please refer to the hotspots module MT561 section of the extended module user guide. Busbar temperature protection MC510 monitors the copper temperature in the switchgear by extending the module MT564 to monitor the copper temperature in the switchgear, including the main busbar, the copper platoon of the ACB cabinet, and the copper row of the fixed circuit. The bus temperature measurement is realized by self-powered wireless temperature measurement module WT01, and transmitted to MT564 through Zigbee. MC510 monitors the temperature of the bus bar to decide whether or not to trigger the bus temperature protection. Fig 38 WTM temperature protection For details, please refer to the wireless temperature module MT564 in the user guide of the extended module. Thermal protection of motor (PTC/PT100/PT1000) The thermal protection of the motor is used as a protective condition to determine the protection function of the PTC/PT100/PT1000 thermistor detector, which is pre buried on the stator winding or bearing of the motor. MC510 realizes motor thermal protection through analog input and output module MA552. MC510 according to the measured resistance value, decide whether to turn on the corresponding motor thermal protection. 61/110

62 Fig 39 PTC/PT100/PT1000 temperature protection For details, please refer to the MA552 section of the analog input and output module in the extended module user guide. Analog input signal monitoring function MC510 monitors the input of analog input in analog input and output module MA552 in real time, and sends out corresponding signal according to the preset alarm level value and trip level value. For details, please refer to the MA552 section of the analog input and output module in the extended module user guide. Autorestart Function The line voltage (U L1L3) is supervised continuously. It is possible to automatically restart the motor after momentary power loss. Two alternative models of auto restart function are provided in MC510: Standard and enhanced. When any DI is set to "main switch state" and the main switch state is not input, the automatic restart function will automatically fail. Function Enable/Disable Setting range 0=Disabled 1=Enabled Default value 0 Step value 1 Function mode Setting range 0=standard 1=enhanced Default valuez 0 62/110

63 Step value 1 Max. autoreclose time Setting range Default value Step value ms 200ms 100ms Max. power down time Setting range s Default value 5s Step value 0.1s Staggered start delay Setting range s Default value 5s Step value 0.1s Table 39 Autorestart function parameters Autorestart function (standard) In standard mode, the reaction of the auto restart function depends on the length of the voltage dip. The following cases show the different reactions of MC510 in different voltage dip situations. Case 1: Voltage dip< autoreclose time Fig 40 Autorestart (Voltage dip< autoreclose time) 63/110

64 If voltage is restored within the autoreclose time, the motor will be restarted immediately. Case 2: autoreclose time<voltage dip< Max. power down time Fig 41 Autorestart (autoreclose time<voltage dip< Max. power down time) If power is restored after autoreclose time but before max power down time, motor will be restarted after the staggered start delay time. Case 3: Voltage dip> Max. power down time Fig 42 Restart (Voltage dip> Max. power down time) 64/110

65 If supply voltage remains below restore level long enough and exceeds max power down time, no automatic restart will be initiated. Autorestart function (enhanced) If the voltage dip is taken more serious, the enhanced autorestart function can be applied. In the enhanced mode, the reaction of the auto restart function not only depends on the length of the voltage dip, but also the number of voltage dips within short period of time. The following cases show the different reactions of MC510 in different voltage dip situations. Case1: Voltage dip< autoreclose time Identical to Case1 of standard mode Case2: autoreclose time<voltage dip< Max. power down time Identical to Case2 of standard mode Case3: Voltage dip> Max. power down time Identical to Case3 of standard mode Case4: 2xdip<200ms within 1s Fig 43 Restart (2xdip<200ms within 1s) If the interval between two voltage dips (which length less than 200ms) is less than 1 second. Automatic delay restart is triggered after second voltage restore. 65/110

66 Modbus TCP Failsafe Functionality MC510 failsafe function supervises the network interface and connection to the remote devices controlling the motor/starter equipment by MC510. Remote device have to refresh the certain MC510 network input variable to indicate that the control is operating normally and the network interface is in good condition. If a loss of Modbus/TCP communications for preset timeout value (1-25 seconds) is detected, the failsafe activates with the parameterized function as follows: No operation Start motor direction 1 Start motor direction 2 Stop motor When communication failure is detected and activated by MOSBUS TCP failsafe mode, MC510 will automatically release remote control permissions (if remote control authority has been selected). IO BUS Failsafe Functionality MC510 failsafe function supervises the network interface and connection to the extension modules by MC510. Remote device have to refresh the certain MC510 network input variable to indicate that the control is operating normally and the network interface is in good condition. If a loss of IO BUS communications for 200ms is detected, the failsafe activates with the parameterized function as follows: No operation Start motor direction 1 Start motor direction 2 Stop motor Main Switch Protection Function When Main switch or Test switch function is enabled, main switch protection function is enabled accordingly. Below tables show the logic relationship of main switch protection functions: Main switch function is enabled, and Test switch function is disabled: Motor status Main switch status ON OFF OFF ON Running Trip Remark* Stop No operation No operation Remark*:When main switch status is OFF, motor can t be started, i.e. motor status couldn t be Run- 66/110

