MNS Insum Ii


MNS INSUM II
ABB - ATLV Low Voltage Systems
BA LVS 15/10/01 Page 1
MNS Licensees
Europe:

Austria Germany Norway
Belgium Great Britain Poland
INSUM® projects Czech. Rep.

Denmark
Finland
Greece
Ireland
Italy
Switzerland
Sweden
France Netherlands Turkey
Asia:
China
India
Malaysia
Philippines
Singapore
Arabia: Taiwan
Saudi Arabia Thailand
United Arabic Indonesia
South America: Emirates
Argentina
Brazil Africa:
Egypt
South Africa
Oceania:
Australia

The Hard Part: Hidden Costs

KNOWN COSTS Equipment Costs

Price Engineering Costs
Construction Costs Inspection & Testing
Performance Problems Safety Costs

Customer Dissatisfaction Spare Parts
Duplication of Effort Debugging Costs Scrap
Liability Costs Expediting Shipments
Air Freight
Overtime
Late Delivery Costs Startup Delays
HIDDEN COSTS Maintenance Costs
Equipment Service Calls Energy Costs
Equipment Shutdown Costs High Inventory Costs
Standardization Toxic Emissions

Construction Rework
Training Costs Environmental Regulations Stress
Ease of Repair
Engineering Changes Frustration
Stocks
Paperwork Inspection
Rescheduling

An Investment in the Future 
 Total Solution Provider (Control, Monotoring, Protection, Events and Annunciation)
 Over 14 years experience with intelligent systems
 50.000 MCU units in more than 200 different proyects.
 Reduction in maintenance time and cost
 Reduced design, build, and commissioning time
 Complete flexibility for reconfiguration on line
 MNS Asta certified to IEC439 and IEC1641
 High stacking density MCC
 Experience with > 87 % of all DCS
 Direct integration via fieldbus or via gateways
 Continous process of improvements
 Optimizing of the technology according to market requirements
 Over 700,000 installed cubicles through 27 years experience in Low Voltage technology

MNS / INSUM High Power Motor
Control & Power Distribution 
 Reduced costs
 Lower installation costs

 Less engineering & commissioning allows earlier production
start
 Less downtime
 Reduced maintenance costs
 Preventive maintenance can be scheduled
 Available information gives total overview (instead of local)
 Easy Upgrades and Additions

MNS INSUM experience since 1988 in critical applications industries.
Petrochemical
Mining Heavy Industry
MCU
Power Plants
Commercial Light Industry

INSUM Components
• Intelligent MCU
• Backplane
• LON Bus Router
• DCS Gateway
• HMI
Simple, flexible and cost effective.

Intelligent MNS INSUM II - Components 
4
INSUM OS
Ethernet TCP/ IP
2
Router
LON 1,25 MBaud
3
MMI
1
MCU
LON 78 KBaud

Conventional system requires 23 km
Intelligent system requires 0.5 km of
of 7 core cable and 1125 inputs and
4 core cable and 4 SU nodes.
outputs.
PRE-TREATMENT PRE-TREATMENT
AREA PACKAGING LINE
40 DRIVES AREA PACKAGING LINE
25 DRIVES 40 DRIVES 25 DRIVES
150m 200m
150m 200m
450 DIGITAL INPUTS

675 DIGITAL OUTPUTS
CONTROL ROOM
CONTROL ROOM
40m
40m
PRODUCTION
PRODUCTION
160 DRIVES
160 DRIVES
Cable and I/O requirements

BA LVS 15/10/01 Page 10
Intelligent vs Conventional

Process Control System
Remote I/O Motor Control Center
Discrete I/O Cabling

Control Network
Control
Start/Stop
Central Controller Monitoring

Running
Stop
Plant Network Trip
Local/Remote
Analogue
Current

BA LVS 15/10/01 Page 11
Intelligent vs Conventional 
Process Control System
Motor Control Center

Backplane & MCU’s
Detailed Information
from the Motor
Control Network
Pre Trip Alarms
Time Tagged Events
Quick Fault Diagnosis
Central Controller Maintenance Period
Maximum Availability from

