MCC Panel Design

Improving Motor Reliability with Intelligent Motor Control
Centers and theTesys-T
Presenters Name: Wayne Thygesen, Consulting Engineering Specialist

December 3, 2008
Improving Motor Reliability with

Intelligent MCCs and the TeSys-T
Add photo in this area
Make the most of your

energy
Make the most of

SM
your energy
Schneider Electric
Intelligent MCC
2008
Schneider Electric - Water Wastewater Competency Center Wayne Thygesen 3 December 2008
TeSys T is the
Basic Tool
Used for iMCC
TeSys T System Components

Native protocol
Native protocol
connectivity
connectivity
X
MODBUS
Ethernet TCP/IP
Additional
Additional
protection
protection
functions
functions
Controller expansion module
or
Magelis terminal
or
PC with
PowerSuite
External CT
Ground CT
Remote control
Remote control
and monitoring
and monitoring
Control Unit
Operator
For up to 810A
For up to 810A
Ground Fault
Ground Fault
Sensitivity
Sensitivity
TeSys T Motor Management System
TeSys T Motor Management Controller and Control Unit Operator

Modbus is native in the TeSys T relay plus additional
communication options are available
Currently designed into Model 6 iMCC
Motor Managment Controller : LTMR
Front view description

Power
Supply
6 Discrete inputs
(internal powered inputs)
1 Fault relay
output (NO/NC)
Plug-in terminals
Expansion module/
HMI/PC connection
(modbus RS485)
Network
connection
(RJ45 port)
Reset or
Self test
Button
Diagnostic Leds
3 relays
outputs 5A
Ground Temp.
Network
fault
connection
Probe (screw terminal)
input
Expansion module
Assembling
Side by side or
Remote
Power Supply
Powered by Controller
Additional Motor Protection

Over / Under Voltage
Over / Under Power Factor
Over / Under Power
Load shedding
Voltage phase imbalance,
lost and reversal
Additional Input
4 discrete inputs
Input Power supply

24 VDC or
100-240 VAC 50/60Hz
TeSys T Measurements
Current
Voltage
Power
Depending on the controller configuration
Functions
Measured range
Thermal capacity
Motor temperature sensor
Line currents
Ground current
0 to 200 %
Average current
Current phase imbalance
Frequency
Line to line voltage
Line voltage imbalance
Active / Reactive Power
Power factor (1)
Active/Reactive Energy
Controller
Controller
& Exp.
module
0 to 6500 Ohms
0,4 to 810 A
Internal : 0 to FLC
External : depend on settings
0,4 to 810 A
0 to 200 %
0 to 100 Hz
0 to 830 VAC
0 to 200 %
0 to 6553.5 KW / KVar
0 to 100
0 to 400,000 KWhr / KVarhr
(1) : Value saved on power loss
TeSys T Motor Protection functions
Depending on the controller configuration
Functions
Current
Voltage
Power
Thermal overload (inverse & definite time)

Current phase (imbalance, loss, reversal)
Under/Over Current
Long start, Jam
Ground current
Rapid cycle lockout
Voltage phase (imbalance, loss, reversal)
Under/Over Voltage
Voltage load shedding
Under/Over Power
Under/Over Power factor
Controller
Controller &
expansion
module
Note : All the protection functions include fault detection and most protection functions include warning detection
10
Monitoring : Statistics
Counting log for every kind of faults
Tesys T records the
faults statistics for
the analysis of the
system maintenance
Protection faults : overload, overcurrent,

Diagnostics faults : HMI port com loss, internal
fault,
Recording the motor control history

Motor starts count and operating time
Motor starts per hour
Rapid cycle lockout count
Load shedding count
Last start record
11
Monitoring : Statistics
Recording the last 5 faults
Fault code
Date and time
Value of parameters & measurements
12
Monitoring : Diagnostic faults

Internal faults
Tesys T records
faults which affect
the ability of the
controller to work
properly
Watchdog : stack over/underflow

Temperature
Control command checks

Start /stop command (current checking after the command)
Run /stop check back (current checking during the stage)
Connection fault
Current Transformer connection
Voltage connection
Temperature sensor connection
Communication loss
Local terminal connection
Communication loss : HMI, Network, expansion module
13
Monitoring : Motor states

Operating states
Tesys T records the
motor states for the
analysis of the
device operation
Ready
Start
Run
Not ready
Thermal overload status

