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MNS iS Motor Control Center

System Guide System Release 1.5/0

ABB

MNS is a registered trademark of ABB Schaltanlagentechnik GmbH. Microsoft, Windows and Windows XP are registered trademarks of Microsoft Corporation. MODBUS is a registered trademark of Schneider Automation. PROFIBUS is a registered trademark of PROFIBUS Nutzerorganisation e.V. (PNO). Technical descriptions relate to Release 1.5/0. 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 ABBs 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 2006 ABB Automation Products GmbH Ladenburg, Germany

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CCoonntteenntt MMNNSS iiSS SSyysstteemm OOvveerrvviieeww MNS Since 1975 ......................................................................................................................................5

MNS iS One step ahead ...........................................................................................................................5

Function module concept...........................................................................................................................6

MMNNSS iiSS DDeessiiggnn AAssppeeccttss Switchboard Construction..........................................................................................................................8

Busbar Systems.........................................................................................................................................11

MNS iS Withdrawable Modules MStart ....................................................................................................13

MMNNSS iiSS CCoommmmuunniiccaattiioonn Communication..........................................................................................................................................17

2nd Fieldbus Interface...............................................................................................................................18

System wide aspects.................................................................................................................................19

MMNNSS iiSS UUsseerr IInntteerrffaaccee MLink and MView - Information and communication ..........................................................................21

MNavigate - Software tool.........................................................................................................................22

MMNNSS iiSS CCoonnttrrooll aanndd PPrrootteeccttiioonn MStart - Motor starter power unit...........................................................................................................23

MControl - Motor starter control unit.....................................................................................................24

I/O Interfaces ..............................................................................................................................................25

Modular software application...................................................................................................................26

MMNNSS iiSS TTeecchhnniiccaall DDaattaa MNS iS Electrical characteristics.............................................................................................................38

MNS iS Standards and Approvals............................................................................................................38

MNS iS Mechanical characteristics .........................................................................................................40

Module Types and Dimensions................................................................................................................42

Module Selection tables............................................................................................................................43

Control and Communication components..............................................................................................46

MMNNSS iiSS SSyysstteemm OOvveerrvviieeww MNS Since 1975

Thirty years ago, ABB engineered MNS - the first modular Low Voltage Switchboard. The separa-ted functional areas combined with the arc con-tainment design received immediate customer recognition. Since then, MNS is the synonym for personnel and operational safety. The most customer-acknowledged MNS attri-butes that have now become the industry standard are:

Modular, arc proof design Functional Area segregation for highest per-

sonnel safety Withdrawable module technique for system

integrity under live bus condition for operation and maintenance ease.

INSUM integrated microprocessor based motor control and protection with open fieldbus based interfaces to plant Process Control Systems

MNS iS A jump ahead

MNS iS retains the best of MNS technology and evolves it into next best operational handling benefits for customer Low Voltage Motor Control Center applications.

The distinct elements in MNS iS are:

Physically separated and independent

operational handling of power and control parts

Power and Control part operational safety

Standard Power Modules Fully assembled, ready to use and offered for a wide range of motor starter kW ratings Flexible Control Modules Scalable for basic to complex motor starter types, protection functions and field input/ output signal requirements Integrated Control Schematics All starter level interlocking scheme between control and power module is built in. No hard-wiring or input/ outputs assignment required. The control schematic is reduced to assigning field I/O signal contacts only. Free usable I/Os for field connection provided.

Measurement variables Selectable Temperature, Current and Voltage measurement for various protection needs for both motor and switchgear itself. No traditional transformers are utilised for any measurements. Information Distribution as required Industry standard communication interfaces, such as PROFIBUS DP, Modbus and OPC are avail-able, enabling site wide distribution of information (operator, maintenance, management). System accessibility with off the shelf web browser based devices With inbuilt Web server, the user can select any web browser based device to interrogate the system. User Job handling ease features Self supervision of module location, module type, power rating and automatic installation onto the communication network.

1970s MNS: Any electronics in separate boards.

2005 MNS iS: All intelligence integrated in the switchgear but separated from starter modules.

1990s MNS+INSUM: Protection, mea-surement and control unit located in starter module. Centralized Operator panel.

ABB MNS iS System Guide Rev.03 April, 2006 55

MMNNSS iiSS SSyysstteemm OOvveerrvviieeww

Function Module Concept

MNS iS motor control center solution delivers all the functions for control, protection and monitoring of the motors and motor starters using software and hardware modules for the specific tasks. Right information is provided to the right people at the right time.

Hardware modules are designed to fulfil desired tasks (power module containing electrical parts e.g. to isolate power, control module containing software applications etc. to control a motor).

System functions are provided as functional modules to be downloaded to the control module. Only required functions may be downloaded while others are available as options. System functionality may be enhanced at any time without the requirement for additional hardware or wiring.

Time synchronization with a Time Server in the plant or locally in the switchboard allows accurate time stamps of alarms and events collected in the control module.

Module and location supervision are available as a standard. These functions ensure the corresponding power and control modules are installed to the correct location for the particular motor application.

Maintenance functions are an integral part of the system. Asset Monitors measuring of system performance data (e.g. outgoing line temperature, numbers of switching cycles) allows to schedule maintenance activities only if they are really required.

The flexibility of the system allows modifications by a simple Plug and Produce concept. Ex-changing the modules or changing the parameter settings is easily achieved by using system inherent functions and tools.

Fieldbus

MControl 1 Control & Protection MStart 1

MControl Control & Protection MStart

MControl 60 Control & Protection MStart 60

MView Web Browser

MControl 1 Control & Protection

MLink 1 Communication I/F Web Server OPC Data Provider Time Server

MNavigate ParameterizationWeb Browser

Switchgear Control Network

OPC Server

Process Control System / OPC Client

MLink n Communication I/FWeb Server OPC Data Provider Time Client

MControl Control & Protection

MStart 60


MStart

MStart 1


MMNNSS iiSS SSyysstteemm OOvveerrvviieeww Components Overview

The power module MStart comprises: the motor isolator the short circuit protection (fuses or circuit

breaker) contactor, electrical control equipment and

status indication. the sensor module (measuring the electrical

values, which are made available to the process via the MControl processor module.