67 ning status. Main switch function is disabled, and Test switch function is enabled: Motor status Test switch status ON OFF OFF ON Running Stop Stop Stop No operation No operation Both Main switch and Test switch function are enabled Motor status Main switch status Test switch status Both main switch and ON OFF OFF ON ON OFF OFF ON test switch are ON Running Trip Remark* Trip Remark* Trip Stop No operation No operation No operation No operation Trip Remark*:When main switch status is OFF, motor can t be started, i.e. motor status couldn t be Running status. MC510 Control Authority Control Authority MC510 Control Authority is the term describing the privileges on allowing motor control operation through MC510. It is also a setting parameter in MC510 to define which control access group has privilege to operate the motor via MC510. Control Access There are three control access groups defined in MC510, Local Hardwiring: MC510 accepts its commands from the hardwired inputs Remote Fieldbus: MC510 accepts its commands from PLC or higher control system via fieldbus, i.e. MODBUS/TCP. MP Control: MC510 accepts its commands from operator panel MP5x which locates on the front panel of each starter unit on switchgear. CHMI Control: MC510 accepts its commands from CHMI (MV570). Assign Control Authority 67/110

68 There are several means in MC510 to assign control authority and decide which control access group has the privilege to control. Local/Remote control authority assignment Parameter Setting: Select the access group from parameter setting window (Fig 44). This is the most direct option where control access is defined by parameterization software. Fig 44 Parameter Setting of Local/Remote of Control Authority Multi control access group is supported! For MC510, only when no DI is assigned Loc/R, Soft Local/Remote could be selected. Local/Remote Selector Switch MC510 supports hardwired local remote selector switch function which allows selecting control access groups via hardwired inputs. To enable this function, one of the digital inputs has to be defined as Loc/R in MC510 (Fig45). 68/110

69 Fig 45 Assign Local/Remote function to Digital Input Local/Remote Selector Switch will then define if control access goes to Local (Local Hardwired) or Remote (Remote Fieldbus). This function does not include the selection of operator panel MP control which is independent of either Local or Remote and has to be further defined in this case. Loc/R Selector Control Authority Switch Input Local Hardwiring Remote Fieldbus MP Enabled in Local MP Enabled in Remote False input Disabled Enabled Disabled Enabled True input Enabled Disabled Enabled Disabled Table 40 Local/Remote Selector Switch MP control authority assignment The selection of operator panel MP5x control which is independent of either Local or Remote and has to be further defined in this case. There are two ways of defining MP5x control access i.e. through parameter setting in parameterization software or through hardwired input. Parameter Setting 69/110

70 Fig 46 MP Control Select the access group from parameter setting window (Fig 46). This is the most direct option where control access is defined by parameterization software. Hardwired Input Use external selector switch to select MP control. Same as in Local/Remote Selector Switch function, one of the digital inputs has to be defined as MP Control to enable the function. Fig 47 Set DI as MP Control When MP control is enabled in one of the DIs, the MP control access option will be gray out. In another word, Hardwired Selection has privilege over Soft in terms of assigning control authority. CHMI control authority assignment The choice of CHMI control permissions is completely independent of local / remote selection. MC510 provides 2 ways to define control permissions for CHMI human-machine interface, such as parameter setting through software or input signals through hard wire switches. Parameter Setting 70/110

71 Fig 47-1 CHMI Control Authority As shown in Fig 47-1, this is the most direct way to set up CHMI control permissions in the local / remote switch input state. Hardwired Input Use external selector switch to select CHMI control. Same as in Local/Remote Selector Switch function, one of the digital inputs has to be defined as CHMI Control to enable the function. Fig 47-2 Set DI as CHMI Control When CHMI control is enabled in one of the DIs, the CHMI control access option will be gray out. In another word, Hardwired Selection has privilege over Soft in terms of assigning control authority. Main switch protection function The main switch protection function is based on the protection function of MNS drawer handle operation. This function monitors the state of the main switch under different motor circuits and enhances the functional safety of the MNS system. If you want to turn on the protection, you need to connect the main switch status and the test position status to the DI of MC510. In this case, the action performance of MC510 is as follows: Motor Status Main Switch State Test Switch State* Close Main Switch & Close Open Open Close Close Close Open Open Close Test position Running Main switch trip -- Current Stop Stop Main switch trip (Current feedback) feedback trip Running Main swich trip -- Normal Stop Stop Main switch trip (contactor feedback) Stop Normal Normal Normal Normal Normal Main switch trip 71/110

