INSUM for Motor

Management
© ABB Ltd.
Integration of switchgear with DCS
Conventional parallel wiring MNS-INSUM
Fieldbus connection with INSUM®
Interposing Relay Panel
ABB
realized with all major DCS systems
Marshalling Rack
ABB

I/O Wiring

Connection via Fieldbus,

e.g. PROFIBUS, LONworks, MODBUS And Ethernet

redundant interface if required

ABB

ABB

DCS
DCS

intelligent
Motor Control Center
Motor Control Center

STARTSTOP
START STOP

START STOP

Local Operator Station

Control Panel
Motor Local
Operator Station Motor Control Panel

ABB Arab
Conventional Motor starter

Auto
START
Restart

STOP
Digital
I/O
RUN
K1 DCS
Central
READY Control
Station

FAULT
Bimetal

A RESET
mA

Op. Hrs.
Analog
A
inputs

ABB Arab
Intelligent Motor starter with INSUM®
 Only one microprocessor-based intelligent field unit
DCS and SCADA
 Reduced wiring in starter / Switchgear
 Optimum protection through microprocessor
 Integration into DCS via Serial link
 Peer-to-peer communication of field units Serial link

Aux. voltage supply

Test position MCU
Voltage for every motor:
- Supervision of
measured values
Control of contactors - Protection
- Control

Motor current
Limit positions
Earth leakage current &
Feedback from actuators

M Temperature monitoring
3~
Local control box
ABB Arab
 Protection Functions
 Overload protection According to IEC 947-4-1
 Loss of Phase Warning when set thermal conditions are reached

 Thermal Memory Protection  Adjustable time to trip and to possible restart

 Stall Protection  t6 times can be chosen in range 5-40 seconds
 Underload Protection
 No Load Protection
 Contactor Supervision

Consecutive Start Protection

Unbalance Protection
 Earth Fault Protection
 Under voltage Protection

ABB Arab
 Monitoring Functions

 Motor Phase Currents L1, L2, L3

 Overload
 Underload
 Number of Switching Cycles
 Hours Run

 Mains Voltage & Frequency

 Power Factor
 Active Power
 Reactive Power
 Motor Temperature
 Earth Leakage
 Motor RPM

ABB Arab
INSUM Components

 Motor Control Unit (MCU) MCU

 Backplane ,Routers & LON
Interface/ Gateways B.P.
 Man Machine Interface (MMI)
 INSUM MMI
Operator Station (OS)
OS

ABB Arab
 Execution philosophy
OPERATOR

SEQUENCE PROCESS
250 ms DCS LOGIC INTERLOCK
COMM. I/O

100 ms MODBUS

50 ms INSUM
MCU

MECH. SAFETY,
START/STOP M PROTECTION,
etc.
ABB Arab
 Control Access

The System Control can be accessed from:

 The Local Control Panel (LCP)

 Manual Control Panel (MCP)
 MMI (Man Machine Interface)
 PCS/OCS
 O.S. (INSUM Operator Station)

INSUM has a configuration access through

• Password for the PC
• Key for the MMI

ABB Arab
 Advanced Features
Power Features include
 Failsafe Mode
 Soft stop time
 Time Delay Automatic Restart
 Manual or Automatic Overload Reset
 Maintenance Announce on Operations or Run Time
 Interlocks for Star Delta, 2 Speed and Auto Transformer
Supervision Features include :
 Watchdog
 Permit individual control in case of communication failure
 RS 232 interface

ABB Arab
The hard part: Hidden Costs

KNOWN Equipment Costs

Price Engineering Costs
COSTS Construction Costs Inspection & Testing

Performance Problems Safety Costs

Customer Dissatisfaction Spare
Duplication of Effort Debugging Costs PartsScrap
Liability Costs Expediting Shipments
Air Freight
Late Delivery Costs Overtime
Startup Delays
HIDDEN COSTS Equipment Service Calls Maintenance Costs Energy Costs
Equipment Shutdown Costs High Inventory Costs
Construction Rework Maintenance Costs Toxic Emissions
Training Costs Environmental Regulations Stress
Ease of Repair
Engineering Changes Frustration
Stocks
Paperwork Inspection Dissatisfaction
Rescheduling