The interface module MLink serves for the serial gateway interface to higher level systems which communicates through the internal bus to all MControl modules. A local Human System Interface MView is available to monitor the MNS iS status and display information on each connected module.

The microprocessor module MControl (located in the control compartment) comprises: the processor performs all the protection,

control and monitoring functions. It sends and receives information to and from the MStart via an internal bus.

I/O interface modules provide an interface to external components for both control and indication.

MLink

Control Condapter

MControl

Power Condapter

MStart


MMNNSS iiSS DDeessiiggnn AAssppeeccttss

Switchboard Construction

MNS iS as part of the ABB Low Voltage Switchgear solution uses the well proven ABB MNS standard design aspects. MNS aspects described in this section are fully applicable to MNS iS. MNS system is a type-tested switchgear assembly (TTA) in accordance with IEC60439-1 and IEC61641. The consistent application of the modular principle both in electrical and mechanical design as well as the use of standardized components allows its flexible and compact design. Depending on operating and environmental conditions different design levels are offered.

Notable system advantages with regard to design aspects: Compact, space-saving design Easy project and detail engineering

through standardised components Fully Type Tested including Internal Arc

Fault Earthquake-, vibration- and shock-proof

designs are available Easy conversion without the need for

switchgear de-energizing Maintenance-free busbar construction High operational reliability and availability Optimum personal protection

Functional separation

The switchboard is divided into vertical and hori-zontal compartments thus separating different func-tional areas.

As a standard power cabling and control wiring are strictly separated within MNS iS, the switch-board is structured as follows:

1. Equipment compartment All equipment, including the standard motor starter modules (MStart) in withdrawable design, is situated therein. The compartment can be divided in horizontal and vertical sub compartments. 2. Control cable compartment Contains the smart motor control devices (MControl), control cables and terminals. 3. Power cable compartment Contains power cables and connection units. 4. Busbar compartment Contains the MNS main busbar system and distribution bars. The distribution bars are embedded in the Multifunction Separation Wall (MFW) which is located between the Equipment compartment and the Busbar compartment

System Highlights Functional areas are separated from each other in accordance with IEC 60439-1. Power cables are fully separated from the control cables, thus avoiding electromagnetic interferences. Different access rights to cable compartments can be granted using different key locks.

4

2 31

1

Incomer MCC


MMNNSS iiSS DDeessiiggnn AAssppeeccttss Switchboard Arrangements

MNS cubicles can be arranged as follows: in stan-dard execution (back-to-wall), back-to-back or duplex.

Frame Construction

Basic elements of the MNS frame construction are C shaped steel profiles with a 25 mm (=1E) hole distance according to DIN 43660. Each cubicle is precision constructed by bolting horizontal and vertical profiles together, to form a rigid modular structure. The assembly is maintenance free as a result of the construction method utilizing thread-locking screws and a bolted pressure plate design. The profiles are galvanic protected (Zn or AL/Zn) against corrosion.

Enclosure

MNS switchboard enclosure is made of sheet steel protected by galvanic coating and powder coating for maximum durability. The construction of the enclosure (doors, roof plates, rear walls) varies in dependence from the degree of protection. In accordance with the general safety philosophy followed with MNS, each compartment and sub-compartment which requires access for commis-sioning, operation or maintenance, has its own door.

Standard (Back-to-wall) Back-to-back

Duplex (common busbar compartment)



Cable Compartments

Access to smart components such as electronic protection relays on standard switchgears is usually not possible if the module is energized. As an outstanding attribute MNS iS switchgear provides separate compartments, one for power cables on the right hand and another for control cables on the left hand. The two cable compart-ments can be provided with different key locks in order to assure specific access rights.

MNS iS motor/feeder cables are housed in their own power cable compartment completely isol-ated from any control equipment or wiring. The cubicle arrangements are configured suitable for front cable access. The power cable compartment can be provided with cable entry from the top or bottom of the cubicle.

The control cables have their own control cable compartment completely segregated from the power compartment. This control compartment also houses the smart motor control units MControl and other associa-ted control equipment. The control wiring can enter from the top or bottom as required for the project.


MMNNSS iiSS DDeessiiggnn AAssppeeccttss Busbar Systems

Main Busbars

The MNS main busbar system is arranged in the rear of the switchboard. This assures a maximum distance from the busbars to the operator and maintenance staff. The main busbar system is fully separated from the equipment compartment as well as the cable compartments.

The busbar system is a maintenance free construction with regard to all kinds of inter-connections including those completed on site. Screw connections are treated with securing varnish. No additional connection plates are necessary.

The copper busbars can optionally be protected using galvanic coating Ag/Sn and/or insulated using shrink-ing tube.

More about: Busbar Ratings

Technical Data, page 39

System Highlights: The location of the main busbars at the rear provides maximum safety to personnel Isolating materials are free of CFC and halogens A full size neutral can be provided. Arc protection: Active and passive arc fault prevention is tested according to IEC 61641.

MNS design will prevent an arc from occurring (first priority), however in cases arc faults do occur the fault is limited and contained within its own compartment.



Protective Earth and Neutral Bars

In standard protective earth and neutral bars run horizontally in the front of the switchboard just above the base. They are fastened to the frame to assure electrical continuity. Inside the cable compartment they run vertically.

In case 50% or 100% neutral size is required due to unbalance or harmonic distortion, the neutral conductor will preferably be arranged in the rear of the cubicle running in parallel with the main busbars.

Distribution Bars

A fully phase segregated and insulated 3 or 4 pole distribution bar system runs the full height of the cubicle. Distribution bars are silver plated as standard, optionally avaiable coated with tin. The multifunction separation wall (MFW) embedding the distribution bars is a unique ABB design. It constitutes a complete barrier between the main busbars and the equipment compart-ment. Distribution bars are fully phase segre-gated and insulated. This design makes it virtually impossible for an arc to pass between distribution bar phases or between main busbars and equipment compartment. The insulation material is CFC and halogen free, flame-retardant and self-extinguishing.

Main contact openings are finger proof (IP 20) so that personal safety is guaranteed even when modules are removed. With the help of specific contact housings full single phase segregation is assured before the main contacts engage with the distribution bars.

System Highlights: The Multifunction separation wall is a well proven ABB standard design Type tests have confirmed that an eventual arc is isolated and limited to the compartment

where it occurs. Isolating materials are free of CFC and halogens.