72 When MC510 monitors the test position, the "T" will appear on the top right corner of the MP51 LCD. The main switch state can be individually connected to MC510 without the need to access the test position. In this case, MC510 only monitors the state of the DI, and the performance of MC510 is as follows: Motor Status Main Switch State Close Open Open Close Running(Current feedback) Main Switch trip -- Running(contactor feedback) Main Switch trip -- Stop Normal Normal The test position state can be accessed to MC510 individually without requiring access to the main switch state. In this case, MC510 monitors the main switch in real time. When the main switch is in the test position, MC510 monitors the three-phase current and the "I/O" point state, and allows the contactor control loop to be controlled, but all protection functions based on current and voltage are invalid. When the input of the switch is defined as the "test position", if the input point is the same as the set state, the main switch is in the normal working position; on the contrary, the main switch is in the test position. For example, if the contact type is normally closed, when the input is high, the main switch is in the normal working position and the high level is cancelled. However, when the main switch is in the test position but MC510 detects the current (>5% Ie), all the protection functions will be automatically opened according to the set parameters, while ignoring the "test position". The action performance of MC510 is as follows: Motor Status Test position Close Close Open Open Close Running(Current Current feedback trip Stop Stop feedback) Running(contactor Normal Stop Stop feedback) Stop Normal Normal Normal *When MC510 monitors the test position, the "T" will appear on the top right corner of the MP51 LCD. Logic Block MC510 provides freely programmable logic block functions to carry out additional logic functions for 72/110

73 your application. Logic block function provides several logic modules: True table 2I/1O The function block is used to define the logical relationship between 2 input signals and 1 output signals. True table 3I/1O The function block is used to define the logical relationship between 3 input signals and 1 output signals. Timer The function block consists of three modes: power delay output (TON), power off delay output (TOFF) and pulse output (TP). Timer Type Time sequence diagram Remark TP PT:the pulse time of the TP type TON DT:the delay time of the TON type TOFF DT:the delay time of the TOFF type Fig 48 time sequence diagram of timer Counter The function block will change according to the input signal, each effective count input signal, and the counter value will be increased by 1 or reduced by 1 according to the set counter mode. 73/110

74 Flashing When the input signal is valid, the function block will output the signal according to the set duty ratio and frequency. For example, the duty cycle is 50%, the frequency is 0.5 Hz, the output duty cycle is 50%, and the frequency is 0.5 Hz. Logic block function also provides below operation modules: F_Ca/F_Cb/F_Cc This function is used to monitor the feedback state of the contactor CCA/CCB/CCC (R1), and is the level detection mode.start1/start2 The local control authority should be opened beforehand before use. This function is used for hard wiring starting motor. After receiving the starting 1 instructions, the motor will be running or running at low speed. After receiving the 2 instructions, the motor will reverse or run at high speed. The function is an edge trigger mode. Stop (edge triggering) / Stop (level trigger) The local control authority should be opened beforehand before use. This function is used for hard wiring stop motor.limit1/limit2 This function is used to install the limit switch. When the function is activated, the motor stops, and the motor can only reverse control. That is, the limit switch 1, which limits the positive or low speed operation of the motor, and the limit switch 2, which limits the motor reversing or the high speed operation of the motor. The function is a level trigger mode. Trip Reset The local reset authority should be opened before use. This function is used to reset the tripping signal for the edge triggered mode. PLC Control1/2 When the function is set to "PLC control 1" or "PLC control 2", and when the action signal is monitored, the motor will continue to run in one direction or at a given speed until the opposite stop signal is received. "PLC control 1" allows the motor to rotate or run at low speed. "PLC control 2" allows the motor to reverse or run at high speed. If you want to turn on the PLC control function, you need to set the control authority to local hard wiring. Torque Switch When the function is set to torque switch, when the input signal is opposite to the setting state, MC510 will release all control relays to stop the motor. This function is a level trigger mode. External Trip 74/110

75 This function is used to define the external tripping signal, which will cause the motor to trip. When the signal is effective, the motor is tripped and needs to wait until the signal is lost before it can be restarted. The signal is a level detection mode. When the input point does not detect the external tripping input signal, MC510 will reset automatically. MP Control This function is used to decide whether the operation panel can control the motor. When the function is set to "MP control", the control authority of MP can t be changed by parameter settings, and is determined by the state of the input signal of the function. If the input signal is effective, the operation panel MP can control the motor and vice versa. The signal is a level detection mode. Loc/R This function is used for local / remote state control. For MC510, if the local / remote input function is valid, the control permissions are local hard wiring; if the signal is invalid, it is a remote bus. The signal is a level detection mode. Test Switch This function is used to monitor whether the main switch is in the test position. If the main switch is in the test position, MC510 monitors the three-phase voltage and the various "I/O" point states. MC510 can control contactors, but all protection functions based on current and voltage are automatically closed, and only the control loop is tested. When the current value of the monitor is not 0, all protection functions set by the parameter will automatically turn on. This function protects the motor in the case of contact failure. The contact is a level trigger mode. Opening the "test position" function will trigger the monitoring function of the main switch to turn on. The function of the main switch can be seen in detail as the main switch protection function. Main Switch When the function is set to "main switch state", the monitoring and protection functions of the main switch will be switched on immediately. The input is the level detection mode. Process Interlock1 The process interlock 1 function is used to specify the time to allow the interlocking switch state to change. When the motor starts, if MC510 detects that there is no interlocking signal input, and the duration exceeds the set time, MC510 will operate according to the defined execution mode. When this parameter is set to 0, the interlocking signal must be active before starting the motor. The signal is a level trigger mode. 75/110