Additional Plant Information
Plant Network Online Configuration
Need based Maintenance
Full Protection
Plant Wide Information

BA LVS 15/10/01 Page 12
Potential Starter Components 
Conventional System INSUM System
1 Main Isolator 1 Main Isolator
3 Main Fuses 3 Main Fuses
1 Control Fuse 1 Control Fuse
1 Contactor 1 Contactor
1 Thermal Overload 1 MCU
3 Interposing CT’s 1 LED Block
1 Core Balance CT
1 Earth Fault Protection Relay
3 Push Buttons (Start, Stop, Tripped)
4 Lamps (Running, Stop, Overload Trip,
Earth Fault Trip)
1 Manual/Auto Selector Switch
1 Ammeter (With Max. Demand Indicator)
1 Operations Counter
1 Hours Run Counter
Options
PLC Interposing Relays
Star-Delta Change Over Timer

BA LVS 15/10/01 Page 13
Technology Advantage: Protection 
Causes of Motor Failures

ABB Study
19% 26%
Thermal Overload
Insulation (Earth) Fault
Faulty Protection
20% Motor Bearing Fault
Other
5% 30%

BA LVS 15/10/01 Page 14
Technology Advantage: Protection 
Covered by
Intelligent MNS Causes of Motor Failures
ABB Study
19% 26%
Thermal Overload
81% Insulation (Earth) Fault
Faulty Protection
20% Motor Bearing Fault
Other
5% 30%
Intelligent MNS Covers Your System

against 81% of these Causes,
Greatly Improving Protection!

BA LVS 15/10/01 Page 15
Control & Power Distribution : 
INSUM Motor Control Unit
MCU 1- (0.1 -- 3.2 A) -(2.0 -- 63 A) MCU 2- (0.1 -- 3.2 A) -(2.0 -- 63 A)

BA LVS 15/10/01 Page 16
INSUM Motor Control Unit 
Starter Types Supported
MCU 1 MCU 2
 DOL  DOL
 Reversing  Reversing
 DOL/RCU  DOL/RCU
 Reversing/RCU  Reversing/RCU
 Actuator
 Star Delta
 Star Delta Rev
 Two Speed
 Two Speed Rev
 Softstarter
 Autotransformer

BA LVS 15/10/01 Page 17
Protection Functions
MCU 1
 Thermal Overload
 Stall Protection
 Phase Loss Protection
 Underload Protection
 No Load Protection
MCU 2 Additional functions:-

 Unbalance Protection
 Underload Cosphi Protection
 Earth Fault Protection
 PTC Protection
 Undervoltage Protection
 Auto-Restart
 Start Limitation
 Thermal Overload
 Locked Rotor Protection
BA LVS 15/10/01 Page 18
Phase Current Loss Protection 
(ILmin / ILmax) Phase Current Loss Alarm
Alarm Level 1
Trip Delay 1 Trip Delay 1

Trip Level 1
Phase Current Loss
Phase Current Loss Trip

Alarm
Phase Current Loss - t

trip
Alarm Level: “Phase Loss Alarm” is initiated when the phase current is below the set
point 10 … 90%
Tripping: “Phase Loss Trip” occurs when the trip level is reached 5 … 90%
tripping takes place on completion of the trip delay 0 … 60 sec.

BA LVS 15/10/01 Page 19
Earth Fault Protection 
(I0)
Earth Fault Current Trip
Trip Delay 1 Trip Delay 1
Alarm
Trip Level 1
Earth Fault
Current
Alarm Level 1
Earth Fault
Earth Fault Current Alarm Current -trip
Alarm Level: ”Earth Fault Current Alarm” is initiated when the earth fault
current reaches the set point.
Trip Level: “Earth Fault Current Trip” occurs when the trip level is reached,
tripping takes place on completion of the trip delay.

BA LVS 15/10/01 Page 20
Consecutive Start Protection 
ILmax
MCU Programmable restart
block out timer.
Startup current
IN
Startup Start lockout t
Restart Protection: Consecutive restart , current model allows protection of motor

due to excessive starts.
Trip : When the limit is reached the adjustable “ Restart Delay”
0 .. 1200 sec, will block restarting of the motor .