MMNNSS iiSS DDeessiiggnn AAssppeeccttss MNS iS Withdrawable Modules MStart

The withdrawable design of MStart provides a maximum of plant and operator safety. As per definition in IEC 60439-1 withdrawable modules can be electrically disconnected (withdrawn) without the help of a specific tool. This is applicable to the main incoming circuit, the main outgoing circuit as well as the auxiliary circuits.

MStart are standardized components, ready-to-use and offered for a wide range of motor starter ranges and applications leading to maximum flexibility. The high device packing density allows a comparatively low footprint of the MCC.

Available options for the selection of MStart modules are: Starter types:

Non-reversing Direct Online (NR-DOL) Reversing Direct Online (REV-DOL) Heavy Duty (HD) Star-Delta (NR-S/D) * Contactor Feeder (CF)

Rated voltages: 400V, 500V, 690V Short circuit protection device (SCPD):

Fused, Fuseless

* Planned for Release V2.0 Main characteristics Multi-functional operating handle connecting

to module interlocking mechanism Ergonomic module handle to withdraw the

module Motor status display (4 LED) integrated in

module front Module rear wall with integrated contact

system and sensors Control terminal block

MStart comprises the power circuit and measure-ment functionality. It is therefore decoupled from smart control. Smart control, protection and monitoring function-ality is taken over by the allocated MControl located in the control cable compartment.

More about: Module Dimensions




Interlocking System / Operating Handle Position

Position Mechanical status Electrical status

6E/4, 6E/2 6E24E Designation Module interlocked Padlock possible

Withdrawable contacts

Main switch

Control circuit

ON position

( I )

OFF position

( O )

Test position

Disconnected position

(Isolated position)

30 mm withdrawn

Moving Position

(Withdrawn position)

removal possible

or

System Highlights: MStart can be replaced while switchboard is energized Integrated contact system and sensors Power loss reduction due to separation of control components permits high-density module arrange-

ment in the switchboard

Module Connection to Distribution Bars

A condaptor unit facilitates the horizontal distribution of power from the vertical distribution bars for 6E/4 and 6E/2 modules. The condaptor enables the modules to be located adjacently within the same horizontal position of the cubicle.

Modules of size 6E and above are connected directly to the vertical distribution bars.


MMNNSS iiSS DDeessiiggnn AAssppeeccttss Power Contact Connection to the distribution bars is achieved using the precision-engineered MNS power contacts.

The contact has been subjected to several tests in order to prove the sophisticated design and the high quality:

The contact type 101 is characterized by a turn-able bearing, thus decoupling cable and contact. Consequently any occurring bending forces can-not affect the stability of the contact. The mechanical stabilisation is taken over by the supporting plate whereas the contact fingers ensure positive electrical contact. Contact fingers are silver plated, optionally tin plated.

Type test acc. IEC 60439-1 Corrosion test acc. DIN 50017 and IEC

60068-2-60 Crimping quality check acc. IEC 61238-1 Vibration and shock test acc. IEC 60068-2-6

and IEC 60068-2-27 Further on during manufacturing each single contact is subject to a particular routine test screening its function and contact force.

Contact type 101 Cable sections up to 70 mm

Small module contact Cable sections up to 10 mm

System Highlights: Although IEC 60439-1 requires 50 connection cycles only, the MNS contact system is tested, certified

and proven for contact cycles (plug in / unplug) up to 1,000 The contacts are galvanic coated (Ag standard, Sn on request)



Incoming Feeders and Bus Couplers

MNS incoming feeders and bus couplers (630A and higher) use ABB circuit breakers or switch disconnectors connected directly to the main busbar system.

Solutions to choose from: 3pole or 4pole devices with up to 100%

neutral. Withdrawable or fixed design Moulded case circuit breakers (MCCB) or Air

circuit breakers (ACB) Motor or manual operation Optional shunt release, undervoltage release

with or without time delay Optional electronic release Cable or bar connection (incoming and

outgoing) from top or bottom Earthing switch for maintenance purposes

ABBs electronic releases of PR series offer a variety of programmable protection functions for all mentioned circuit breaker types: Overload protection L Selective short circuit protection S Instantaneous short circuit protection I Earthfault protection G

Options to be selected: zone selectivity annunciation of measured values event log load control self diagnosis and integration into a plant wide process control

system

As soon as the withdrawable device is moved to disconnected position, shutters are closed to prevent any possibility to touch live parts. A complete removal of the device can be under-taken by the use of a carriage.

More about: Technical Details MCCBs, ACBs

ABB SACE catalogues

Compatibility with existing Switchboards in MNS Design

The switchgear system allows to combine MNS iS MCC cubicles with e.g. MNS power distribution boards.


MMNNSS iiSS UUsseerr IInntteerrffaaccee Communication

The communication between MLink and the MControl devices internally is a RS485 peer-to-peer communication (max 10MBps ) with a de-terministic Master-Slave Real-time protocol. Up to 60 MControl devices can be connected to one MLink. The wiring between all MControl and MLink is inbuilt inside the switchboard, no addi-tional wiring is required.

Multiple MLinks can communicate via fieldbus to the control systems. The MLink acts as a standard fieldbus slave device in Master-Slave communication protocols. MLink contains time server / client functionality as an option to provide accurate time signal to all MControl. The time stamp of alarm and events is distributed to higher level Process Control System.

Fieldbus Protocols MLink provides connection and data filters for communication of essential information to higher-level systems. The communication is based on standard fieldbus protocols such as Modbus RTU and PROFIBUS DP.

* Planned for Release V2.0

Modbus RTU *

PROFIBUSDP / DP-V1

Maximum communication speed 38.4kbps 1.5 Mbps

Master-Slave



MControl 60Control & Protection

MView Web Browser

Process Control System


MLink 1 Communication I/F Web Server OPC Data Provider Time Server

Fieldbus (PROFIBUS, Modbus)

Ethernet

MLink n Communication I/F Web Server OPC Data Provider Time Client




MMNNSS iiSS UUsseerr IInntteerrffaaccee

2nd Fieldbus Interface

Direct fieldbus communication on MControl is available. The ABB FieldbusPlug solution is uitilized inside MNS iS, thus selecting the appropriate FieldbusPlug type and MControl will communicate via this protocol.