76 Fig 49-1 Process interlock1 Case 1: When t1>t2, motor can run normally. Case 2: When t1<t2, a trip or stop will be performed according to the predefined operation. If the signal is detected active, the trip will be reset automatically. Process Interlock2 The process interlock 2 function is used to specify the time to allow the interlocking switch state to change. When the motor starts, if MC510 detects interlocking signal input, and the duration exceeds the time set by this parameter, MC510 will operate according to the defined execution mode. When this parameter is set to 0, the interlocking signal must be inactive before starting the motor. 76/110

77 Fig 49-2 Process interlock2 Case 1: when t1>t2, motor can run normally. Case 2: when t1<t2, a trip or stop will be performed according to the predefined operation. If the signal is detected active, the trip will be reset automatically. Emergency Stop It is used to define the emergency stop device. When the motor is running, once the emergency shutdown input is effective, the motor will stop running or trip immediately according to the set execution mode. The motor is not allowed to restart until the input point is cancelled. The input signal is a level trigger mode. 1)Emergency stop function is not used for functional safety. 2)When the function block does not detect the emergency stop input signal, MC510 will reset automatically. CHMI Control This function is used to decide whether CHMI can control the motor. When the function is set to "CHMI control", the control authority of CHMI can t be changed by the parameter settings, and is determined by the state of the input signal of the function. If the input signal is effective, CHMI can control the motor and vice versa. The signal is a level detection mode. TOL Bypass If the thermal overload bypass function is selected and the signal input function block is detected by MC510, the thermal overload bypass instruction of the motor is issued. When the TOL bypass function is activated, MC510 allows the thermal capacity trip level to rise to 200% temporarily, that is, the motor can run continuously when the heat capacity is less than 200%, and does not trip the motor, or allows the motor to start immediately when the heat capacity is less than 200%. If the TOL bypass function is to be activated, TOL bypass function must be enabled at TOL protection window in MCUSetup, and then TOL bypass signal should be given to TOL bypass function block or from fieldbus. The signal is a level detection mode. 77/110

78 TOL bypass function increases the thermal capacity trip level value, which may cause the equipment to overheat or even burn down. Protection Bypass If the protection bypass function is selected, MC510 will detect the signal input function block and issue the protection bypass instruction. At this time: Motor is running. When MC510 detects the protection bypass signal input, all protection functions that allow the protection bypass are switched to alarm only mode automatically. When the protection bypass signal disappears, all the protection functions that allow the protection bypass are restored. Protection with protection bypass is during trip delay time. When MC510 detects the protection bypass signal input, the delay calculation will stop immediately. When the protection bypass signal is lost, the delay calculation will restart if trip signal is still available. The motor is tripped, but the trip is not cleared. When MC510 detects the protection bypass signal input, the trip will be reset immediately. When the protection bypass signal disappears, the trip information is redisplayed if the judgment condition of the trip is still available. After the bypass is protected, the motor may run under dangerous conditions. Please be careful when using it. Digital output relay This function maps the signal status to the output relay of MC510, and the digital output relay will be ON or OFF according to the state of the input signal. All kinds of signals/variables are provides for the input signals of logic modules and operation modules: True/False Clock signal DI status Output of Truth2I1O Output of Truth3I1O Output of Counter Output of Timer Output of Flashing Alarm signal Trip signal 78/110

79 Control authority status Motor status Switch position Logic block function could be edited in MConfig and CHMI. Below picture shows an example of logic block function. For more details of logic block, please refer the MC510 parameter description document. Fig 50 Example of Logic Block Program Maintenance Function MC510 provides maintenance function for motor by supervising running hours, start numbers, trip numbers and SOE. When the maintenance parameter over the predefined alarm level, MC510 will trigger an alarm signal accordingly. The operation of separate maintenance functions is independent thus these functions can be active and given an alarm at the same time. Number of Starts MC510 counts number of starts. For each startup, MC510 updates the number of starts in memory map. When start number alarm level exceeds, MC510 will issues an alarm. Motor running time MC510 counts motors running hours. When running hours exceeds, MC510 will issue a running time alarm. 79/110

80 Insertion cycles MC510 gets the value of insertion cycles via counting control power cycles. When times of Insertion cycles exceeds alarm level, MC510 issues an alarm. MC510 also provides some other maintenance information of motor, which will convenience users to get the report of motor. Number of Trips MC510 counts number of trips and updates in memory map. Parameter change counters MC510 counts times of parameter change and updates them in a memory map. SOE MC510 provides event recorder data for up to 256 events with time stamp. Metering and Monitoring MC510 provides an extensive range of motor operation supervisory functions. Supervisory data are transmitted via MODBUS TCP to the upper level system for centralized management and also can directly displayed on the operator panel MP51 if installed on the front of the motor starter module. Metering and Monitoring Power Information Current L1,L2,L3 (A) Current L1,L2,L3 (%) 1 Current Unbalance(%) 2 Thermal Capacity (%) Power Factor Line Voltages (V) Frequency (Hz) Earth Fault Current (A) Active Power (kw) Apparent Power (kva) Energy (kwh) Time to TOL trip Time to TOL reset Actual Startup Time Contactor Temperature 3 80/110

