ABB M10 Series User manual

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MANUAL
Motor control and protection unit
M10x User Guide

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ABB low voltage MCC with M10x is the intelligent motor
control center solution integrating protection, control,
monitoring and communication through single M10x, a
signature motor management device of ABB low voltage
switchgear business.
Main benefits of ABB MCC with M10x
• Unmatched safety for protection for personnel and plant
• Simplicity and high functionality
• Integrated communications
• Reliable solution proven by years of market experience
• Flexibility in a standardized solution
• Less spare starter module types
• Rapid fault detection and rectification
• Easy integrate and access to digital service
• Fully integrated into ABB AbilityTM CMES condition monitor-
ing solution

07. Configurable Inputs and Outputs
09. Operator panel MDx
08. Monitoring and reporting
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Contents
01. General 04
02. Product overview 08
03. Installation and wiring 10
04. Motor starters control 22
05. Protection functions 40
06. Control access 61
64
70
72
10.Communication interface 86
11.Parameterization 90
12. Fault messages and troubleshoot 91
13. Appendix A: technical data 95

4MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
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01. General
Target group
This manual provides information on the
internal parameters of M10x for the purpose of
understanding, engineering, testing, system
integration or commissioning of the product.
Each chapter consists of brief explanations of the
functions, the relevant parameters and the
parameter descriptions, along with ranges.
Default values of all parameters are listed in
appendix: Factory settings for M10x.
Examples and further explanations are provided
for user reference in parameterization.
The electrical warning icon indicates the presence of a hazard that could result in electrical shock.
The warning icon indicates the presence of a hazard that could result in personal injury.
The caution icon indicates important information or warnings related to the concept discussed in the text. It might
indicate the presence of hazard that could result on corruption of software or damage to equipment/property.
The information icon alerts the reader to pertinent facts and conditions.
The tip icon indicates advice on, for example, how to design your project or how to use a certain function
Use of warning, caution, information and tip
icon
This publication includes Warning, Caution, and
Information icons where appropriate to point out
safety related or other important information. It
also includes Tip icons to point out useful hints to
the reader. The corresponding symbols should be
interpreted as listed on the table below.
Although Warning notices are related to personal
injury, and Caution notices are associated with
equipment or property damage, it should be un-
derstood that the operation of damaged equip-
ment could, under certain operational condi-
tions, result in impaired process performance
leading to personal injury or death. It is, there-
fore, imperative that you comply fully with all
Warning and Caution notices.

5
01.GENERAL
Terminology
List of terms, acronyms, abbreviations and definitions used in the document:
Abbreviation Term Description
Alarm Alarm is defined as status transition from any state to abnormal state.
Status transition to abnormal state can be data crossing over the
predefined alarm limit.
DCS Distributed control system High level distributed control system
Local hardwiring A control access term describing that the M10x accepts its
commands from the hardwired inputs when the local control
authority is enabled.
PCS Process control system High level process control system
MODBUS Fieldbus communication protocol
MODBUS RTU Fieldbus communication protocol
PROFIBUS-DP Fieldbus communication protocol with cyclic data transfer (V0).
PROFIBUS-DP/V1 Fieldbus communication protocol, extension of PROFIBUS-DP allowing
acyclic data transfer and multi master (V1)
PTC Positive temperature coefficient PTC thermistors are semiconductor elements with a very high positive
temperature coefficient.
RCU Remote control unit Local control unit with pushbutton and indicator to operate a device (eg,
motor) from field level.
Remote fieldbus A control access term describing that the M10x accepts its commands
from the fieldbus inputs when the remote control authority is enabled.
RS485 Communication interface standard from EIA (Electronics Industries
Association, USA), operating on voltages between 0V and +5V. RS-485 is
more noise resistant than RS- 232C, handles data transmission over longer
distances, and can drive more receivers.
STP Shielded twisted pair A type of cable commonly used for signal transmission.
TOL Thermal overload
protection
Protection against overheated caused by overload
Trip A consequence of an alarm activated or an external trip command from
another device to stop the motor or trip the circuit breaker.
MCC Motor control center Common term for a switchgear used for motor control and protection.
SOE Sequence of events A record of events with time stamp.

6MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
Related documentation
1TNC 911112 M10x User Guide
1TNC 911507 M10x-P PROFIBUS Protocol Implementation
1TNC 911505 M10x-M Modbus Protocol Implementation
1TNC 911104 MCUSetup User Guide
1TNC928239 M10x -TCP User Guide
Related System Version
The content of this document is related to M10x products (1TNA920xx) with the following hardware and
firmware version release:
HW FW
M10x-M 24VDC 2.0 3.5
M10x-M 110VAC 1.0 3.5
M10x-M 240VAC 1.0 3.5
M10x-P 24VDC 3.2 5.4
M10x-P 110VAC 1.0 5.4
M10x-P 240VAC 5.2 5.4
MD21 1.0 2.3
MD31 1.0 1.1
EM01 1.0 1.1
Revision Description of change Date
D0201 Initial Edition 10/2003
D0202 Product revisions 10/2005
D0203 Revise COM terminals; Revise terminology of
control authority. Revise earth fault setting.
10/2007
D0204 Template changed as per BU Guideline. 10/2010
D0205 Released for M10x products with new hardware,
suitable for both M10x-M and M10x-P
01/2013
D0206 Feature "Ready to start" is added to DO 07/2013
D0207 Add in Phase sequence protection and more
DO functions, modify main switch supervision
function.
09/2016
D0208 Add in insertion cycle supervision, external VT
setting and M10x-TCP with EM01 module
02/2020
Until further notice, this document is also applicable for future firmware versions other than those listed
above.
The described functions are designed but may not be fully implemented in all details. Please refer to the
release notes regarding possible restrictions.
Document revision history

7
01.GENERAL
New features available in enhanced products (1TNA920xxx)
In comparison with classic products (1TNA911xx)
General features
1 One single type of integrated CT ranging from 0.24~63A replaces all 6 types of CTs in previous
products.
2 Products with options for 110VAC or 240VAC power supply and DI types are available in addition to
24VDC option.
3 Additional SOE function in M102 provides event recorder data up to 256 events with time stamp.
4 Products in the same categories are made with the same features and functionalities and are
only different in power supply and communication interface from each type. For example, M101's
range of products has identical functionalities regardless of different types of power supply and
interfaces, such as M101-M 24VDC, M101-P 240VAC, etc.
Physical dimension
1 Main unit dimension remains the same as previous revision. MDx panel is slightly larger in width
and length (both 3mm extra) while cutout dimension remains the same.
Control features
1 Contactor feeder and contactor feeder/RCU are added into starter types.
2 Two separate start types are available for two-speed starters. NR_2N is for two-speed motor with
separate windings while NR_2N Dahlander is for Dahlander connection motor.
3 Control logic in NR_softstarter and REV_softstarter are modified slightly.
4 Control authority feature in M10x-M has been revised to be identical to M10x-P.
Digital inputs and outputs
1 All DIs in M10x are configurable and also selectable with NO or NC.
2 E-stop, Limit 1, Limit 2, External trip input control definition has been revised.
3 More features are added to DOs.
Protection
1 Long start protection is available to provide stall protection during motor startup.
2 Options are provided to enable or disable TOL protection during motor startup.
3 PTC short circuit protection and PTC open circuit protection are available.
Communication
1 Additional communication speeds are available for MODBUS: 38400 bps and 57600 bps.
2 Additional communication option Modbus TCP is added in.
Measuring and monitoring
1 Additional running data are monitored such as current phase unbalance, thermistor resistor, time
to TOL trip, time to TOL reset, startup time, DI status.
2 Phase-to-phase instead of phase-to-neutral voltage is directly measured.
Maintenance
1 More maintenance features are implemented, including providing number of trips, SOE with time
stamp, etc.
Operator panel MDx
1 MDx is provided as IP54.
2 Color and function of LEDs are selectable.
3 Messages on MD21 are selectable.
4 Multiple languages are supported including , English and Chinese.
5 Parameter setting via MD21 is available.
6 Parameter setting port on MDx is mini USB connector in lieu of USB connector.

8MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
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02. Product overview
Introduction
M10x is an intelligent motor control and
protection device based on current measurement
or current measurement and voltage
measurement. It is designed to be integrated with
with ABB Low Voltage switchgear MNS® and
NeoGearTM . ABB Low voltage switchgear with
M10x device provides customer a simply but intelli-
gent motor control center solution.
M10x device have measuring, monitoring, motor
protection and controlling functions built in one
single unit. By configuring of parameters to the
device, M10x device is customized and engineered
with application specific motor protection, moni-
toring and controlling features to serve different
industry process. Each motor starter is usually
managed by one M10x device with standard di-
mension regardless different available functions.
Available with communication interfaces
(PROFIBUS DP, MODBUS RTU and TCP), M10x inte-
grates smoothly and efficiently into industrial
control and plant management systems. Every in-
dividual M10x device can be accessed and interro-
gated to determine both actual and operating pa-
rameters. Fast response time for alarm or trip sta-
tus makes real time control of a complete process
possible. Statistical recording of running hours
and number of operations assists with predictive
maintenance scheduling.
For AC motor and the operated installations this
means:
• Reliable protection
• Maximum utilization
• Continuous supervision
• Flexibility
Product Variants
M101 basic version
M102 advanced version
M10x-M Modbus RTU type
M10x-P Profibus type
M10x-TCP Modbus TCP type
M10x 24VDC
M10x 110VAC
M10x 240VAC
Components Description
Main unit
The main unit is constructed with two parts: the
electronics of the motor control unit and the
integrated CT. Main unit is a one type device with
the integrated CT range starting from 0.24 to
63A. For motor ratings 63A ~6300A,
interposing CTs are required. (Fig 01)
Operator panel MD21/MD31
The operator panel is the user interface mounted
on the front door or drawer. With control buttons,
LED, LCD module (MD21 only), MD21/MD31
provides functions for motor control, supervision
and parameterizing. One operator panel is pro-
vided for each main unit upon request.(Fig 01)

9
02.PRODUCT OVERVIEW
Analogue Output Module AO11
Analogue output module AO11 is an optional
add-on module to main unit, providing one
channel 0-20mA or 4-20mA analogue output.
Details of AO11 module including how to do the
configuration is provided in a separate
document, 1TNC 920204 M10x AO Module User
Guide.
M10x-TCP Ethernet module EM01
Ethernet module EM01 is the dedicated
Modbus TCP interface to M10x-TCP. It provides
two Ethernet ports. Details of M10x-TCP is de-
scribed in 1TNC 928239 M10x-TCP User Guide.
M10x material
The enclosure of the M10x is made of
polycarbonate. Flammability rating of the
material is UL 94 V-0 and material is halogen free.
Color of the enclosure is RAL 7012.
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01 M10x and MD21

10 MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
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03. Installation and wiring
Dimensions
Basic dimension of M10x
W x H x D=110mm x 140mm x 75mm
Typical installation of M10x
Vertical DIN rail or vertical screw mounting on
horizontal plate
Basic dimension of MD21
W x H x D=91mm x 75mm x 24.3mm
Mounting dimension of MD21
W x H=84mm x 68mm
Basic dimension of MD31
W x H x D=88mm x 50mm x 24.3mm
Mounting dimension of MD31
W x H=84mm x 46mm
For installation details of M10x and
MDx, see installation manual.
MD31
M10x
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02 M10x in 8E/4 module
Main unit is designed with a mounting rail
fixed to the bottom of the device for easy
vertical DIN rail mounting.
Screws and other mounting accessories also
provide for vertical and horizontal screw
mounting.