Communication via the 2nd fieldbus interface * allows several different configurations depending on the selected fieldbus protocol. It optionally allows to include the MLink in the configuration to use external viewer (MView or web browser).

The ABB FieldbusPlug is available for: Modbus RTU Profibus DP and DP-V1 DeviceNet





MView Web Bro

MLink 1 Communication I/F Web Server OPC Data Provider

Ethernet

Process Control System

1188

Remark: The number of MControl connected to a Fieldbus Master in the process control system depends on the selected fieldbus protocol.




wser

MLink n Communication I/F Web Server OPC Data Provider

ABB MNS iS System Guide Rev.03 April, 2006

MMNNSS iiSS UUsseerr IInntteerrffaaccee System Wide Aspects

Time Synchronization Plant wide accurate status reporting may require MNS iS to be synchronized to ensure MControl device times are the same across the whole plant. In MNS iS the communication interface MLink acts as a Time Server for the MControl connected to it. This enables MNS iS to provide time stamped messages via MLink and OPC Server.

MLink receives the accurate time from a Time Server residing in the switchgear control network. Alternatively one MLink can be configured to act as a Time Server. With the standard network time protocol (SNTP) the time is sent to all other devices connected to the same network. Time stamped messages are not sent through fieldbus interfaces in MNS iS.

Option 1 Option 2 A Time Server exists in the switchgear network. Its time signal is received from all MLink and distributed internally. 3rd party products allow the connectivity to a GPS Receiver for highly accurate time synchronization plant wide.

If no Time Server is available, one MLink is configured as Time Server. The time signal is sent to all MLink on the switchgear network and pro-cessed accordingly.

GPS Global Positioning System The satellite Global Positioning System (GPS) distributes precise time, frequency and position worldwide. At a height of about 20,000 km satellites circle around the earth on different orbits. An atomic clock runs in every satellite whose time is constantly transmitted together with the orbital data. The GPS Receiver records the data of up to 6 satellites and uses this information to calculate its position and time.


MLink 1 Opt.1 Time Client Opt.2 Time Server





OPC Server

MLink n Time Client

SNTP Server (optionally w/ GPS Receiver )





OPC In addition to the MLink protocols or the Fieldbus plug interfaces to the higher level control system, extended data may also be required for Asset Management or SCADA applications. An OPC Interface* is available as an option via the MLink interface. OPC stands for OLE** for Process Control and is based on the component model from Microsoft. Thus information ex-change is possible without directly accessing hardware and software components inside the switchgear system. Information exchange to process control systems is based on common standards, such as PROFIBUS or Modbus. Application can use predefined data sets for example on PROFIBUS, where the Motor Manager profile from PROFIBUS User Organization is used.

Fieldbus interface provides the data for process control, whilst OPC interface provides the bulk of the data for Asset Management etc. The MNS iS OPC Server resides in the environ-ment of the higher level system. E.g. installed in a connectivity server as part of the control system it automatically searches for all connected MLinks in a network and configures itself for data exchange. Several OPC Clients can access the MNS iS OPC Server. This allows different application to receive information from MNS iS devices. MNS iS is capable to handle many information requests simultaneously, e.g. process control goes through the fieldbus interface whilst Asset Management is using OPC data to create a report.

* Planned for Release V2.0 ** OLE (Object Linking and Embedded) was used by Microsoft in their

architecture. Today it is named as COM or DCOM, Distributed Component Object Model and part of Microsofts Operating System architecture as basis for interoperability of software components and application.

Connectivity Limitations The following limitations have to be considered:

Maximum number of MView (incl. MNavigate) performing Operation/Monitoring) connected to one MLink simultaneously:

4

Maximum numbers of OPC Servers accessing data from one MLink simultaneously:

2

System Highlights: Flexibility of fieldbus protocols to communicate to different type of process control systems. Simultaneous information exchange between switchgear and process control systems. Simple integration of OPC Server in process control system Accurate time stamp of events from MNS iS is available for analysis in process control systems.

MLink 1 OPC Data Provider

Fieldbus


OPC Client

OPC Server

Process Control System / OPC Client

MLink n OPC Data Provider


MMNNSS iiSS UUsseerr IInntteerrffaaccee MLink and MView - Information and Communication

Information collected through MControl is sent to a communication interface module MLink in MNS iS.

As an option, through an Ethernet interface on MLink, access to information from and controlling of each MControl is available via a web server.

MLink is the communication centre internally to max. 60 MControl modules and externally between MNS iS and the higher level PLC or Process Control System. The main tasks are gateway functionality and information provider.

A local HMI (MView) can be installed in the switchgear and connected to the web server on MLink to monitor and operate the system depending on the access rights. The MView is a standard Industrial Panel. Touch screen functionality allows easy operation and navigation through windows. The connection to MNS iS is configuration free, all information displayed is received directly from MLink.

Also a standard Explorer software directly or throughto access the web s The operator accesbased on control MLink, thus prounauthorized use.


MLink

PC, with Microsoinstalled, can be

a standard Ethernerver in MLink.

s to displays and faccess rights impletecting the sys

MView

ft Internet connected et network

unctions is mented in tem from

2211


MNavigate - Software Tool

The Microsoft Windows XP based software application can be used to operate and monitor MNS iS from a convenient location outside the switch room environment. The PC is connected via Ethernet network topology to the installed MLink devices in this network.

Operation and Monitoring: opens web browser on PC, connects to selected MLink and works as above described (see chapter MView).

Parameterization: opens an application

window, which allows the viewer to read and modify parameters as required.

Access to manuals (such as standard PDF documents) and online help.

2222


MMNNSS iiSS CCoonnttrrooll && PPrrootteeccttiioonn

MStart - Motor Starter Power Unit

The withdrawable MStart modules come in the size from 6E/4 to 24E depending on the kW rating of the connected motor / load. Each MStart has a motor isolator, short circuit protection, contactor, any control equipment required and the sensor module.

Sensor Technology

High accurate current detection and processing is a major function to fulfil protection and control of the electrical motor. In addition other electrical values such as voltage, power, power factor are measured or calculated to provide detailed infor-mation about the motor and its application in a plant environment.

In conventional technologies measuring is done through current and voltage transformer devices whereas in MStart, the electrical module in MNS iS with incoming and outgoing electrical contacts, measurement of electrical values is based on sensor technology. The outgoing contact includes the new sensor technology.