81 Environment Temperature 3 Busbar Temperature 4 PTC Resistance 5 PT100/PT1000 Temperature Value 5 Analog input (0-10V) 5 Analog output 5 Motor status Motor status DI status Diagnosis Alarm/Trip for each function Maintenance Motor Running Hours Motor Stop Time Number of Starts Number of trips Number of insertion cycles Parameter change counter Pre Trip Phase A/B/C current Pre Trip Earth Fault Current SOE Table 41 Monitoring and metering by MC510 1)Current% measured current compares with nominal current. For expmple, Current% of L1 = I L1 / I n*100% 2)Current Unbalance measured the max. difference between current and average current with average current. The formula is : I ave=(i L1+I L2+I L3)/3 Current Unbalance = max(i L1- I ave, I L2- I ave, I L3- I ave )/ Iave *100% 3)Need extended MT561 module. 4)Need extended MT564 module. 5)Need extended MA552 module. 81/110

82 Extension modules Max.4 extension modules are allowed to connect with MC510 basic unit. All extension modules have the same enclosure dimension design. All extension modules are powered from the basic unit. The type of extension modules will be automatic detected by the basic unit after they are configured in parameter setting. The following extension modules are available: 1)DIDO modules MB550/MB551 DI/DO extension 2)AIAO module MA552 AI/AO extension or motor thermal protection (PTC/PT100/PT1000) 3)Hotspots module MT561 Contactor and Environment Temperature Supervision 4)Wireless temperature module MT564 Bus bar Temperature Supervision Fig 51 Max.4 extension modules with MC510 module For more details, please refer to the document Extension Module User Manual. The extension module connected the closest to the basic unit via IO-BUS will be identified as extension module 1. The modules that follow behind will be identified as extension module 2, extension module 3, and extension module 4. 82/110

83 Communication MC510 provides two 10/100Mbps Ethernet interfaces. Several protocols are supported, such as Modbus/TCP, SNMP, SNTP, HTTP, TFTP and MRP etc. Communication interface Designation Physical interface Connector Speed Description 10/100 BASE-T RJ45 10 /100Mbps (Yellow LED of RJ45 connector lighted means communication speed =100Mbps) Table 42 Ethernet interface Fig 52 RJ45 pin assignment Pin no. Signal Description 1 TD+ Transmit + 2 TD- Transmit - 3 RD+ Receive+ 4 No connection - 5 No connection - 6 RD- Receive- 7 No connection - 8 No connection - Table 43 RJ45 pin assignment Pin 4, 5 are internally shorted, Pin 7, 8 are internally shorted. 83/110

84 MODBUS/TCP MODBUS/TCP is MODBUS over TCP/IP protocol. It is mainly used the monitoring and control of automation. MODBUS/TCP implemented in MC510 follows the specification below, - Modbus application protocol V1.1b - Modbus Messaging on TCP/IP Implementation Guide V1.0b Refer to 1TNC928207M0201 for the MODBUS command supported by MC510. MC510 supports 4 ODBUS/TCP master at the same time. Modbus/TCP connection Two-port Ethernet switches are integrated inside MC510. It makes system integration flexible and econic. Three topologies are supported, -Start -Daisy chain -Ring Network characteristics Designation Description Type of cable Straight or crossed category 5 shielded twisted pair Maximum cable length between two adjacent devices 100 m Maximum number of devices per network segment 160 Maximum number of devices per ring 50 Table 44 Network characteristics The same network segment must have the same network identifier. For example, x is in the same network segment, while x and x are not in the same network segment. 84/110

85 Topologies Following figure illustrate the typical topology support by MC510. Fig 53 Topology Using ring topology in withdrawable cubicle The drawers have the characteristics of low downtime. In the low voltage switchgear, the protection and control equipment of a motor starter are all installed in the same drawer. When the circuit fails, the user can replace the equipment quickly and conveniently to reduce maintenance hours. Moreover, ring topology will ensure that replacing any one drawer will not affect the communication quality of the whole system. But if two drarwes are withdrawn, as shown in right part of fig 54, even if the system has MRP redundancy function, the situation is totally different. Devices between these two drawers cannot be accessed anymore. Here MS571 should be used to ensure stable communication even if two or more drawers are withdrawn, as shown in left part of fig 54.The MS571 is mounted in the cable compartment instead of mounted inside the drawer. When draws are withdrawn, MS571 will bypass the withdrawn drawer automatically to keep communication working in ring. When the drawer withdraws, the network will spend less than 200ms to re-organize a new network. 85/110