03 . INSTALLATION ANDWIRING 11
Digital inputs for various
functions
Digital inputs for various
functions
CT inputs
(lead-through)
CT inputs
(lead-through)
Thermistor
input
Thermistor
input
Interface for MDx
Interface for MDx
Communication ports
Communication ports
RCT inputs
RCT inputs
Relay output
Relay output
Ground safety
and surge
Ground safety
and surge
Voltage input
Voltage input
Power supply
Power supply
1 2 3 4 5 6 7 8 9 10 11 1
1 2 3 4 5 6 7 8 9 10 11 1
2
2
1 2 3 4 5 6 7 8 9 10 11 12 1
1 2 3 4 5 6 7 8 9 10 11 12 1
3
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1
6
6
X2
X2
X1
X1
X3
X3
X4
X4
L
L
T
T
Interfaces
Terminal blocks of M10x are located on the top of
the main unit for easy access. There are 3 sets of
I/O terminal blocks and 1 set of RJ11 connectors
as shown.
—
03 Top view terminal layout (24VDC)
—
04 Top view terminal layout (110VAC or 240VAC)

12 MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
Terminal block Terminal number Designation… plug/contacts Remarks
X1 24VDC type X1:1…X1:14 Digital input Cross section 1.5mm2
X1:15…X1:16 PTC input
X1 110/240VAC type X1:1…X1:10 Digital input Cross section 2.5mm2
X1:11…X1:12 PTC input
X2 X2:1…6 Interface for MDx Cable with RJ11
connector provided
X3 X3:1…5 Fieldbus for external
communication
Cross section 2.5mm2
X3:6,7 RCT input
X3:8…13 Voltage input
X4 X4:1…9 Relay output Cross section 2.5mm2
X4:10,11 Power supply
X4:12 Ground
L1-T1; L2-T2; L3-T3 Lead-through Current measurement 110mm Window
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
Terminal designations
Regardless of different types of M10x product, the
definition of the terminal blocks on each type of
M10x remain the same. Depends on the selected
type, the quantities of the available terminal num-
bers may be different.
Integrated L-T Current Measurement
Current measurement in M10x is via the inte-
grated current transformer which comes with
one size measuring from 80mA to 63A. Exter-
nal interposing CT shall be used for measuring
from 63~6300A.
To ensure the correct current reading, wiring
of three phases should follow the same direc-
tion, i.e. either L-T or T-L.
In single phase application, current measure-
ment is based on Phase A or L1. The wiring has
to follow L-T direction only.
Current measurement is illustrated in the typi-
cal diagram Fig (13)
Wiring Tip:
In the application that motor current is less
than 500mA, it is essential to increase the
wiring turns on CT primary to avoid possi-
ble nuisance reading, also known as ghost
current. M10x supports up to 5 turns wiring
through parameter configuration.
The parameters are explained in 'M10x pa-
rameters description ' manual.

03 . INSTALLATION ANDWIRING 13
Functions
Terminal no. M10x 24VDC
X1:1 DI0
X1:2 DI1
X1:3 DI2
X1:4 DI3
X1:5 DI4
X1:6 DI5
X1:7 DI6
X1:8 DI7
X1:9 DI8
X1:10 DI9
X1:11 DI10
X1:12 DI11
X1:13 DI12
X1:14 DI_COM Digital input common terminal
Digital input common terminal
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
Terminal block X1 Digital Inputs
Terminal block X1:1 ~10 is allocated for digital in-
puts (DI) wirings. Depending on voltage type,
there are 13 sets of DIs in M10x 24VDC type and 9
sets in 110/240VAC type. Actual function of DIs is
individually configurable.
M10x 110/240VAC
DI0
DI4
DI5
DI6
DI8
DI_COM
DI1
DI2
DI3
DI7
—
05 An example of using two sets of power supply
Wiring Tip:
As M10x measures the voltage drop through
DIs, any unnecessary voltage changes or dis-
turbance on DI circuit should be avoided.
e.g. if DIs are to be wired to a remote field
from the starter in a DC application, a sepa-
rate supply from the field may be consid-
ered. (Fig 05). If DIs are supplied by AC, an in-
terposing relay may be used to segregate
the interference from the field.
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Functions

