Technical Journal

December 2011

Intelligent and Efficient Low Voltage Motor Management In the present industrial scenario, whether it is a continuous process plant or water treatment plant or even potable water pumping stations, system efficiency is becoming more and more important for better output. In most applications today the induction motor is invariably part of the system. Any unplanned stoppage of these motors can lead to multiple faults in the process sequence. These tripping could lead to huge amount of production loss. As demand for efficient performance of complete system is increasing, Intelligent Motor Managers are being used very often in these systems. For better performance of these Motor managers, following technical parameters have to be considered before selection. Versatile Motor control and protection options Flexible communication options and communication redundancy option Motor Modeling and Diagnostics features Other devices like circuit breakers/ Soft starters having flexible communication options for complete integration Motor Control and Protection The Motor manager selection becomes very critical when intelligent motor control center is planned. The basic requirement is that electrical wiring within the MCC is to be limited as less as possible. More the wiring lesser is the reliability of starter module. When Motor managers are equipped with various control function for e.g. Star delta starting function, total starter wiring and number of components per starter is reduced which improves reliability of the starters. The following control and protection function are be ensured that Motor managers have these built in and they are configurable.

Control Functions
1. Starter options like Direct online, Star-Delta starter, Pole changing, Actuator Module and Reverse starting 2. Application specific easily programmable logic with function blocks. These blocks should be configurable without connecting to PC or Laptop(Via LCD display)

Protection Functions

1. Protection function include Over/Under load, Over /under current, Locked rotor protection, Phase failure, Phase imbalance, Phase sequence, Thermistor motor protection. 2. Protection trip class setting in accordance to IEC 60947-4-1 from class 5 to class 40 3. Additionally earth fault protection with both option of inbuilt or with external sensor The minimum and maximum trip time based on trip class selected can be derived out of IEC 60947-4-1 which defines trip class criteria. For example, the standard specifies that an overload relay with trip class 20 should be switching off the motor within 6 to 20seconds when current is 7.2 times the rated current.

Intelligent and Efficient Low Voltage Motor Management

Motor managers minimum requirement is to full this clause of the standard. When there is option available within the Motor manager to change this trip class, User will have an additional benefit of changing the class at site as well as reduction in maintenance inventory (multiple relays of different trip class). Another important aspect which user has to keep in mind is use of external protection class CTs in conjunction with motor manager. Some of the manufacturers insist on use of their own CTs which makes solution costlier. However there are manufacturers who offer only motor managers with locally manufactured external CTs (can be sourced locally) Communication features The communication feature of the motor manager plays a vital role selection process. There various manufacturers of motor managers in the market with a single communication protocol like Modbus, Profibus, Device net etc However this brings lot of limitation for the end user. Any future expansion, only possible devices to be considered is of one specific protocol. With latest developments in the field of communication, Electrical equipments like Circuit breakers, Soft starters, and Motor managers are capable of accepting various communication protocols with the introduction of Field Bus Plug concept. With this feature, End user has a flexibility to change communication protocol even after the installation of MCCs. Within an MCC, one can achieve various network topologies like daisy chain or star network as shown.

Depending on the application, Redundancy in communication becomes necessity. Both processors as well communication redundancy becomes very important. However dual communication port on motor manager will not serve the purpose except the cost of complete installation is increased substantially. Instead of opting for communication port redundancy, it is advisable to consider the option of device (motor manager) redundancy where both communication and protection are redundant. With following configuration, one can achieve communication redundancy with single communication port on motor manager or circuit breakers (ACBs/MCCBs) or Soft starters. With this configuration, One can achieve high availability or commonly known in the market as self healing ring concept where in you achieve both communication redundancy in processors and as well as communication network. With this one can achieve most cost effective and reliable solution.

Intelligent and Efficient Low Voltage Motor Management

Motor Modeling and Diagnostics Feature Motor managers are normally equipped with various logarithmic functions which develop thermal models considering both iron and copper parts of the motor and provide best possible protection to the motor. Motor manager monitors the thermal capacity of the motor continuously and generates pre warning to the user about overloading of the motor. With this user is able to take corrective actions and ensures motor is not tripped affecting production. In the event motor is tripped, it provides indication to the user about cooling time required prior to the restart of the motor. The motor manager offers versatile diagnostics and service data to the users. The diagnostics data like operating hours, number of starts and trips, Motor Status, Warnings, Fault history. Measurement parameters like Current, Voltage, Power factor, Active/Apparent power, Energy and THD (Total Harmonic Distortion) are also available to the users. For feeder protection application, it is recommended to consider an option of circuit breakers with extensive protection features which makes overall system reliable and cost effective. Circuit breakers of latest technology are also having feature to adapt various communication protocol with field bus plug technology. ABB as a company with expertise on both power control and motor control offer complete solutions in line with customer requirement for motor and feeder protection in low voltage system with various communication protocols like Modbus, Profibus, Devicenet and CANopen. These solutions are offered both as product and system based on customer needs.

In case of further information, please contact

ABB Limited Design Institute 88/3, 88/6, Basavanahalli Village 562123, Bangalore North, Karnataka, INDIA email: Ramprasad.satyam@in.abb.com
005/2011