86 Fig 54 Ring topology in withdrawable cubicle No more than 5 consecutive drawers can be withdrawn in the same ring, otherwise, the quality of communication will be affected. Loop switch MS571 The loop switch is used for keeping the Ethernet loop healthy while the withdrawable module with MC510 is removed. As shown in left part of fig 55, there are 4 RJ45 ports in MS571, 2 ports with MCU mark are MCU interface to connect to MC510, 2 ports with BUS mark are BUS interface to connect in Ethernet loop. The principle is shown as right part of fig 55, MC510 is introduced into the Ethernet loop via MS571. When MC510 is removed, MC510 will be auto bypassed by MS571, so that the ring Ethernet loop is still available. 86/110

87 Fig 55 Loop switch MS571 The power supply of MS571 is provided from the BUS interface. As shown in fig 54, TA60 should be use for connecting the first and last MS571 to external device in one loop. Directly connecting MS571 to external device may damage the device! Accessary TA60 Fig 56 TA60 87/110

88 The power supply of MS571 can be provided via TA60, there are 3 ports in TA60: RJ45 modular plug, RJ45 modular jack, and two pair s redundancy power cables. RJ45 modular plug is used to connect to external device. RJ45 modular jack is used to connect to MS571 to provide power supply and Ethernet loop signals. Two power cables should be connected to two redundancy 24VDC power supplies. The red core is 24VDC+ while the black core is 24VDC-. In case there is only one power supply, both power cables should be connected to this power supply. SD card interface If SD card is detected during MC510 power up, below operation will be executed according to the preset function in SDFunction.INI file, which is stored in SD card. Function code Description File name 0x No operation 0x Upgrade MC510 boot firmrware from SD card Boot.bin 0x x x x x x x Upload parameter from MC510 module to SD card Upgrade MC510 application firmrware from SD card No operation Upgrade extention module firmware of slot1 from SD card Upgrade extention module firmware of slot2 from SD card Upgrade extention module firmware of slot3 from SD card Upgrade extention module firmware of slot4 from SD card Para_upload.csv User.bin Hotspotsmeasurement.bin /PT100.bin /PTC.bin /AIAO.bin /DIDO.bin 0x Upgrade operator panel firmware from MP.bin Table 45 Function code of SD card 88/110

89 PARAMETERIZATION Parameterization MC510 can be configured with MP51 or MP52 operator panel keypad, via MCUSetup software, and through fieldbus if the communication network is available. Parameterization via MP51 By pressing keypad on MP51 panel, most of the parameters can be set or changed through operator panel MP51. Details of the parameters menu structure, please refer to MP51/MP52 Operator Panel Chapter. Parameterization via MConfig Software Via mini USB-Pin physical interface on MP51 or MP52, users can connect MC510 with computer where MConfig software is installed and running to complete the parameters setting. Parameterization via CHMI All parameters of MC510 are stored in registers, and users can set parameters through CHMI (human machine interface). Parameterization via Fieldbus MC510 parameters are listed in the memory map. The user can parameterize MC510 by MODBUS/TCP refer to the MC510 MODBUS/TCP Protocol Implementation. MC510 Parameters MC510 Parameters are listed together with explanations, ranges and default values in separate document MC510 Parameter Description. 89/110

90 ACCESSORIES Accessories MP51/MP52 Operator Panel Overview MC510 device provides an operator panel as optional accessory for local operating and parameters setting to individual motor starter. There are two types of operator panels available, i.e. MP51 and MP52. MP51 is the operator panel with control buttons, LED indicators and LCD display. MP52 is more compact in size with control buttons and LED indicators only. Both operator panel types are equipped with communication port (mini USB connector) in the front for remote parameterizing via engineering station. Operator panel is connected to main MC510 device via RJ12 interface (RS485 port) which is located on the back of the panel. Fig 57 MP51 Operator Panel Fig 58 MP52 Operator Panel 90/110

91 ACCESSORIES LED Indicators There are 4 sets of LEDs available in the front of MP5x panel. All LEDs color are configurable. Following table describes LEDs functions and configuration. LEDs Configurable color Configurable functions LED1 Power, Running, Stop, Fault, Start1, Start2, Ready to Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault(default, color can t be configured), temperature LED2 (default) Power, Running, Stop, Fault, Start1(default), Start2, Ready to Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, temperature LED3 (default) Power, Running, Stop, Fault, Start1, Start2(default), Ready to Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, temperature LED4 Power, Running, Stop, Fault, Start1, Start2, Ready to Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, temperature(default, color can t be configured) Table 46 LED configuration LED functions Power Running Stop Fault Start1 Start2 Ready to Start DIx Ready/fault Temperature Meaning of the function MC510 unit is powered up and ready for operation Motor is running CW/N1 or CCW/N2 or feeder is closed. Motor is stopped or feeder is open Motor is in faulty status Motor is running CW/N1 Motor is running CCW/N2 Motor is ready to start, i.e. there is no active internal or external trip, motor is not under emergency stop state (if defined) & Main Switch is ON (if defined) The status of DIx LED color for Ready/fault function can t be configured. When motor is ready to start, the LED turns green; When motor is in faulty status, the LED turns yellow. LED color for Temperature function can t be configured. When the temperature measured by hotspots monitor is in normal range, the LED turns green; Once the temperature is above the alarm level or MT561 communication failure with the Basic Unit, the LED turns yellow; once the temperature is above trip level the LED turns red. If MC510 does not configure hotspot monitoring module MT561, LED does not display. Table 47 LED indicator function definition 91/110