ABB Arab
MNS-INSUM®: savings during investment
Relative Cost without conventional
Switchgear
connected to DCS
- spare parts
100 %
- commissioning Costs
- repair costs 24 70%

- down-times 16
3
2

60 65
MNS-INSUM®
I/O DCS
Connect.
MCC

Typical cost savings

ABB Arab
 Time savings during manufacturing
Convential swgr. MANUFACTURING

CUSTOMER Detailed process eng. O P T I MI I Z I N G of P R O C E S S

commissoning
Technical Changes on site
complex long-lasting
offer clarifications
complex detailed procurement of documentation
assembly
SUPPLIER engineering material

20 weeks

MNS- INSUM: standardized MANUFACTURING

CUSTOMER rough process eng. O P T I M I Z I N G of P R O C E S S

Process data
Commission.
Shopping- simple order series production final sett. of
List clarifications of moduls parameters
simplified assembling
SUPPLIER Simple
engin. of moduls
documentation

8 weeks
ABB Arab
 Summary
 Reduces costs of investment
 with less equipment and wiring more cost effective installation and commissioning

 Easy optimizing of your process

 i.e. reduced time and costs needed for project management and engineering by increased
flexibility thanks to intelligent software
 Changes possible by software

 Standardized integrated hard- and software reduces:

 the complexity of the system
 the volume of spare parts
 the need for expensive specialists
 the operation and maintenance costs

ABB Arab
 Integrated System - New Generation

First generation INSUM, 1987 to present,

controls more than 50,000 motors worldwide.

Through evolution we have INSUM II which

offers:
 Decentralized Intelligence
 Connection to third party devices
 Event Driven
 Fast Communication
 Additional protection functions

ABB Arab
 Back
Motor Control Unit (MCU)
Microprocessor
MCU1 MCU2
• Basic MCU 1
• High Level MCU 2
Maintenance / Monitoring Functions
As MCU1 with the additional
 Thermal capacity functions:-
 Phase currents  Power, Power factor
 Time to trip, Time to reset  Active power
 Alarms / Faults messages  Earth leakage current
 Operating hours  Phase voltages
 Switching cycles
 Maintenance period

MCU1 MCU2 Protection Functions

Starter Types Supported  Thermal overload As MCU1 with the additional
functions:-
As MCU1 with the additional types:-  Stall protection
 Phase loss protection  Unbalance protection
 DOL  Actuator
 No load protection  Underload cosphi protection
 Reversing  Star Delta  Earth fault protection
 Start limitation
 DOL/RCU  Star Delta Rev  PTC protection
 Reversing/RCU  Two Speed  Undervoltage and Auto-restart
 Two Speed Rev
 Softstarter
ABB Arab
Back
Switchgear Man Machine Interface (MMI)

The MMI is a powerful

configuration and interrogation
tool, usually mounted within the
MCC.
Navigation is made easy through
user friendly menus utilising the
encoder wheel and the 8 keys
provided.

The display is a back lit LCD with

contrast control giving 6 lines of 20
characters in clear text.
Multilingual support is available
based on the Latin1 character set

The MMI is protected against unauthorised use with a Data Key having upto sixteen levels of user access,
monitoring of all information is possible without the Data key.

ABB Arab
 Back
INSUM Back-plane with Devices Mounted

Filtering/Protection

Output Terminals
Routers for
Connection to Controllers
twisted Pair Free Topology
2 x 2 lines of 32 devices
Lon ‘Backbone’
78 KBaud, Lon Bus
1.25 Mpbs

Communication to Control System Modbus, Profibus , Ethernet 24V DC Power Supply

Serial connection RS232, RS485, RS422.
Selectable Baudrate 9600 bd, 19200 bd, 38400bd, 76800bd

ABB Arab
Back INSUM Operator Software

ABB Arab