BA LVS 15/10/01 Page 21
Auto Restart Function Protection 
M M M M V
C C C C
U U U U Programmable restart
timer.
Voltage Set point
Auto restart
Level Alarm Trip Delay 1
Trip Level 1
Function activated
Trip t
Restart V Level: “Undervoltage ” if initiated and the system voltage restores

above the adjustable set point 65 .. 100% within the programmable voltage
restoration time, motors can be individually selected to restart.
Restart : When the voltage level is reached the “Restart Delay” 0 .. 60 sec. will
allow stagger re starting of selected motors.

BA LVS 15/10/01 Page 22
Maintenance / Monitoring Functions
 Thermal capacity
 Phase currents
 Time to trip, Time to reset
 Alarms / Faults messages
 Operating hours
 Switching cycles
 Maintenance period
Additional monitoring MCU 2

 Power, Power factor
 Active Power
 Earth Leakage current
 Phase voltages

BA LVS 15/10/01 Page 23
Limit switch input function. 
Additional dual input limit
switch for process control .
•Level
•Pressure
•Limit
MCU
•Torque
•Flow
•Temperature
With built in programmable

timers for time delay ON /OFF.
Configurable NO or NC
contacts

BA LVS 15/10/01 Page 24
MCU Functions 
X11 N C 1 1 C W D A L A X13
N C 2 2 C W D A L B
N C 3 3 G P O 1
C C W D LI 4 4 G P O C O M
N C 5 5 G P O 2
C C LI 6 6 R U N S 1
N C 7 7 R U N S 2
C C A 8 8 R eady
C C B 9 9 A la r m
C C C 10 10 T r ip
11 Local
MCU X12 S G B A 1 12 S ta rt 1
S G B B 2 13 S ta rt 2
S G B S h ie ld 3 14 S top
15 R eset
X15 N C 1 16 Local
N C 2 17 E m S top
D F P _R U N S 3 18 L im it 1
D F P _R E A D Y 4 19 L im it 2
D F P _ T R IP 5 20 T orque
0 V D C 6 21 G P I 1
22 G P I 2
X14 T E S T 1 23 N C
S D 2 24 N C
S D R I 3 25 U A U X 1 ( 0 V D C )
24V D IG I 4 26 U A U X 1 ( 0 V D C )
24 V D IG I 5 27 U A U X 1 ( + 24 V D C )
M C B 6 28 U A U X 1 ( + 24 V D C )
C F A 7 29 N C
C F B 8 30 N C
C F C 9 31 N C
G P I 1 10 32 24 V D IG I
G P I 2 11 33 Io A
N C 12 34 Io B
I0A 13
I0B 14
G ro u n d G RO UND
X16 N C 1
P T C A 2
P T C B 3
N C 4
B a s e p l a te /M U
I1 A L1 T 1 I1 B
I2 A L2 T 2 I2 B
I3 A L3 C u r r e n t U n it T 3 I3 B
X17 M V M L1 1 1 U a u x 2 (L ) X18
M V M L2/N 2 V o l ta g e U n i t 2 U a u x 2 (N )
M V M L3 3
I / O a v a il a b le in M C U 1 a n d M C U 2 A W G 28 1,0 m m 2
I / O a v a il a b le o n ly in M C U 2 A W G 24 2,5 m m 2
A W G 20 12 m m D ia m e t e r