14 MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
Terminal block X1 PTC input (M102 only)
PTC function is available in M102 only. To en-
sure the proper reading, type A temperature
sensor with a characteristic curve according
to IEC 60947-8 shall be used along with the
device.
Terminal no. Name Description
X1:15 PTCA PTC measurement input A
X1:16 PTCB PTC measurement input B
Terminal no. Name Description
X1:11 PTCA PTC measurement input A
X1:12 PTCB PTC measurement input B
—

—

Wiring Tip:
Standard twisted pair should be used for PTC
circuit wiring. When PTC function is not in use,
X1:15 and X1:16 should be shorted.
—
06 PTC wiring for M102 24VDC type

03 . INSTALLATION ANDWIRING 15
Terminal block X3 Communication interface
Depending on device type, Modbus RTU inter-
face, Profibus DP interface are available through
X3. Modbus TCP interface is available in a seper-
ate EM01 module which connects to X3.
M10x Modbus type has dual RS485 interfaces
supporting a complete redundant network
setup.
Wiring Tip:
Modbus redundancy feature needs to
be enabled if both interfaces are wired
to be used. (Fig8 )
Profibus network requires dedicated Profibus ca-
ble type. 5VDC (X3:1) is reserved to supply for net-
work terminator. (Fig9)
Details of M10x-TCP wiring is in ' M10x-TCP user
guide'. When connecting to EM01, either of the
RS485 interface may be wired.
Terminal no. Name Description
X3:1 2B Serial RS485 B
X3:2 2A Serial RS485 A
X3:3 SHIELD 485 shield
X3:4 1B Serial RS485 B
X3:5 1A Serial RS485 A
Terminal no. Name Description
X3:1 5V Power supply 5V+ for bus terminator
X3:2 BRS485 B
X3:3 ARS485 A
X3:4 GND Power supply GND for bus terminator
X3:5 SHIELD Shield
—

—

Terminal block X2 Interface for MDx
M10x is connected with operator panel
MD21/MD31 using RJ11 interface.
Wiring Tip:
A dedicated cable is used to connect from X2
to MD panel. (Fig 07)
—
07 X2 connection with MD21 panel

16 MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE
Terminal no. Name Description
X3:6 Ioa Residual current transformer input A
X3:7 Iob Residual current transformer input B
—

Terminal block X3 Residual current input
M10x supports earth fault protection by
wiring external residual current trans-
former(RCT) to X3 :6 & 7. M10x dedicated
RCT type is ABB LNG CT. (Fig 10)
08 M10x-M X3 Modbus Dual ports wiring
09 M10x-P X3 Profibus wiring
Wiring Tip:
Standard twisted pair cable should be
used to wire RCT inputs. When earth fault
protection function is not required, X3: 6
&7 should be shorted.
10 RCT circuit wirng

03 . INSTALLATION ANDWIRING 17
Terminal block X3 Voltage measurement
(M102 only)
M102 provide three voltage inputs sup-
porting up to 690V ac direct connection. It
can be used for three phases and single
phase application.
Voltage phase connection shall follow the
terminal definition listed in table 8 to en-
sure correct power factor and phase se-
quence reading.
In case of single phase, the voltage con-
nections are X3:9 & 13 as listed in table 9.
Voltage measurement circuit is included in
typical wiring diagram Fig 13.
Terminal no. Name Description
X3:9 VL3 Phase L3 voltage input
X3:11 VL2 Phase L2 voltage input
X3:13 VL1 Phase L1 voltage input
—

Wiring Tip:
In case external voltage transformer (VT) is
used,take care of the connections from VT
secondary which should be wired according to
table 8. (Fig 11)
VT type may be a single-phase type or a
three-phase transformer with Yy0 connection.
Terminal no. Name Description
X3:9 N Neutral input
VL
X3:13 Phase voltage input
—