Time to trip (before the fault occurs)
Time to reset (after a thermal overload occurs)
14
Control functions
Motor control Overview
Control Modes
determines the device or devices that will command controller
outputs :
Local mode : Local terminal or Local HMI
Remote mode : PLC or DCS connected to the network
Operating Modes
determines the behavior of the controllers inputs and outputs (5
predefined modes and 1 custom mode) :
Overload, Independant, Reverser, Two-Step, Two-Speed
Custom : user customize the logical operation for the output command
Operating States
The controller provides control, monitoring and protection functions
appropriate to each of the motors operating states :
Ready, start, run and fault (not ready)
Fault Management
determines how the controller manages faults :
Manual, Automatic and Remote reset
15
Operating modes
Pre-configured operating mode
Overload : The Start/Stop of the motor is realized by a mechanism other
than the controller
Independant : Direct on line full voltage non reversing motor starting
Reverser : Direct on line full voltage reversing motor starting
Two-Step : Reduced voltage starting motor
Two-Speed : Two-Speed motor for motor types : Dahlander, Pole
Changer
Custom operating mode

PowerSuite logic editor : provides logic functions (Boolean, Register,
Timers, Counter,) that manage the controller behavoir to create a user
mode
Note
Note: :The
Theselected
selectedoperating
operatingmode
modedetermine
determinethe
thebehavior
behaviorofofall
all
controller
inputs
and
outputs.
controller inputs and outputs.
16
Custom operating mode
PowerSuite logic editor : 2 languages
Possibility
Possibilitytotouse
usean
an
existing
logic
file
to
existing logic file tomodify
modify
the
logic
command
that
the logic command that
manage
managecontroller
controller
behavior
behavior
List
List
Language
Language
Function
FunctionBlock
Block
Diagram
Diagram
17
Motor Management Controller : LTMR

Overview
Current Rating (internal CT)
Control Power supply
0.4 to 8 A
1.35 to 27 A
5 to 100 A
24 VDC or
100-240 VAC 50/60Hz
Operating mode
Motor Protection
Overload
Independant
Reverser
Two-Step
Two-Speed
Custom Mode
Thermal Overload
Over/Under current
Long Start / Jam
Ground current
Network Communication
Inputs & Ouputs

6 discrete inputs
4 relay outputs
Ground fault input
Temperature sensor
LTMR...BD/FM
Modbus
CANOpen
Profibus DP
DeviceNet
Ethernet (MB + TeSys Port)
18
Expansion Module : LTMEV
Front view description

3 Phase inputs Voltage
(0 to 690 VAC)
HMI/PC
connection
Controller
RJ45 port
Status indication
LEDs
Expansion module
powered by the
controller
4 discrete inputs
(external powered inputs)
19
Operator Terminal: Magelis XBTN410
Configuration, Display & Control
Custom-built
Touchscreen available
for Water/Wastewater
Applications!
One to One
Application
Magelis
MagelisXBTN410
XBTN410
Local
LocalControl
Control
Configures
Configuresparameters
parameters
Displays
real-time
Displays real-timevalues
values
Alarm
monitoring
Alarm monitoring
One to Many
Application
24V
24VDC
DCsupply
supplyneeded
needed
XBTZ938
cable
XBTZ938 cable
Modbus
Modbusprotocol
protocolfor
fordata
data
tranfering
tranfering
20
Maintenance
Controller LED description
LED
Appearance Description
HMI
Comm
Power
Flashing yellow
Off
- Communication
- No communication
Green
Flashing green
Off
Red
Flashing red
(2/s)
Flashing red
Off
(5/s)
Red
- Motor off, no internal faults

- Motor on, no internal faults
- Power off or internal
faults
- Internal or protection
fault
- Warning
-- Load
shedoror
rapid
No power
not
com.cycle
Loss
Alarm
Fallback
PLC
Comm
Yellow
Off
- Com. loss with network

or
HMI communication
- Network
- No network
communication
Problems
Problemscan
canbe
bedetected
detectedusing
usingthe
theLEDs
LEDson
onthe
theexpansion
expansionmodule,
module,
Magelis
terminal,
PowerSuite
running
in
a
PC
or
PLC
connected
Magelis terminal, PowerSuite running in a PC or PLC connectedtotothe
the
controller.
controller.
21
MCC Starter
With Configuration, Display & Control LUCM Display
22
MCC Starter
With Configuration, Display & Control LUCM Display
23
TeSys T Connected on Modbus

OR
PLC
DCS
OR
OR
Modbus
Modbus
DeviceNet
Modbus is good data collection system
Ethernet TCP/IP
Up to 32 devices for data (Practical limitation is lower for control)

Network not compromised by lost node
Redundancy is not standard or easy to implement with Modbus
24
TeSys T Connected on CANopen