BA LVS 15/10/01 Page 25
INSUM® MCU: Typical REV - D.O.L. 1/2


BA LVS 15/10/01 Page 26
INSUM® MCU: Typical REV - D.O.L. 2/2


BA LVS 15/10/01 Page 27
MCU functions. 
1.1 Standards and Approvals
The MCU will conform, where applicable to the following standards and approvals.
Standards
IEC 1010-1 Safety requirements for electrical equipment for measurement, control
and laboratory use. Part 1: General requirements.
IEC 947-1 Low-voltage switchgear and controlgear. Part 1: General rules. MCU
IEC 947-4-1 Low-voltage switchgear and controlgear. Part 4: Contactors and motor-
starters. Section One: Electromechanical contactors and motor-starters.
IEC 947-5-1 Low-voltage switchgear and controlgear. Part 5: Control circuit devices
and switching elements. Section One: Electromechanical control circuit
devices.
IEC 255-8 Electrical relays. Part 8: Thermal electrical relays.
EN 55011 Conductive and radiated RF-Emission.
EN 61000-4-2 Electromagnetic Discharge (ESD).
EN 50140, ENV 50204 Radiated RF Electromagnetic Field.
EN 61000-4-4 Electrical Fast Transient / Burst.
EN 61000-4-5 Surge.
ENV 50141 Conducted Disturbances Induced Fields.
Approvals
PTB TOL and PTC protection is approved according to PTB requirements.

BA LVS 15/10/01 Page 28
Programmable starters allow simple

design and project management !!
MCU
 0 -15 kW starter 8E/4.

 15 - 30kW starter 8E/2.
 30 - 75kW starter 8E.
0 I
 75 -132kW starter 16E.
 132kW - 315kW starter 24E.
 Above 315kW fixed execution.

BA LVS 15/10/01 Page 29
8E/4 Module - 15kW D.O.L. 
38 pin Aux. Plug
A30 Contactor
240V Control MCB
24V D.C. Control Fuse
MCU1 Motor Control Unit
Front panel with OESA63 Fuse Switch

Isolator Handle and
ON-OFF-FAULT LED’s

BA LVS 15/10/01 Page 30
8E/2 Module - 30kW D.O.L. 
38 Pin Aux. Plug
240V A.C. Control MCB
24V D.C. Control Fuse
A63 Contactor (1.5kW A9-30)
MCU2 Motor Control Unit

& Voltage Unit
OESA63 Fuse Switch

BA LVS 15/10/01 Page 31
MNS® Intelligent Switchgear 
INSUM® provides:
 Motor Protection
 Monitoring
 Additional Features
MMI monitors:
128 Field Units
Motor starter w/-

controller located
inside the starter
Optional
LED ON-OFF-FAULT

BA LVS 15/10/01 Page 32
INSUM® Man Machine Interface
Interfaced on Main LON bus 
Home
Key
Encoder
Wheel
Data Access Warning Function Trip Enter Escape

Key Indication Keys Indication Key Key
and Listings and Listings
The MMI is connected to the backplane 1.25 MB/s open fieldbus

The encoder wheel simplifies the operation, configuration and monitoring of the MCU’s
The digital key allows different access level and prevents unauthorized operation

BA LVS 15/10/01 Page 33
INSUM® Backplane with Devices Mounted 
Main LON BUS

@ 1250KB/s
Subnet Connections
Routers Gateway Filtering/

24V DC PCS Connection
Power Supply Protection
(Optional)
Optional

BA LVS 15/10/01 Page 34
INSUM Backplane 
ROUTERS
 Connecting MCU’s to the main
net
 A filter downward to the MCU’s,
translating the 1.25Mbaud to
78kBaud for the MCU’s
GATEWAY
 Modbus RTU
 Profibus DP
 Profibus DP Ext (Future)
 Ethernet TCP/IP Ind.
 Direct LON.

BA LVS 15/10/01 Page 35
Gateways: Modbus RTU 
 Flexibility to Configure the Desired Information
 RS 232C/RS422/RS485 Serial Interface
 Selectable Baud rate of 9.6, 19.2, 38.4, and 76.8 KB/s
 ISO OSI Layers 1,2, and 7 Implemented
 Master - Slave Philosophy
 Standard Function Codes: 02, 03, 04, 06, 08, 16, 20, 21.
 The Protocol Allows
 Read In Status, Holding Registers, I/P Registers
 Preset Single Registers, Multiple Registers
 Diagnostics
 Read General Reference, Write General Reference

BA LVS 15/10/01 Page 36
Gateways: Profibus DP 
 Full Functionality with 48 Motors per Gateway

 Two Gateways for control 96 Motors
 RS485 Serial Communication at the speed of 1.5MB/s
 Master-Slave Philosophy
 Pre-defined Data Mapping of information