11 Voltage inputs via 3 phase VT

Terminal block X4 Digital output relays
Two sets of output relays are available from
X4:1~5 in M102. Relay 1 (GR1) provides one pair
of NC and NO outputs which is configurable as
different functions, e.g. trip, alarm indication.
Relay 2 (GR2)provides one set of NC output
which is also configurable.
Only relay 1 is available in M101 version.
Digital output relays are indicated in typical
wiring diagram Fig (13).
Wiring Tip:
Take note of the rating operational
current and load type of digital out-
puts which are listed in technical data
section in case a external load is con-
nected.
Spark suppression is necessary for connect-
ing contactor (except AF type) to ensure a
reasonable service life of output relays.
GR1 & GR2 contact status may change accord-
ing to the assigned function. For example, if
GR1 is assigned as "trip", NO contact close un-
der healthy condition and open under trip.
contact status resets during power loss.
Terminal no. Name Description  
X4:1 GR1_A Programmable relay output 1
X4:2 GR1_B (NO+NC) √
X4:3 GR1_C
√
X4:4 GR2_A Programmable relay output 2 (NO) √
X4:5 GR2_B
—

Terminal block X4 Contactor control relays
Three sets of contactor control relays are avail-
able in M102, i.e. Relay A (CCA), relay B (CCB)
and relay C (CCC). Three relays are pre-config-
ured to respond to different motor starter con-
trol logic. For example, in a direct on line
(DOL) starter control, CCA is dedicated to be
used as open and close the contactor.
CCA and CCB are internally interlocked through
hard-wired.
Only relay CCA and CCB are available in M101.
Wiring Tip:
Take note of the rating operational current
and load type of digital outputs which are
listed in technical data section in case a ex-
ternal load is connected.
Spark suppression is necessary for con-
necting contactor (except AF type) to en-
sure a reasonable service life of output re-
lays. (Fig 13)
Terminal no. Name Description  
X4:6 CCLI Contactor control voltage input √ √
X4:7 CCA Contactor control A √ √
X4:8 CCB Contactor control B √ √
X4:9 CCC Contactor control C √
—

18 M OT O R C O NT R O L A N D P R OT E C T I O N U N I T M 10 X U S E R G U I D E

Terminal no. Name Description
X4:12 GROUND Ground safety and surge
—

Terminal block X4 Ground terminal
This is an additional ground terminal provided
for dissipating transient signals and surges. It
must be connected by a thick wire or braid to
the system ground for reliable operation.
Terminal no. Name Description
X4:11 24VDC or L 24VDC , 110VAC or 240VAC
X4:10 GND or N 0VDC or Neutral
—

Terminal block X4 -Power Supply
Depending on the selected product type,
the power supply may be 24Vdc, 110Vac or
240Vac . Regardless of the voltage type, the
power supply should always be supplied
from an uninterrupted and reliable supply
source to ensure the operation reliability of
the device.
Power supply inputs are not phase re-
stricted which means in a 3 phase AC
power supply, any phase may be
wired to the inputs in any phase se-
quence.
03 . INSTALLATION ANDWIRING 19

Shield and Ground (X4:12) are
connected internal of M10x.
Shield and Ground (X4:12) are
connected internally in all
M10x types.
—
12 Typical wiring diagram for M102-M (24VDC type)
Terminal layout example
The terminal layout of M102-M 24VDC
product type is shown as an example in
Fig 12. The terminal blocks may have dif-
ferent definitions and available terminals
depending on the selected product type.
The details are explained in terminal des-
ignations above.
M10x device is certified to work un-
der EMC environment according to
relevant IEC standards. However a
network exposed to high electro-
magnetic disturbance may still
cause an unstable system and mal-
function devices.
In applications that variable speed drives
are used in a large scale, harmonic filter de-
vices shall be required in system design to
reduce impact to the network.
20 MOTOR CONTROL AND PROTECTION UNIT M10X USER GUIDE