92 ACCESSORIES LED Status On Wink Off Explanation Assigned function is activated. Alarm active or device is initializing Inactive or off power Table 48 LED indicator message i)if MP5x is under parameterization with parametering cable plugged on or scrolling through setting menus, all LEDs in the front panel wink at the same time. ii)additional label of LED should be prepared, if LED is not assigned to default function. Control Buttons MP51 provides 7 buttons and MP52 provides 3. Customer could control motor via buttons on MP51 and MP52. And customer can control motor, do monitoring and parameterization via buttons on MP51. Button Function Remark Start 1 button, to Start motor CW/N1 Start 2 button, to Start motor CCW/N2 Stop button, to Stop motor Also used to reset fault trip Enter button, to enter selected menu Only in MP51 Down button, to show next messages or menus Only in MP51 Up button, to show past messages or menus Only in MP51 Back button, to exit selected menu or go back one step. Only in MP51 Table 49 MP51/52 Button Icons 92/110

93 ACCESSORIES Monitoring value display After power on, MP51 initially enters Monitoring Values display stage, during which all values, alarms, trips and control authority can be displayed here. Fig 59 View of monitoring value display window Page Title: At the top of the LCD to show the tag name. Main display Area: Main display area to display process data. Test Switch: show test switch is active. Indication Type: At the left side of the bottom of the LCD to show the type of the indication (Alarm/Trip). Indication text: Following Indication Type to show the detail alarm/trip message Control Authority: show control access Icon Meaning Alarm Trip Local control is active Remote control is active Test switch is active 01, highlighted, DI1* status is closed 02, not highlighted, DI2* status is open Table 50 Description of icons displayed on MP51 93/110

94 ACCESSORIES *) The number stands for the port of DI. Status of each DI is available on MP51. Displaying parameters MP51 supports up to 16 running parameter windows/pages. Users are free to choose any or all of the parameters to be shown on MP panel and masked out unwanted information. User can navigate through displaying pages by pressing Up or Down button. Page No. Meaning 1 Current (A) 2 Current (%) 3 Line Voltage 4 Power Related (include Power, Apparent Power, Power factor) 5 Thermal Capacity 6 Frequency 7 Energy 8 Ground Current 9 Time to TOL Trip/Reset 10 DI Status 11 Startup Time 12 Current Unbalance 13 Extension Module 1 14 Extension Module 2 15 Extension Module 3 16 Extension Module 4 Table 51 Parameters on different displaying page i) Enter button is NOT active when scrolling through running parameter windows. ii) Table 51 shows the actual sequence of displaying pages on MP51. Alarm message Alarm message will come up on the bottom of the display window as shown in fig 59 with indication icon whenever there is an alarm active. Possible alarm messages include the following, 94/110

95 ACCESSORIES Thermal Capacity Overload Phase Failure Phase unbalance Underload Noload Earth Fault Undervoltage Overvoltage Autoreclose Feedback Welded Contactor Start limitation Communication failure Running time Start number Watchdog Ready to trip reset Hotspots Temperature Drawer Environment Temperature WTM CH1 Temperature WTM CH2 Temperature WTM CH3 Temperature WTM CH4 Temperature More detail alarm information, please refer to 1TNC928207M MC510 Modbus TCP Protocol Implementation. Trip message Trip message will come up on the bottom of the display window as shown in fig 59 with indication icon whenever there is a trip active. Possible trip messages include the following, TOL Stalled rotor Phase Failure Phase unbalance Underload Noload Earth fault Undervoltage Overvoltage Feedback Communication failure Start Limitation Feeder Trip Long start Emergency Stop External Trip Current Feedback Main switch off Hotspots Temperature WTM CH1 Temperature WTM CH2 Temperature WTM CH3 Temperature WTM CH4 Temperature More detail trip information, please refer to 1TNC928207M MC510 Modbus TCP Protocol Implementation. 95/110

96 ACCESSORIES The Menu Tree Press Back" button at monitoring value display window to enter the main configuration menu Fig 60 View of menu Press Back" button at the main configuration menu to enter running parameter window. Page Title: At the top of the LCD to show the tag name or submenu table Highlighted Item: The current active menu item Current Number: At the right of the top of the LCD to show the number of the current selected menu item Total Number: At the right of the top of the LCD to show total menu item numbers in the current page. Hint: At the bottom of the LCD to describe the current highlighted item or the related value of the highlighted item. Press Up/Down button, could move the highlight to previous/next items. Press Enter button to enter next level of menu. Press Back button to go back to previous level of menu. 96/110