BA LVS 15/10/01 Page 37
Gateways: Ethernet TCP/IP Industrial 
 Up to 16 independent clients per Gateway
 Independent operation of the clients
 Configuration free
 Fast and easy to use protocol
 Up to 8 channels per client
 Query response procedure for any data
 Event driven transfer for any data and events
 File transfer protocol supported
 The protocol allows full control: (Operation, Annunciation,

Parameterisation, Control access, Life lists for all devices,
Diagnostics)

BA LVS 15/10/01 Page 38
Redundancy for ABB Low Voltage Systems 
Plant Control System SCADA System
Plant Control System / SCADA

Interface Options
Modbus LON
Profibus Ethernet
LON Bus @ 1.25MBaud
INSUM
Backplane
LON Bus @ 78KBaud

MCC Mounted HMI
Abbreviations
LON Local Operating Network MCU/FCU
HMI Human Machine Interface
MCU Motor Control Unit SACE PR
FCU Feeder Control Unit INSUM
PR Programmable Release Four LON Links of 32 Devices per link total 128 Devices Operator
Station

BA LVS 15/10/01 Page 39
MNS®/INSUM®, Part of ABB
Integrated Control System 
ADVANT Station 500 AdvaSoft X-terminal External
IMS Station for Windows Computer
Plant Network
(TCP/IP, MasterBus 300, GCOM . . )
ADVANT Station 500 ADVANT Station 500 ADVANT Station 500

IMS Station Operator Station Engineering Station MasterView 800/1
MasterGate 230/1 Operator Station
Gateway MasterBatch 200/1
Control Network
(MasterBus 300)
ADVANT Controller 410 ADVANT Station 100 ES ADVANT Controller 450 MasterPiece 200/1
Process Controller AdvaBuild for Windows Process Controller Process Controller
AdvaSoft for
Windows
AdvaCommand
AdvaBuild
AdvaInform
LON
RCOM
ADVANT Fieldbus
ADVANT Controller 100
55
ADVANT Controller ADVANT Controller
Process Controller S800 I/O 110 70
Process Controller Process Controller
MNS/INSUM

BA LVS 15/10/01 Page 40
Site Wide Information 
Process control system
MNS - Intelligent Power
Central controller
Engineering Office
Control network
Sub Station n+1
Plant network
Sub Station n
Controller
Medium Voltage
Sub Station n+2

Discrete I/O Low Voltage
Field network
Variable Speed Drives

BA LVS 15/10/01 Page 41
Motor Grouping 
INSUM allows motors to be grouped in functions so that the starter controllers can communicate
with each other without a master
 Minimises response time
 Time Delay Interlocking between Motors
 Chain reaction Starting & Stopping
Motor A
PROCESS Motor B
Motor C

BA LVS 15/10/01 Page 42
Motor Group Command Chains for Process
Interlocking 
Switchgear Bus
Motor Group Group Command Data Group Command Data

Command
DC M2 DC M2 DC M2
Device A Motor
Device B Motor
Device C
Command Group
Input Command
Feedback
Motor A Motor B Motor C

BA LVS 15/10/01 Page 43
Insum OS 
Windows NT
based
Human Machine Interface

BA LVS 15/10/01 Page 44


BA LVS 15/10/01 Page 45
Insum OS Conceptualisation 
 Architecture
 Client - Server
 Client: For User Interface, Data Storage and Retrieval.
 Server: For LON Network Monitoring and Updating of
Client Whenever the Changes Detected.
 Two Types of Servers

 OS Server: This is a software that runs on PC under
Windows NT
 Ethernet Gateway: Hardware module that can be
connected to the Insum System
 TCP/IP Protocol for Communication Between Client and
Server.