PLC
DCS
Modbus
DeviceNet
CANopen is good data collection and control system
Ethernet TCP/IP
Up to 63 devices for data (Practical limitation is ??? for control)

No redundancy on CANopen
Similar network to DeviceNet
25
TeSys T Connected on Profibus

PLC
DCS
Modbus
DeviceNet
Profibus is good data collection and control system
Ethernet TCP/IP
Up to xx devices for data (Practical limitation is 4 to 8 for control)

Multi-masters is available on Profibus
26
TeSys T Connected on DeviceNet

PLC
DCS
Modbus
DeviceNet
DeviceNet
DeviceNet is good control system
Ethernet TCP/IP
Up to 63(?) devices for data (Practical limitation is 4 to 8 for control)

No redundancy on DeviceNet
27
TeSys T Connected on Ethernet

AND
/OR
PLC
DCS
AND
AND
/OR
/OR
Modbus
Daisy chain Ethernet (Potential ring)

Ethernet TCP/IP
Traditional Star wired Ethernet
DeviceNet
Ethernet is good control and data acquisition system
Ethernet TCP/IP
Up to 32 devices on self-healing ring

More devices on ethernet switch
No redundancy on DeviceNet
28
PowerSuite Software V2.5
Programming, Configuration & Display

One to One Application or
One to Many Application
PowerSuite
PowerSuiteSoftware
Software
Configures
Configuresparameters
parameters
Displays
real-time
Displays real-timevalues
values
Alarm
monitoring
Alarm monitoring
Logic
Logicblock
blockprogramming
programming
RS232/485
RS232/485Converter:
Converter:
VW3A8106
VW3A8106
Direct
Directethernet
ethernet88pin
pincable:
cable:
VW3A8306R10
VW3A8306R10
29
TeSys T with the PowerSuite
Setting menu
30
TeSys T with the PowerSuite
Monitoring interface
31
To Summarize
Controller integrated design: 1 single product
Main protection and control features integrated into the controller
Current sensing integrated from factory up to 100 A
Most common Operating Mode ready to use
Full functionality and protection even when bus system fail
MODBUS
Ethernet TCP/IP
Communication
5 main protocols
Double network connectivity
Customization
Custom operating mode: truth table and logic block
User map: rearrange register table for faster communicating
Flexible cabling layout: removable and changeable terminal strips
Optional enhancement
Voltage and Power protection
Voltage, Power and Energy consumption monitoring
32
Preferred System Architecture

Ethernet Network
Ethernet
Switch
Ethernet
Switch
Ethernet Switch located in each shipping split

All motor control will have direct ethernet connection
w/ IP address
utilizing advanced services like Faulty Device Replacement and
Transparent Ready Webpages
Existing Schneider Products:
ATV61/71 VFDs; TeSys-T Overload; ATS48 w/ETG
Factory
tested for correct device operation
33
Architecture Questions
TeSys
T Overload:
Should it be powered by bucket CPT?

O/L and display will be OFF when disconnect is OFF
Disallows daisy-chain ethernet with possible redundancy
No communications issue with Modbus, DeviceNet, Profibus
Should it be remotely powered by 24 VDC?
O/L and display always ON
Disconnect can still be effectively Locked
Possible redundant ethernet communications
These factors should be considered:
TeSys T has realtime clock Clock
or CANopen
Out/Tagged Out
is stopped when power not applied
34
Transparent Ready Advantages

Keep
in mind that ethernet web pages can be accessed without using I/O
Points in the Scada System. (See costs on List Price sheet below)
Note
that pages are already built no engineering costs
If
device is replaced or updated years from now with newer product

Scada web link would still be good!
35
Embedded Webpages in TeSys T!
36
Embedded Webpages in TeSys T!
37
38
Measure of the current

Internal CT for current
range up to 100A
External CT to expand the

current range up to 810A
External load CT
LT6CT... or
LUTC or
Customer Choice
33windows
windowswith
withembedded
embeddedCT
CTfor
for
measuring
the
phase
current
measuring the phase current
Controller
Controlleraccept
accept5A
5Aand
and1A
1A
secondary
signal
from
external
secondary signal from externalCT
CT
39
External Current transformers
Characteristics of the external CT
Protection CT provides a good accuracy at high current and has a higher

precision limit (linearity zone) .
Requirement for the CTs (standard IEC 60044-1)
Accuracy
class
5
Motor
protection
P
Accuracy limit
factor
10 or 15
Accuracy class : define the current error at the nominal current and at the
accuracy limit current ( example : accuracy class = 5, the current error is +/- 1% if
current 2x I nominal and +/-5% at the Accuracy limit current)
Accuracy limit factor : define the maximum error at the accuracy limit current
(example accuracy class=5 and accuracy limit factor=10, the maximum error is +/5% at 10xIn.
40
Measure of ground fault