The sensor has been especially developed for data logging in electric and electronic systems. A combination of high precision shunt and micro-processor forms a complete measuring system, which does not only measure current very pre-cisely, but at the same time measures the voltage and temperature.

System Highlights: Simultaneous high accuracy measurement of phase current and voltage for AC and DC Temperature measurement Industrial standard proven sensor product

Circuit board with microprocessor

High precision shunt (integrated in the copper busbar)



MControl - Motor Starter Control Unit

The MControl is a powerful and modular platform for communication, control, data processing and protection functions. The main control board is based on a microprocessor platform and includes memory for application and process data and a fast communication interface to MLink as well as an interface to the MStart. It contains the basic I/O and provides sockets for plug-in extension I/O modules for digital signals, analog signals and special boards for temperature measurement. In addition to the standard communication available from the MControl a 2nd fieldbus interface can be connected to MControl, which is in the form of the ABB FieldbusPlug*.


The MControl module boards are plugged into separate slots in the control cable compartment. Each slot belongs to a dedicated MStart power module.

System Highlights: Modular construction of system components (main board, extension boa

required. Central system communication through MLink or single communication

fieldbus interface. Extension of system functions is possible, securing hardware investmen

replacement.

t

MControl (includes Main Board and I/O boards)

Contro(interf

Remote Control Unit and Emergency Stop connection

ABB MNS iS S2244

MControl Motor Starter Control Uni

rds) allows configuration as

directly to fieldbus via 2nd

t and avoiding device

l Terminal Plugs ace to MStart)

ystem Guide Rev.03 April, 2006


I/O Interfaces

In motor control centre local operation, inter-action from other components outside the switch-gear and emergency stops are required to provide full operational plant. I/O interfaces to MControl are provided to fulfill all requirements.

Digital signals In MNS iS digital signals (such as pushbuttons, indicator etc.) are directly connected to the MControl main board or to the additional I/O cards. For these purposes 7 binary inputs (24V DC) and 4 relay outputs (up to 230 V AC) are provided.

Additional digital signals * An additional I/O card type with 4 binary inputs (24 V DC) and 2 relay outputs (up to 230 V AC) is available if the numbers of I/O on the main board are not sufficient for the application (e.g. special motor applications).

Analog signals ** Analog input and output signals (e.g. position measuring or current indication) can be connected using the analog I/O card type with 1 analog input and 1 analog output. The signal level is 0-20 mA, 4-20 mA or 0-10V DC (selectable).

Motor temperature PTC * Motor winding temperature supervision is provided by using the PTC input card type. The board contains 1 measurement input for PTC's according DIN 44081 and 44082. Short circuit situations or open connections at the PTC connection are monitored by the circuit supervision.

* Planned for Release V2.0 ** Planned for Release V3.0

More about: Technical Data of MControl


MControl Main board with add-on cards



Modular Software Application

In MNS iS the control device MControl contains an application program composed of only those required software modules needed for its desired application. Different software function modules are available for control, protection maintenance and monitoring functions as well as assignment of in/outputs.

The desired functions are selected during engi-neering phase and downloaded as an application to MControl prior start-up. Those applications are available as template or generated during design phase of the switch-board. Installing of additional function modules at a later stage is supported.

Control Function Modules

MNS iS provides all required software functions to control, protect and monitor the motors with a minimum of module types and components. The control modules available for MControl are capable of handling all functions with one type of common hardware.

Starter Type Control Options

Control Function Module Standard Heavy Duty RCU (1) *

NR-DOL (Non-Reversing Direct Online Starter)

REV-DOL (Reversing Direct Online Starter)

NR-S/D (Star- Delta switchover Starter) *

Transparent Mode (2) (1) RCU = Remote Control Unit starter type (2) The Transparent Mode allows control of up to three

contactors inside the MStart module directly from the process control system. Measurement functions are available in this mode (current measurement etc). No protection function is required as the contactor is controlled via the process control system. Contactor Feeders use the Transparent Mode for control function.


Maintenance SwitchCycles

Maintenance Temperature

Protection Underload

Protection Phase Loss

Protection TOL

Control NR-DOL

ApplicationMotor 1ABC01

Monitoring Current Value



Protection Function Modules

The motor protection functions safeguard the motor against the unwanted process or mechan-ical stresses and strains. The protection functions allow pre-sets for Alarm Levels, Trip Levels together with Alarm Delays and Trip Delays thus protecting your valuable assets your mechanical and electrical equipment and safeguarding your production.

The philosophy is simple: Alarms are generated when the pre-set alarm level is reached and the adjustable Alarm Delay time is expired. If the Trip Level is crossed and the Trip Delay expires the motor will trip. In each event messages are generated.

The detailed information on the motor status and configuration is communicated site-wide, providing the plant operator with information enabling preventive actions and educated decision to be made before plant status becomes critical, ensuring plant operators are pro-active in maximizing plant availability with unwanted trips being avoided. The protection functions are configurable and can be enabled or disabled depending on the requirement.

Additionally a variety of protection functions can be set to trip only or alarm only. Specific functions are suppressed during motor start up. The maximum motor start-up time can be set using a parameter, however, MControl monitors the motor start-up and measures the real start-up time. Protection functions are based on this up-to-date value.

The trip-reset modes can also be configured for either of the following: Auto Trip Reset Remote Trip Reset Local Trip Reset Remote & Local Trip Reset



Thermal Overload Protection Thermal Overload Protection (TOL) protects the motor against overheating. The motor thermal condition is simulated by calculation both when running and when stopped. The resulting calcu-lation i.e. thermal capacity is stored in the ther-mal register. The value stored in the thermal register is communicated via the switchgear bus to other devices capable of interpreting the infor-mation. Functionality of the thermal model according

to IEC 60947-4-1 MControl calculates Time to Trip and Time

to Reset. Additionally a message TOL Reset Level Reached is generated to inform the user of a possibility to reset the trip.

In some process applications it may be

beneficial to bypass the TOL protection for short periods. If the TOL Bypass command is given after the TOL alarm, the thermal capacity is allowed to rise up to 200% before tripping. This feature cannot be activated for EEx-e applications.