BA LVS 15/10/01 Page 46
Insum OS: Main Screen 
 Tree
View of
Devices all the In
Panel View: s um
Devices Offline
 Mon
itor the
Tree View: MNS sw complet
itchboar e Insum
X Devices d -
Device in
Offline Fault State
 Dy n
amic sta
starters tus of al
at a glan l the
ce
Devices
Ready to
Start

BA LVS 15/10/01 Page 47
System Administration 
 User Administration  System Administration
 Allows to create the users  Allows to configure the OS
and controls the user Server
access rights  User Preferred Alarm and
 Guard against the Status Colour Configuration
Unauthorised Use of the
System

BA LVS 15/10/01 Page 48
Insum OS:Main Functions 
 Parameterisation
 Allows configuration of motor related parameters and protection
functions for Insum Motor Control Units. Allows Offline, Online and
Group Parameterisation
 Tool Aid
 Copy: Parameters from configured device can be copied to the device of same
type.
 Compare: Comparison of parameters in the MCU to the local copy on the client
machine or with the specified file.
 Verify: Verification of parameters for ranges and data types.
 Besides above fly over text for while configuration of parameters is the online
help provided to the user.
 Parameterisation
Easy is access controlled to guard against the unauthorised
Help:
modification.
Fly Over Text
Copy Parameterisation

BA LVS 15/10/01 Page 49
Device Operate Screen 
Time to Trip
before Tripping

BA LVS 15/10/01 Page 50
Parameterisation Screen 

BA LVS 15/10/01 Page 51
 Trending
 Short Term
 Online Data Collection
 Up to 5 MCU data can be viewed simultaneously
 Long Term
 Historical Data Collection for Post Analysis
 User Configurable Data Deletion Mechanism (from V1.2 onwards)
 Trending Parameters
 Phase Currents  Earth Fault Current
 Phase Voltages  Temperature
 Active and Reactive Power
 Power Factor

BA LVS 15/10/01 Page 52
Trending Screen 

BA LVS 15/10/01 Page 53
 Annunciation
 Possible to configure all the measuring values supported by
the MCU’s for dynamic annunciation
 Measuring values upto 5 devices can be viewed
simultaneously
 The measuring values that can be configured are
 Phase Currents  Phase Voltages

 Active Power  Reactive Power
 Switch Cycles on all Main  Motor Running Hours
Contactors  Rotation
 Thermal Image
 Motor Temperature
 Time to Trip
 Time to Reset
 Power Factor
 Frequency
 Earth Fault Current

BA LVS 15/10/01 Page 54
INSUM OS: LOGS 
 Alarm Log
 Shows all records of ‘Events and Alarms’ with
 Time Stamp
 Alarm Type
 Event Description
 Acknowledged or Unacknowledged
 User configurable storage of data (from V1.2 onwards)
 EARO Log
 Shows latest 40 alarms and events on the selected device.
 User Activity Log

 Shows the user activities performed since the login with date
and time and activity details.

BA LVS 15/10/01 Page 55
INSUM OS: Alarms LOGS 

BA LVS 15/10/01 Page 56
INSUM OS: Activity LOGS 

BA LVS 15/10/01 Page 57
Improved Help 

BA LVS 15/10/01 Page 58
Systems Integration Experience 
 ABB Advant Systems  Eurotherm

 ABB Symphony Systems  Measurex
 ABB Sattline products  Alstom
 Honeywell  Valmet
 Yokogawa  Allen Bradley
 Fischer-Rosemount  Fix D Max
 Siemens
 Foxboro

BA LVS 15/10/01 Page 59
Experience List 
Country Project Customer No of No of Interface DCS Industry
MCU MCU
1 2
UK United Distilleres UVD 28 3 Modbus ABB Mod 300 Food
Egypt Suez Petroleum Suez 32 15 Modbus Petrochemical
Belgium Refinery Antwerp FINA 50 Modbus Oil&Gas

