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STG- Pumps and motors management Table of contents Chapter Topic Page 1 Introduction 2 2 Selection phase 5 3 Design phase 17 4 Configuration phase 33 5 Implementation phase 43 6 Operation phase 55 7 Water application example 59 8 Glossary 77 11
STG- Pumps and motors management 1-Introduction Purpose The aim of this STG (system technical guide) is to provide recommendations, guidelines, and examples to help you develop the best application for pump and motor control. The guide targets especially the medium size process control application setting up a mix of cost effective and advanced motor control systems.
STG- Pumps and motors management 1-Introduction Solution tested and validated In order to ensure all information provided by this STG is tested and validated, a solution platform has been developed to validate and document all explanations provided in this guide. The platform integrates various motor control architectures with various types of communication. It comprises all components required to build a complete motor control application from SCADA system to starter devices.
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STG- Pumps and motors management 2-Selection phase Table of contents Principle 6 Selecting starter mode 8 Selecting motor control devices 10 Selecting architecture 14 5
2-Selection phase Principle Introduction This chapter presents the various steps required to select the most appropriate starter components as well as the automation architecture which will ensure control. Selection criteria Each process control project has specific requirements and constraints that influence the selection of a motor control solution. The project specification present the characteristics that determine the selection criteria to be used in the selection steps.
2-Selection phase Principle Selection steps Selection criteria Project specification -Complexity -Physical dimensions Functional constraints -Power supply -Network load -Duty cycle Operational constraints -Process type -Operator profile -Environment Selection steps Selecting start mode Direct on line Soft starter Variable speed drive Page 8-10 Selecting starter and functions and type of links Page 11-13 Select architecture PLC and network Page 14-15 7
2-Selection phase Selecting starter mode Motor starter basic functions A motor starter unit has four basic functions: -- Isolation of the load from the main power supply, -- Protection against short-circuit, -- Protection against overload, -- Control (start, stop, speed). Each motor starter unit can be enhanced with additional functions depending on its system requirements: -- Power: speed controller, soft starter, phase reversal, etc, -- Control: auxiliary contacts, time-delay, communication, etc.
2-Selection phase Selecting starter mode bb TeSys T motor management system The capability of over-current relay is limited when problems associated with voltage, temperature or special applications must be taken into account. TeSys T provides complete management of the motor and its load.
2-Selection phase Selecting motor control devices Introduction Selecting devices The starter mode is closely linked to the load carried by the motor. The table below presents several typical applications in process control, part of which are used in processes such as water treatment or cement production. The examples illustrate how the selection is made. Type of actuator Centrifugal Pump Description/ comment . Centrifugal pumps are used to cover a wide range of volume and pressure conditions. .
2-Selection phase Selecting motor control devices Control starter functions Depending on needs, it is necessary to control some or all functions of a starter. The principal function groups are: Motor control performance Control on power, torque, speed, reversing, start time, and risk of jamming are required.. Next table summarizes the main characteristics of pumps found in process applications.
2-Selection phase Selecting motor control devices D.O.L. starter Monitoring functions Metering functions Motor protection functions Motor circuit Starter controller TeSys U breaker + Standard Advanced Multifunction Contactor LC.
2-Selection phase Selecting motor control devices Monitoring functions Metering functions Motor protection functions DOL Motor management system TeSys T Short circuit Overload Locked rotor No load running Earth fault Supply phases failure and imbalance Ventilation fault Abnormal temperature rise Shaft bearing seizure Insulation fault Long starting time Current phase reversal load fluctuations (I, U, P), Overtorque Indication of motor load Current on 3 phases (rms value) Average current Thermal capacit
2-Selection phase Selecting architecture Architecture introduction The previous two steps allow the starter mode and motor control device type to be selected. It is now time to build the final architecture that allows all motor control devices to be connected to the PLC, HMI and SCADA system. As described above, the choice of architecture depends on the requested level of monitoring, metering and diagnostics and also depends on how much consistency is required with the other parts of the system.
2-Selection phase Selecting architecture Architecture example Operator workstation 2 Engineering Web client 1 11 Ethernet 13 9 12 3 4 5 6 7 8 10 This architecture example is a distributed peripheral architecture with a centralized Premium PLC (1) and a standalone Vijeo Citect SCADA system (2). A Magelis HMI XBT-GT (3) is used to allow local control and monitoring. Ethernet network (11) connects all process steps in order to allow good diagnostics and performance.
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STG- Pumps and motors management 3-Application design Table of contents Operating modes 18 Hardware design 20 Software design 26 17
3-Application design Operating modes Introduction The aim of this chapter is to provide recommendations that facilitate the design phase of your process control project. It comprises three main parts: -- Description of global application operating modes -- Description of hardware design -- Description of software design Principle Application operating modes are the most structuring elements in the automatism system definition phase.