Thermal Overload Protection Models

Thermal Motor Protection

Alarm Level

Alarm Delay

Trip Level

Trip Delay Description

TOL Standard Uses the highest measured phase current for the calculation. The thermal capacity calcula-tion considers actual load, phase unbalance and motor rated load in ambient temperature.

TOL EEx-e * TOL for EEx-e application. Takes into consideration stall / nominal current ratio and the maximum temperature allowed by the environment class definition.

* ATEX Certification planned for Release V2.0



Motor Protection Module Any deviation from normal condition of motor operation is monitored and alarmed.

Based on measurement of current, voltage and motor temperature an alarm is issued and after exceeding trip limits, the motor is stopped immedia-tely.

Motor Protection Function Alarm Level Alarm Delay

Trip Level

Trip Delay

Phase Loss

Phase Current Unbalance

Undervoltage *

Motor Temperature Protection (PTC) *

Earth Leakage

Process Monitoring Module Plants are running continuously for a long time. Mechanical stress can cause problems in me-chanical connection of motor to machines and pumps.

With MNS iS mechanical motor connection and machines are supervised by monitoring the motor current.

Process Function Alarm Level Alarm Delay

Trip Level

Trip Delay

Stall

Underload

No Load

Underload Cos Phi

Emergency Stop trip

Start Limitation fixed * Planned for Release V2.0



Platzhalter X X X X

X

Description

Phase loss can be caused by blown fuse etc. The protection function uses the highest and lowest measured phase currents to compare against set levels.

Unbalance can be caused by pitted contacts, faulty motor, loose connections etc. The difference between the minimum and maximum phase currents is compared against the set parameters.

Protects the motor against undervoltage condition (voltage drop or loss).

Protects against too high temperature by using PTC sensors. The resistance values are compared against the set levels. Automatic restarting is available if desired. Supervises for open circuit and short circuit conditions.

MControl uses the measured phase current to calculate the earth fault current level. The value is compared against set level.

Other problems may be caused by process related starts / stops of the motor. Too many starts or at a high load may cause interruption.

Any deviation can be informed to the automation and maintenance system.

Description

Protects against stall, the highest measured phase current to compare against the set parameters, activates only after motor start-up time is complete.

Uses the highest measured phase current, to compare against set parameters. Trip level can be disabled; therefore MControl can be set to alarm only.

Similar to Underload but with different set levels and messages. No load uses the highest measured phase current to compare against the set parameters.

Protects the motor against underload condition based on cos phi detection. The cos phi value is compared against the set levels. Most accurate method of protecting against cavitations.

When the Emergency Stop is operated the MControl executes a contactor trip. The release of the Emergency Stop button will not start the motor.

Limits the number of starts during a time interval. Number of starts and time interval are parameter settings. It automatically resets if starts allowed again.



Maintenance Function Module

MControl continuously supervises the other trip situations as well as keeps track of maintenance data. The below information is available to the user via communication links or at the MView display. Analog values are given as true RMS values.

Messages are generated on status change or when thresholds are exceeded indicating that a certain planned or unplanned system status may be reached. These messages may be alarms or trips generated by the MControl.

Maintenance Function Module

Alarm Level

Alarm Delay Trip Level

Trip Delay

Outgoing Line Temperature Supervision

Contactor Switching Cycles

Operating Hours

MStart Inserting Cycle Counter

MStart Type Supervision fixed

MControl Location supervision fixed



Predictive maintenance is one of the key factors in modern application and plant processes. Availability of the process is ensured with online monitoring and information based on current conditions. XX

These conditions are extended with MNS iS by monitoring temperature in outgoing cable connec-tion.

Description

Temperature rise in the outgoing line of motor starter may be caused by loose terminals and cable connection, detection prevents damage on cable and switchgear.

Each complete close-open cycle of every single contactor is counted and updated. When the contactor switch cycle limit is exceeded MControl initiates an alarm.

The MControl counts the motor running hours. An alarm is initiated when the predefined operating hours limit is exceeded.

Counting insertion cycle of MStart module, an alarm is initiated if alarm level is reached.

MStart hardware compatibility check, detects if the correct type of MStart is used for the modules loaded into MControl. If a wrong type is used, MControl will issue a trip to disable operation.

Location recognition and supervision, check if MControl module hardware and the loaded function modules are in the correct location of switchboard. If wrong location is used, MControl will disable operation.



System Status

MNS iS monitors the system integrity and provides facilities to ensure correctness of operation. It also includes internal monitoring functions of devices.

The operation of the contactor and main switch are continuously monitored to advise on asset availability.

System Status Description

System integrity

Failsafe

Supervises the network communication. If a loss of communications is detected the failsafe activates with either one of the following pre-parameterized functions: No Operation, Start Motor (direction 1 or 2), or Stop Motor. By selecting the correct actions appropriate to the process, total plant shutdown can be avoided.

Control Access Control Access provides the facility to define the access control rights for a specific location (such as MView or the Process Control System or locally via Pushbutton etc.)

Starter monitoring

Main Switch Position

MControl monitors the main switch position of MStart, if it is moved from ON to Off position during motor operation, the MControl issues a command to trip the contactor.

TEST Position is also detected. Moving from TEST position to any position if a running motor is simulated also a Trip is issued.

Contactor Feedback Supervision

Following receipt of a command signal, MControl monitors the status of motor and contactor to ensure correct execution. Status is checked by using feedback signals and by current measurement. When enabled will cyclically check the above.

Starter Ready Indication Motor starter condition is monitored and an information is sent to the operator indicating readiness for operation .

Control Voltage Supervision Contactor control voltage level is monitored, any deviation from a set value leads to a trip of motor.

Auto-Restart * After main voltage loss the restart of the motor can be initiated automatically. A time can be parameterized in order to allow staggered start of motor in the plant.




Measurements and monitoring

Status information and measured values from MControl are available system wide. Depending on the application the values are used for Process Control or Maintenance tasks.

Process and maintenance related values are freely selectable. Table below is a guideline only.

Measuring and Monitoring Module

Process related value

Maintenance related value Description

Motor Status Motor status such as On / Off; Open / Closed; Tripped etc.

Phase Currents Three motor phase currents. Absolute and relative values.

Outgoing Line Temperature Temperature measurement in the outgoing line of all three phases of MStart

Calculated Thermal Capacity Thermal capacity calculated from motor and environmental parameters.