Belgium Cockerill Cockerill 52 Modbus Modbus or Bailey Steel
China Jiffar Cerestar 850 Ethernet Siemens PCS Food
Germany Celanese Hoechst 15 Modbus Hartmann & Braun Chemical
Germany Gersthofen KoSa 150 Profibus Siemens S7 Chemical
Germany Uedersen Stora 55 Profibus Siemens PCS7 Paper
Germany/NL Sas van Gent (extension) Cerestar 30
Germany Erdölchemie Köln Erdölchemie 204 Modbus Siemens Oil&Gas
Ireland OSP4 Köln
Pfizer 300 Modbus Fisher Rosemount Pharmacy
Netherlands Sas van Gent (different projects) Cerestar 1000 Modbus Siemens Teleperm, S7 Food
Norway Waste Treatment Plant ENERGOS 90 Profibus Alan Bradley Power Plant
Norway Elkem Elkem 50 TBC Advant Silicium
Sweden Lulea SSAB 25 TBC Advant Steel
Sweden Hafreström 50 TBC Advant (spring 2000) Paper
Sweden Borealis Borealis 90 TBC Advant Chemical
Switzerland Paper Plant Utzendorf Paper Plant 20 Modbus Modicon Paper
Utzendorf
BA LVS 15/10/01 Page 60
Example: Calculating Installed Cost 
 INSUM® vs. Conventional (Norske Skog/Follum
Fabrikker Paper Mill)
System INSUM
(USD) (USD)
Switchboard price 203000 251000
Cost Difference Before Installation 48000
Interface and Marshalling Panels 12000 0
Site work of switchboard and cabling 18000 3000
Cables and Cable ladder from MCC to I/O -panel 23000
Communication cable PK's to DCS 1000
DCS -Input/ Output cards 38000
Communication cards on DCS 5000
Spare Parts (MCC) 20000 6000
Restart relays
Engineering time (Design, DCS-programming, MCC Interfacing) 18000 13000
Variation costs during project period (Engineering / Material / Work) 15000 5000
TOTAL INSTALLED COSTS: 347000 284000
Cost Difference After Installation -63000

BA LVS 15/10/01 Page 61
Technology Advantage: Total Value 
MCC Connected to DCS
 Faster Engineering, Delivery

and Commissioning 24% 30% Savings
3%
 Superior Protection and 16%
Monitoring for Maximum Asset 2%
Optimisation DCS I/O
Wiring
60% 65%
Reduction in: MCC
 Engineering, Operation
and Service Costs
 Investment Costs
Resulting in: Downsized Life-Cycle Costs

BA LVS 15/10/01 Page 62
Insum reference list 2001 
Project Customer Industry Country
Pellet Mill United Distillers & Vintners Food UK

Formosa Coke Yard Nan Ya Switchgear Oil & Gas Taiwan
Zhuhai PTA BP - Amoco Oil & Gas China
Coke-Fonte Cockerill Sambre Steel Belgium
IPA BP Chembel Geel Chemicals Belgium
Aromatics Total Fina Elf Chemicals Belgium
MLNG3 Petronas Oil & Gas Malaysia
Drewsen Valmet Pulp & Paper Germany
Västeras Panna Foster Wheeler Power Sweden
OMG Kokkola OMG Kokkola Chemicals Finland
Sorter Valmet Pulp & Paper Finland
Härnösand Fortum Power Sweden
BASF H700 BASF Chemicals Germany

BA LVS 15/10/01 Page 63
VISY PAPER 
GIBSON ISLAND, QUEENSLAND
Dennis Kennedy - Commission/Plant Engineer
In 1995 Visy Paper purchased a total electrical package from ABB which included ZS1 , Uniswitch
11kV Switchgear, Distribution Transformers, MNS®/INSUM® 415 V Intelligent MCC’s, Sami VS
Drives and an ADVANT DCS Control System.
Thanks to the speed and accuracy of the INSUM® monitoring, protection and control system , Visy
Paper can manage the plant with only nine operators from whom a decision can be taken to shut
down a motor before mechanical damage or blockages occur.
This high level of control and low downtime has never been possible in our other plants. As a result,
we have reduced our motor replacement costs by 90%. The savings here have been far greater
than ever expected when we placed the original order with ABB.