External ground CT for
precise ground sensitivity
Ground
GroundCT
CTmeasures
measuresground
groundfault
faultas
aslevel
level
significantly
lower
then
internal
ground
significantly lower then internal groundfault
fault
(controller
sensibility
:
20
mA
to
10
A)
(controller sensibility : 20 mA to 10 A)
Ground fault CT
(current =0 => no
ground fault)
41
Architecture : TeSys T connected on the

Modbus
network
PLC
DCS
DeviceNet
Ethernet TCP/IP
TeSys
TeSysTTon
onthe
thenetwork
network: :
Remote
RemoteControl
Control
Configures
Configures&&sets
setsup
upthe
the
functions
functions
Monitoring
Monitoring
Network
NetworkConnection
ConnectionPort
Porton
on
the
thefront
front(picture
(pictureshows
showsRJ45
RJ45
for
Modbus)
for Modbus)
Terminal
TerminalStrip
Strip
(For
DeviceNet,
(For DeviceNet,only
onlyterminal
terminal
strip
is
presented)
strip is presented)
42
Main power circuit

11 Circuit
Circuitbreaker
breaker
22 Contactor
Contactor
33 Control
Controlpower
powersupply
supply
(24VDC
/
100-240VAC)
(24VDC / 100-240VAC)
2
66 HMI
HMIororPowerSuite
PowerSuiteport
port
connection
connection
77 Cable
Cableconnection
connection
(controller
(controller&&expansion)
expansion)
88 Network
Networkport
port
Controller
Expansion module
44 Ground
Groundfault
faultcurrent
current
transformer
transformer
55 PTC
PTCthermistor
thermistor(binary
(binaryoror
analog)
analog)
4
5
43
Control wiring
66logic
logicinput
input- -Internal
Internal
supplied
power
supplied power
44logic
logicinput
inputrequire
requireexternal
external
power
power
22control
controlrelay
relay
output
output
Fault
Faultrelay
relayoutput
output
97-98:
97-98:NO
NO; ;95-96:
95-96:NC
NC
Warning
Warningrelay
relay
output
output
isolated
isolatedwith
withinput
inputon
onthe
thecontroller
controller
44
Control modes
Local mode : Terminal or HMI

Control
ControlThrough
ThroughTerminal
TerminalStrips
Strips
Monitor
MonitorThrough
Through
Network
Network
Control
ControlThrough
ThroughMagelis
MagelisHMI
HMI
Network
Control
Controllocal
localmode
modeselection
selectionisisdefined
definedby
byinput
inputI.6:
I.6:00==Local
Localmode
mode
Control
Controllocal
localchannel
channelsetting:
setting:00==Local
LocalTerminal,
Terminal,11==Local
LocalHMI
HMI
Local
LocalStop
StopCommand
Commandwill
willalways
alwaysbe
beresponded
respondedregardless
regardlessofofthe
thecontrol
controlmode
mode
45
Control modes
Remote mode
Terminal
TerminalStrips
Stripsonly
onlyfor
forSignal
SignalInput
Input
Control
ControlCommand
Command
Through
ThroughNetwork
Network
Magelis
MagelisHMI
HMIonly
onlyfor
forMonitoring
Monitoring
Network
Control
ControlRemote
Remotemode
modeselection
selectionisisdefined
definedby
byinput
inputI.6:
I.6:1=
1=Remote
Remotemode
mode
The
Thebumpless
bumplessparameter
parameterdetermines
determinesthe
thebehavior
behaviorofofoutputs
outputsO1
O1&&O2
O2when
when
changing
control
mode.
If
this
parameter
is
enable
the
outputs
remain
the
changing control mode. If this parameter is enable the outputs remain thesame
same
position
when
there
is
a
changing
control
mode.
position when there is a changing control mode.
Local
LocalStop
StopCommand
Commandwill
willalways
alwaysbe
beresponded
respondedregardless
regardlessofofthe
thecontrol
controlmode
mode
46
Current Transformer wiring

Internal CT
Measuring phase currents direct from 0.4 to 100 A
Wiring
Wiringthrough
throughthe
thewindows(
windows(18mm)
18mm)
Wiring
Wiringusing
usingMulti-turns
Multi-turns
Wiring
Wiringusing
usingLug-Lug
Lug-Lugkit
kit
2
4
11: :Lug
Lugshroud
shroud(ref.
(ref.31172-005-01)
31172-005-01)
22: :Lug
Lug (ref.
(ref.: :31154-023-50)
31154-023-50)
33: :L1
L1&&L3
L3bus
busterminals
terminals(ref.
(ref.: :31172-017-01)
31172-017-01)
44: :L2
L2bus
busterminal
terminal(ref.
(ref.: :31172-018-01)
31172-018-01)
47