3-Application design Operating modes Principle (cont’d) STATE ACTORS ACTIONS PLC application Run/Stop Parameters modification SCADA / HMI Run/Stop Parameters modification Off Buttons and contactor De-energized starter Local (run/stop) Buttons on starter Run/Stop Light (fault) Auto Remote Manual Local Remote (PLC) Auto Run/Stop HMI / SCADA Manual Run/Stop Local buttons Remote Off Run Local Run Stop Auto Fault Local (wiring) Local Run/Stop Off Starter 19
3-Application design Hardware design Introduction The operating mode described above requires a wiring design for an emergency stop circuit and motor control device. The following paragraphs provide recommendations for developing a consistent wiring solution. Safety requirements impose constraints to protect people and the environment. We recommend measures against electrical risks which are defined in IEC 60204-1. This standard specifies in particular the emergency stop operations.
3-Application design Hardware design Emergency XPS Reset Power off PLC KM_A Ethernet Security active Off Starter_1 Starter_2 TeSys U TeSys U bb Diagram with variable speed drive ATV61 or ATV71 In the case of a requirement not exceeding level 3 (IN ISO 13849-1) contactor KM_1 is not necessary, the power is shut down by function Power Removal (PWR) directly wirely on ATV 61/71.
3-Application design Hardware design Motor control device wiring diagrams This paragraph provides a wiring diagram for the following starters bb Direct on line starting TeSys U bb Progressive starting with soft starters bb Starting at variable speed with variable speed drive (VSD) ATV61 The proposed diagram re-uses previously defined operation modes. They are an extract from the water treatment application described in chapter 7.
3-Application design Hardware design Soft starter ATS48 diagram In the diagram below, a 116KM4 contactor is placed upstream of the ATS48. It allows the power to the starter to be cut. The switch allows the contactor to be controlled, either by PLC in Remote mode, or by start and stop buttons in Local mode. bb Local Mode The Remote/Local lockable commutator includes a 3rd position, Off, which opens the control to the contactor, which cuts the power to the terminals of the soft starter.
3-Application design Hardware design Variable speed drive ATV61 diagram A KM1 contactor upstream of the speed regulator allows the power to the regulator to be cut (power and control diagram page 20). This contactor can be controlled, either by PLC in Remote mode, or by the commutator (selector switch) in Local mode. bb Local Mode The Remote/Local lockable commutator includes a 3rd position, Off, which opens the control to the contactor, which cuts the power to the terminals of the soft starter.
3-Application design Hardware design Variable speed drive ATV61 diagram (cont’d) Local Remote Command part of the upstream contactor breaker and contacter upstream Local Off Fault Run Running ATV61 25
3-Application design Software design Software design introduction Motor control applications require the design of objects located in different devices using various software: -- SCADA application with Vijeo Citect V7.0 -- HMI application with Vijeo Designer V4.6 -- PLC application with UNITY Pro V3.1 The main components of the architecture need to exchange data and data type during build time to have a consistent application, and data during run time to execute effective and complete process control.
3-Application design Software design PLC and motor control device design DFB design The exchange between PLC application and motor control devices is designed using DFB.
3-Application design Software design DFB design (cont’d) 3 Control I/Os This group gathers process data inputs and outputs (I/O ) used to control the device. I/O scanning, based on periodic read / write variables, allows implicit exchanges of modifiable data. This functionality should be reserved for frequently used variables; access to other variables is by explicit exchanges. I/O Scan Input (Structure) Fb_Stat Starter status word.
3-Application design Software design DFB design (cont’d) 5 HMI interface This group gathers all DFB Input/Output type variables exchanged between PLC and SCADA/HMI, for the device considered. Param (Structure) Auto_Man Command to set the block in Auto or Manu Run_Stop Command to run or stop the pump Clear_Fault Command to acknowledge internal and external errors indicated at the output Error. Acknowledgement is done with a rising edge. Clear_warning Command to acknowledge starter warning.
3-Application design Software design DFB design (cont’d) The block supports automatic and manual operating modes. The automatic and manual mode are -- activated by the HMI when the mode is remote. The Manual mode is activated on PLC cold start. The local mode can also be activated by an input pin either in automatic or in manual mode. The local mode inhibits the command from process and HMI. In the automatic mode the motor is started and stopped via the inputs ARun, if the local mode is not activated.
3-Application design Software design SCADA system introduction During SCADA application build time, Vijeo Citect objects have to be defined and the data and data type associated. -- The following recommendations are provided to facilitate design, readability and re-use: -- Exchanges (figure below) are done via DDT variables (Standard Derived Data). -- Interchange file format XVM was chosen to manage the DDT variables type without needing to install the Unity tool on the station.