97 ACCESSORIES Fig 61 View of main configuration menu tree 97/110

98 ACCESSORIES Parameter Within this submenu all motor related parameters can be configured. More details about parameter, please refer to MC510 parameter description document. Operator Panel Within this submenu LCD display and LED indication can be configured. More details about parameter, please refer to MC510 parameter description document. Time Setting Within this submenu actual time can be configured. Below table shows the organization of the different parameter masks in the menu tree. Level 1 Level 2 Time Setting Year Month Day Hour Minute Second Week Table 52 Menu tree of time setting Maintenance Within this submenu all motor related maintenance can be configured. Below table shows the organization of the different parameter masks in the menu tree. Level 1 Level 2 Maintenance SOE Running Time Stop Time Start Number Stop Number Trip Number 98/110

99 ACCESSORIES Last Trip Current (%) Last Trip Current (A) Last Earth Fault Trip Current Insertion cycle counters Parameter change counters Table 53 Menu tree of maintenance Product Info. Within this submenu, information of MC510 and MP51 can be read. Below table shows the organization of the different parameter masks in the menu tree. Level 1 Level 2 Maintenance MC510 Firmware version MP51 Firmware version IP Address Subnet Mask Gateway Address Type of Extension Module 1 Firmware Version of Extension Module 1 Type of Extension Module 2 Firmware Version of Extension Module 2 Type of Extension Module 3 Firmware Version of Extension Module 3 Type of Extension Module 4 Firmware Version of Extension Module 4 Table 54 Menu tree of product info Backup & Download Backup feature is to read the parameters from MC510 device and create a backup file in MP panel. Download feature is to download the backup file from MP panel to MC510 device. This feature can be quite useful when similar parameters are required for several MC510 devices. It is easy to operate on site. Table 57 shows the organization of the different parameter masks in the menu tree. 99/110

100 ACCESSORIES Level 1 Level 2 Backup & download Backup Parameter Download Default Parameter Download Backup1 Table 55 Menu tree of backup & download 1)Download Backup' option will not be available until the 'Backup Parameter' function has been executed. 2)Remember to change slave address after copying parameters from other device to avoid communication problem. Backup Parameter: save current parameter to backup register in MP51. Download Backup: download the parameter in backup register into MC510 Test Select this submenu, MC510 will test itself for a few seconds and feedback. Test function is only for manufactory. Adjusting Parameters Select the item at the last level of Parameter and press enter, a window for password input will appear. Input the correct password to enter the parameter adjusting window. Fig 62 Process of enter parameter adjusting window 1)Default password is /110

101 ACCESSORIES It is recommended to change the default password after first login. There are two types of parameter adjusting window: Numerical Value adjusting window and Option Selecting window. When finish, press Back" button to confirm window. Then select confirm and press enter to download new parameter to MC510. Fig 63 Process of confirm parameter adjusting The slave address could be revised and downloaded to MC510 via MP51. Adjusting a Numerical Value This type of window allows a numerical value to be specified within the given limits. Press up/down button will increase/decrease the digit. Once the value is set, press enter button to acknowledge it. i)the information of given limits of parameters is provided in MC510 parameter description document. ii) Keep pressing up/down button will changing the speed of increase/decrease the digits. iii)when the value reaches the limit, it will automatically count backwards even if the same button is pressed. The following example shows how to set the startup time to 10s. Fig 64 Example of numerical value adjusting 101/110

102 ACCESSORIES Start editing the value by pressing the Up button. If reach 10, press enter button. Selecting an Option from a List This type of window allows an item to be selected from a given list of options. With the up/down keys you can scroll through the list. The highlighted selection shows current position within the list. Pressing Enter button to confirm and then press Back button to exit. Pressing Back button exits the dialog and discards the selection. i)the details of given options of parameter are available in MC510 parameter description document. The following example shows how to set the starter type to NR_2N Dahlander Fig 65 Example of options selecting Parameterization port The parameterization port on MP5x panel is a mini USB type of interface. Once this port is connected with parametering cable, the communication between MC510 main device and MP5x panel is temporarily stopped with a parameterizing status message shown on LCD. No operation is allowed during parameterizing. 102/110

103 ACCESSORIES Fig 66 Parameterizing message MC510 parameters can be uploaded and downloaded from the parameterization device via the interface. Rememer to cover up the mini USB port after parameterization finished. Connection Operator panel is connected to the terminal on MC510 via RJ12 interface. The connection shown below includes power supply and communication. Fig 67 Connection between MC510 and MP5x If MP51 can t get information from MC510, No Comm. will be shown in LCD the window. Fig 68 No Communication message 103/110

104 ACCESSORIES If MP51 does not get correct information from MC510, Comm. Error will be shown in LCD the window. Fig 69 Communication error message Parameterization Software: MConfig MConfig software is used to set parameter. It exchanges data with MC510 via RS485. Fig 70 Parameterization interface Fig 71 MConfig window 104/110