Time to Trip Estimated time to reach 100% thermal capacity.

Time to Reset Estimated cool-down time at which the thermal capacity of the motor allows a restart.

Phase Voltages Three phase voltages. Absolute measured values.

Power Factor * Calculated value.

Active Power Active power as absolute value.

Reactive Power Reactive power as absolute value.

Apparent Power Apparent power as absolute value.

Earth Fault Current Earth fault current calculated as absolute value.

Frequency Frequency of the electrical power system, absolute value.

Digital In-/Output * Monitoring of binary in-/outputs of MControl to connect external devices (i.e. remote I/O).

Analog In-/Output ** Analog in-/outputs are available for external indication and control. * Planned for Release V2.0 ** Planned for Release V3.0



Additional Function Modules

Additional functions like remote control unit (RCU) and emergency stop (EM-Stop) are provided with terminal connections to the MStart power module.

RCU / EM-Stop connection terminals are located above the control module area in a separated compartment. It allows voltage ranges from 24V DC up to 230VAC.

RCU * RCU is a control function that allows the operator to bypass MControl control function by using a local switching panel.

* Planned for Release V2.0 Emergency Stop The EM-Stop connection fulfils the standard requirement to de-energize the main contactor immediately without additional devices.

M

K1

L1L2 L3

contactor control voltage

MStart

Start

Stop

K1 Start Command

K0

Stop Command

K0K1

Em-Stop(optional)

contactor control

MStart

Start Command

K1

M

L1L2

K1

Em-StopAux. Contact

24VDC

DI1S1

MControl

S1Em-Stop



MMNNSS iiSSTTeecchhnniiccaall DDaattaa

MMNNSS iiSS TTeecchhnniiccaall DDaattaa

MNS iS Electrical characteristics

Rated voltages

Rated insulation voltage Ui up to 1000 V 3~ *

Rated operating voltage Ue 690 V 3~

Rated impulse withstand voltage Uimp 6 / 8 / 12 kV *

Overvoltage category II / III / IV

Degree of pollution 3

Rated frequency up to 60 Hz

* Depending on the electrical equipment MNS iS Standards and Approvals **

Standards Type tested switchgear assemblies (TTA) ***

IEC 60439-1 CEI 60439-1 DIN EN 60439-1 VDE 0660 part 500 BS EN 60439-1 UTE 63-412

Test certificates ASTA, Great-Britain (resistance to accidental arcs acc. to IEC

61641 and IEC 60298, Appendix AA) DLR German Research Institute for Aerospace e. V. Jlich, Earthquake Test for Security Areas in Nuclear Power Stations IABG Industrieanlagen Betriebsgesellschaft, Vibration and shock tests

** Derived from MNS *** Definition TTA: Switchgear assembly corresponding, to a large degree, with the original type or system of switchgear assembly

type-tested in accordance with these standards.



MAIN BUSBAR Rated current (A)

Dimension Assumption: 3 pole system, ambient temperature 35C

Phase L1 - L3 Ventilated Non-ventilated Standard IP 30/40

Option IP31/41, IP32/42 Standard IP31/41 Standard IP42/52

1250 1200 1000

1800 1750 1450

2300 2200 1850

3200 3200 2300

3300 3150 2400

3500 3300 2400

4000 3850 2400

4050 3850 2900

4400 4200 2900

5800 5800 3900

6300 6300 3900

Busbar section

MAIN BUSBAR Rated short circuit withstand strength (kA)

Dimension Assumption: 3 pole system, ambient temperature 35C

Phase L1 - L3 Ipk Icw (1s)

74 35 105 50 165 75 176 80

250 100

Busbar section

DISTRIBUTION BAR Rated current (A)

Dimension Assumption: 3 pole system, ambient temperature 35C, with multifunction separation wall

Phase L1 - L3 Ventilated Non-ventilated

Standard IP 30/40 Option IP31/41, IP32/42 Standard IP31/41 Standard IP42/52

750 750 600 1500 1500 1150

1500 1500 1150

Busbar section

DISTRIBUTION BAR Rated short circuit withstand strength (kA)

Dimension Assumption: 3 pole system, ambient temperature 35C, with multifunction separation wall

Phase L1 - L3 Ipk Icw (1s)

105 50 143 65

220 80

Busbar section



MNS iS Mechanical characteristics

Dimensions Cubicles and supporting structures Basic grid size Sheet steel thickness: C shape profiles Transverse sections Recommended height Recommended width MCC / Withdrawable modules

Control cable compartment Equipment compartment Power cable compartment Cubicle total

Incomers/ Bus couplers Equipment compartment (= total)

Recommended depth total

DIN 41488 E = 25 mm acc. to DIN 43660 2 mm 2.5 mm 2200 mm 300, 400 mm 600 mm 300, 400 mm 1200, 1400 mm 400, 600, 800, 1000 mm 600, 800, 1000, 1200 mm

Surface protection

Frame Internal subdivision Transverse section Enclosure

Zinc or Alu-zinc coated Zinc or Alu-zinc coated Zinc or Alu-zinc coated Zinc or Alu-zinc coated and Powder coated (RAL 7035, module doors RAL 7012)

Degrees of protection

According to IEC 60529 or DIN 40050 IP 30 up to IP 54

Plastic components Halogen-free, self-extinguishing, flame retardant, CFC-free

IEC 60707, DIN VDE 0304 part 3

Internal subdivision Device compartment - device compartment Busbar compartment - cable compartment Busbar compartment - device compartment Device compartment - cable compartment Compartment bottom plates

Options (on request)

Busbars Special qualification (tests)

Insulated Silver or tin plated See test certificates listed previously



3

MNS iS switchboard dimensions

MCC

Compartment width

Control cable compartment W1

Equipment compartment W2

Power cable compartment W3

BuW

300 mm 600 mm 300 mm 12400 mm 600 mm 400 mm 14Compartment depth

D1 = 400 mm D2Cubicle height

H = 2200 mm Incomer

Compartment width

Equipment compartment W Bu400/ 600 /800 /1000 / 1200 mm = Compartment depth

D1 = 400 mm (+ 80mm pagoda for withdrawable devices) D2D1 = 600 mm (+ 80mm pagoda for withdrawable devices) D2D1 = 800 mm (for >=4000 Amp) D2Cubicle height

H = 2200 mm


W
W1 W2 W
H

D1

D

D2

W

sbar compartment 1+W2+W3 = W 00 mm 00 mm

= 200 / 400 mm

sbar compartment W

= 200 / 400 mm = 200 / 400 mm = 200 / 400 mm

4411

D

D2

D1

MCC

Incomer


Module Types and Dimensions

6E/4 height 150mm; width 150mm

6E/2 height 150mm; width 300mm

6E height 150mm; width 600mm

150

6 E

3006 E

6006 E





600

8 E

600

12 E

600

16 E

600

24 E

For maximum output per module size and starter type, see detailed Module selection tables.