External CT
Measuring phase currents up 810 A
Controller
Controlleraccept
accept5A
5Aand
and1A
1Asecondary
secondaryfrom
from
external
current.
The
recommended
controller
external current. The recommended controller
model
modelfor
forthese
thesecurrent
currentisis0.4
0.4toto8A
8A(Ref.
(Ref.
LTMR08xxx)
LTMR08xxx)
48

External ground fault CT
Precise ground protection
Z1 Z2
The
Thecontroller
controllerhas
has22terminals
terminals(Z1
(Z1&&Z2)
Z2)toto
connect
connectan
anexternal
externalground
groundCT.
CT.The
Theground
ground
CT
measure
ground
sensitivity
as
level
CT measure ground sensitivity as level
significantly
significantlylower
lowerthen
theninternal
internalground
groundfault
fault
(sensibility
:
20
ma
to
10
A)
(sensibility : 20 ma to 10 A)
49
Temperature sensor wiring

Types of sensor can be used
PTC binary, PTC or NTC Analog (Set up the sensor parameter)
T1
T1and
andT2
T2returns
returnsthe
thetemperature
temperature
value
measured
by
resistance
value measured by resistance
sensor.
sensor.
50
Setting
Configuration & Setting via HMI/PC or Remote PLC/DCS
HMI/PC connection
HMI
Network connection
PLC/DCS
XBTN410
Or
PC
Network
51
Setting with the PowerSuite
Monitoring menu

energy
Make the most of

SM
your energy
Setting with the PowerSuite
Parameters menu

energy
Make the most of

SM
your energy
To summarize
Controller integrated design: 1 single product
Main protection and control features integrated into the
controller
Current sensing integrated from factory up to 100 A
Most common Operating Mode ready to use
Full functionality and protection even when bus system fail
MODBUS
Ethernet TCP/IP
Communication
5 main protocols
Double network connectivity
Customization
Custom operating mode: truth table and logic block
User map: rearrange register table for faster communicating
Flexible cabling layout: removable and changeable terminal
strips
Optional enhancement
Voltage and Power protection
Voltage, Power and Energy consumption monitoring
54
55

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Improving Motor Reliability with Intelligent Motor Control

Centers and theTesys-T

Presenters Name: Wayne Thygesen, Consulting Engineering Specialist

Improving Motor Reliability with

Add photo in this area

Make the most of your

Make the most of

TeSys T System Components

Controller expansion module

TeSys T Motor Management System

TeSys T Motor Management Controller and Control Unit Operator

Motor Managment Controller : LTMR

Front view description

Additional Motor Protection

Input Power supply

Depending on the controller configuration

(1) : Value saved on power loss

TeSys T Motor Protection functions

Depending on the controller configuration

Thermal overload (inverse & definite time)

Protection faults : overload, overcurrent,

Recording the motor control history

Monitoring : Diagnostic faults

Watchdog : stack over/underflow

Control command checks

Monitoring : Motor states

Thermal overload status

Custom operating mode

Custom operating mode

PowerSuite logic editor : 2 languages

Motor Management Controller : LTMR

Current Rating (internal CT)

Control Power supply

Inputs & Ouputs

Expansion Module : LTMEV

Front view description

Operator Terminal: Magelis XBTN410

Configuration, Display & Control

Controller LED description

- Motor off, no internal faults

- Com. loss with network

With Configuration, Display & Control LUCM Display

With Configuration, Display & Control LUCM Display

TeSys T Connected on Modbus

Up to 32 devices for data (Practical limitation is lower for control)

TeSys T Connected on CANopen

CANopen is good data collection and control system

Up to 63 devices for data (Practical limitation is ??? for control)

TeSys T Connected on Profibus

Profibus is good data collection and control system

Up to xx devices for data (Practical limitation is 4 to 8 for control)

TeSys T Connected on DeviceNet

DeviceNet is good control system

Up to 63(?) devices for data (Practical limitation is 4 to 8 for control)

TeSys T Connected on Ethernet

Daisy chain Ethernet (Potential ring)

Traditional Star wired Ethernet

Ethernet is good control and data acquisition system

Up to 32 devices on self-healing ring

PowerSuite Software V2.5

Programming, Configuration & Display

TeSys T with the PowerSuite

TeSys T with the PowerSuite

Preferred System Architecture