BA LVS 15/10/01 Page 64
AMOCO CHEMICALS - GEEL - BELGIUM 
PLANT MANAGER - JAN de CHRIJVER
INSUM WAS INSTALLED IN 1993. IT IMMEDIATELY IMPROVED THE

AVAILABILITY AND RELIABILITY OF THE PLANT WHICH IS ESSENTIAL AS
AMOCO DO NOT HAVE DUPLICATE PROCESSES.
• PRE-PROTECTION TRIP WARNINGS OF INSUM ALLOWED US TO TAKE CORRECTIVE

ACTION AVOIDING UNNECESSARY SHUTDOWNS.
• THE ACCURACY OF INSUM, SUPPORTED BY THE ADDITIONAL STALLED PROTECTION,

REDUCES THE FAILURE RATES OF MOTORS, COUPLINGS AND DRIVES.
• THE SELECTIVITY OF THE INSUM PROTECTION CURVES ALLOWED US TO RELIABLY

START THE VACUUM PUMPS AND CENTIFUGAL FANS UNDER ALL CONDITIONS.

BA LVS 15/10/01 Page 65
AMOCO CHEMICALS - GEEL - BELGIUM 
• PROCESS CHANGES COULD BE MADE WITHOUT THE NEED TO CHANGE THE HARDWARE IN
THE STARTERS.
• A MAINTENANCE PC CONNECTED TO INSUM, INDEPENDENT OF THE DCS, ALLOWED US TO

MONITOR THE HEALTHY STATE OF EACH MOTOR. WE ARE PARTICULARLY INTERESTED IN
MONITORING:
 EARTH LEAKAGE CURRENT
 HOURS OF OPERATION
 NUMBER OF STARTS AND
 LOAD CONDITIONS.

BA LVS 15/10/01 Page 66
THE ZENITH CENTRE 
CHATSWOOD, SYDNEY, NSW
J B Adamski - Engineering & Operations Manager
In 1991, after 5 years of operation, as a result of failures which lead to loss of vital services to the
tenants of the building, the Zenith Centre found it necessary to replace the mechanical services
MCC. A major concern in the replacement was to ensure that interruption to tenant services was
kept to a minimum. This was overcome with the INSUM system’s ability to interface with the
building management system via an RS 232 communication link eliminating the extensive I/O
wiring ensuring the complete replacement over a weekend.
ABB MNS/INSUM provided the most cost effective and practical solutions for the installation. Joe
Adamski, Zenith Centre Engineering Manager, stated the MNS INSUM System fully met our
expectations overcoming the constant problem of outages.
INSUM proved its worth recently when a further upgrade to plant proved that it was unnecessary
to change motor starter hardware; all that was necessary was to reprogramme motor details.

BA LVS 15/10/01 Page 67

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INSUM® projects Czech. Rep.

ABB - ATLV Low Voltage Systems

KNOWN COSTS Equipment Costs

Performance Problems Safety Costs

Standardization Toxic Emissions

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

 Lower installation costs

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

• LON Bus Router

Simple, flexible and cost effective.

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

450 DIGITAL INPUTS

Cable and I/O requirements

Remote I/O Motor Control Center

Discrete I/O Cabling

Central Controller Monitoring

ABB - ATLV Low Voltage Systems

Motor Control Center

Maximum Availability from

Plant Wide Information

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

Causes of Motor Failures

ABB - ATLV Low Voltage Systems

Intelligent MNS Covers Your System

ABB - ATLV Low Voltage Systems

Simple, flexible and cost effective.

ABB - ATLV Low Voltage Systems

MCU 2 Additional functions:-

(ILmin / ILmax) Phase Current Loss Alarm

Trip Delay 1 Trip Delay 1

Phase Current Loss Trip

Phase Current Loss - t

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

Startup Start lockout t

Restart Protection: Consecutive restart , current model allows protection of motor

ABB - ATLV Low Voltage Systems

Voltage Set point

Restart V Level: “Undervoltage ” if initiated and the system voltage restores

ABB - ATLV Low Voltage Systems

Additional monitoring MCU 2

ABB - ATLV Low Voltage Systems

With built in programmable

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

ABB - ATLV Low Voltage Systems

PTB TOL and PTC protection is approved according to PTB requirements.

ABB - ATLV Low Voltage Systems

Programmable starters allow simple

 0 -15 kW starter 8E/4.

Simple, flexible and cost effective.

ABB - ATLV Low Voltage Systems

38 pin Aux. Plug

240V Control MCB

24V D.C. Control Fuse

MCU1 Motor Control Unit

Front panel with OESA63 Fuse Switch