MNS iS Starter Types MNS iS Feeder

NR-DOL, HD Direct Online starters, Heavy-duty starters

REV-DOL Reversing starters

NR-SD Star/Delta starters *

CF Contactor Feeder

MM

MSD

MM

MSD

MM

MSD

-N01

-K01 -K03 -K02


MM

MSD

Abbreviations: MM = Measuring module MSD = Main switching device (Fused or Fuseless)



Module Selection Tables

MStart selection Rated voltage = 400V Fused motor starters 50/65 kA, type 2 coordination

MStart module size

Starter type 6E/4 6E/2 6E 8E 12E 16E 24E

NR-DOL 15 kW 22 kW 37 kW 55 kW 132 kW 250 kW

REV-DOL 5.5 kW 22 kW 37 kW 75 kW

HD 15 kW 22 kW 45 kW 90 kW 200 kW

SD * 55 kW 132 kW 160 kW Fuseless motor starters 50 kA, type 2 coordination,

MStart module size


NR-DOL 11 kW 30 kW 75 kW 200 kW 250 kW

REV-DOL 11 kW 30 kW 37 kW 75 kW

HD 22 kW 75 kW 132 kW 200 kW

SD * 55 kW 110 kW 132 kW 160 kW Fuseless motor starters 65 kA, type 2 coordination

MStart module size


NR-DOL 4 kW 30 kW 55 kW 75 kW 200 kW 250 kW

REV-DOL 4 kW 30 kW 37 kW 75 kW

HD 22 kW 45 kW 75 kW 132 kW 200 kW

SD * 55 kW 75 kW 132 kW 160 kW * Planned for Release V2.0



MStart selection Rated voltage = 500V Fused motor starters 50 kA, type 2 coordination

MStart module size


NR-DOL 18.5kW 30 kW 37 kW 75 kW 160 kW 250 kW


HD 18.5kW 30 kW 55 kW 110 kW 200 kW

SD * 55 kW 160 kW

Fuseless motor starters 50 kA, type 2 coordination

MStart module size


NR-DOL 2.2 kW 37 kW 55 kW 110 kW 250 kW

REV-DOL 2.2 kW 37 kW 75 kW

HD 30 kW 55 kW 90 kW 160 kW 200 kW

SD * 55 kW 90 kW 160 kW




MStart selection Rated voltage = 690 V Fused motor starters 50 kA, type 2 coordination

MStart module size


NR-DOL 22 kW 37 kW 75 kW 160 kW 400 kW


HD 18.5kW 30 kW 55 kW 110 kW 200 kW

SD * 55 kW 160 kW

Fuseless motor starters 50 kA, type 2 coordination

MStart module size


NR-DOL 1.1 kW 15 kW 160 kW 250 kW

REV-DOL 1.1 kW 75 kW

HD 15 kW 110 kW 200 kW

SD * 160 kW


MFeed Selection Rated voltage = 400 690V For contactor feeder operation utilize the corresponding rating for NR-DOL and select the parameter Transparent in MControl.



Control and Communication components

MStart MControl MLink

Electrical Data

Auxiliary supply voltage(s)

Supply voltage 24V DC 24V DC 24V DC

Voltage range 19 31 VDC 19 31 VDC 19 31 VDC

Power consumption

Typical 200 mA 150 mA 1000 mA

Maximum 240 mA 270 mA 1700 mA

Mechanical Data

Dimensions (HxWxD) mm 125x53x260 110x265x230

Weight 0.7 kg 2.0 kg

Environmental conditions

Storage temperature -20 +70C -20 +70C -20 +70C

Operation temperature -5 +55C -5 +55C 0 +55C

Degree of protection IP20 IP20 IP20

In-/ Output connection on MControl front

Input (optical isolated, one common)

Output (two outputs share one common)

Over voltage class II II

Pollution severity 3 3

Nominal voltage 24V DC 250 VAC 50/60 Hz

Impulse voltage withstand level 6 kV (coil-contact, 1.2/50s)

2.5 kV

Nominal current (cosphi 0.4) 10 mA (16mA) 1 A

Nominal cross-section of connector 1.5 mm2 1.5 mm2

Switching cycle 50 ms 5 * 106

Max switching voltage 230V AC

Max switching current 1 A (AC-15 / DC-13)

Max switching capacity 500 VA


ABB

Publication No.: 1TGC910001B0203Revision 03, April 2006 Editor: ABB Automation Products GmbH Dept. APR/S-RDB Wallstadter Str. 59 D-68526 Ladenburg, Germany

ABB Low Voltage Systems Local contacts: www.abb.com/mns

PositionMechanical statusElectrical status

6E/4, 6E/26E24E( O )(Connectivity LimitationsStarter monitoringStandard IP 30/40Option IP31/41, IP32/42MCCCubicle heightIncomerFor maximum output per module size and starter type, see detREV-DOLReversing startersMStart module size6E/46E/26E8E12E16E24EMStart module size6E/46E/26E8E12E16E24EMStart module size6E/46E/26E8E12E16E24E( 4 kW( 30 kW( 55 kW( 75 kW( 200 kW( 250 kW( 4 kW( 30 kW( 37 kW( 75 kW( 22 kW( 45 kW( 75 kW( 132 kW( 200 kW( 55 kW( 75 kW( 132 kW( 160 kWMStart module size6E/46E/26E8E12E16E24EMStart module size6E/46E/26E8E12E16E24EMStart module size6E/46E/26E8E12E16E24EMStart module size6E/46E/26E8E12E16E24EAuxiliary supply voltage(s)Power consumption

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