3-Application design Software design HMI system design During HMI application build time, Vijeo Designer objects have to be defined and the data and data type associated. The elementary variables (located) can be imported directly thanks to a dynamic bond in the Vijeo Designer software.The structured variables must be created manually starting from Unity description. Concrete examples are presented in the configuration chapter.
STG- Pumps and motors management 4-Configuration Table of contents Introduction 34 PLC and motor control device configuration 35 SCADA system configuration 40 HMI system configuration 42 Other systems configuration 42 33
4-Configuration Introduction Purpose The aim of this chapter is to provide key information for configuring the various system components ( PLC, motor control devices, SCADA and HMI application). The main purpose is to build a consistent system configuration with the description of all data exchanged between key solution components.
4-Configuration PLC and motor control device configuration Direct starter TeSys-U configuration principle The TeSys-U in this case is connected to Ethernet through an Advantys STB island. The connection can be done either using a pre-wiring solution or an inter-segment Advantys solution. The configuration of motor starter data used behind an Advantys STB required two steps: vv In the first step the data exchanged between Advantys STB and PLC must be configured in I/O scanning service.
4-Configuration PLC and motor control device configuration Direct starter TeSys-U configuration example bb Second step: Select the Motor starter data The input and output data of the selected motor starter must be identified within the I/O scanning data. The Advantys STB configuration tool is used to determine the right offset that fits the starter. A DDT is associated to the motor starter data type. This data is used as input and output parameters (Control I/O) of the DFB linked to the motor starters.
4-Configuration PLC and motor control device configuration Direct starter TeSys-U configuration example (cont’d) ADVANTYS Input data Output data UNITY Register Item Located address Variable (DDT) 45409 Status 455 %MW617 45410 Status 458 %MW618 45411 Status 461 %MW619 40005 Control Register %MW664 40006 Communication Register %MW665 40007 Contol Output Register %MW666 Type TeSysUa_IO_SCAN_I Type TeSysUa_IO_SCAN_0 37
4-Configuration PLC and motor control device configuration ATS48 configuration principle ATS48 configuration example The ATS48, as well as the TeSys-T is connected to an Ethernet network through an ETG100 gateway. Communication is transparent between the Ethernet and Modbus serial line. Therefore, the I/O scanning service can directly access the ATS48 data. The unit ID identifies the slave address of the soft starter on Modbus.
4-Configuration PLC and motor control device configuration ATV61 configuration principle Considering the ATV61, the input and output I/O scanning parameters can be configured in different ways: vv using Power Suite software vv using the ATV_61 graphic display terminal vv using the ATV_61 Web server and Internet Explorer In Power Suite a dedicated screen is used to declare the data exchange with PLC. A first parameter is added for status purpose. These parameters are numbered from 0.
4-Configuration SCADA system configuration SCADA system principle The SCADA I/O tag database is created in Vijeo Citect from the UNITY variable database. We recommend creating at an early stage the most complete I/O tag database in Vijeo Citect, by importing the relevant PLC tags. The goal is to have a unique tag configuration from PLC to SCADA. bb Database creation The SCADA database is created from the UNITY PLC variable database.
4-Configuration SCADA system configuration SCADA system principle (cont’d) Without describing in detail the Vijeo Citect programming, we will quote only the principle stages (see below): -- Step N°1: Creating clusters Citect Project Editor> Servers> Clusters. Create Cluster 1 -- Step N°2: Creating the network address Citect Project Editor> Servers Network Addresses> OFS server address -- Step N°3: Creating Servers Creating Alarm and Trend servers and link to Cluster 1.
4-Configuration HMI system configuration HMI system configuration principle During the HMI build time the tag database has to be created from the UNITY PLC variable database. A link between Unity XVM file and Vijeo Designer project has to be done. As Vijeo Designer variables do not access Unity structured and unlocated variables, it is necessary to recreate structured datatypes. These structure data types allow us to use generic popups using indexed physical addresses.
STG- Pumps and motors management 5-Implementation Table of contents Introduction 44 PLC and motor control device implementation 45 Unity program implementation 52 SCADA program implementation 53 HMI program implementation 54 43
5-Implementation Introduction Purpose Overview 44 The main purpose of this chapter is to detail how to implement the various components introduced in the Design chapter. An example of implementation will also be described in Chapter 7 with additional information concerning programming rules and examples.
5-Implementation PLC and motor control device implementation TeSys U controler This section describes three references of TeSys_U control unit (Standard, Advanced, Multi-function), connected between STB main rack and STB extension rack. An Ethernet IO scanning service is used to periodically exchange data between the PLC and the motor starter. For TeSys_U behind an Advantys STB island, the STB island I/O mapping is used.
5-Implementation PLC and motor control device implementation TeSys U controler DFB (cont’d) HMI_MOTOR_TU_x (x=s for Standard, x=a for Advanced, x=m for Multi-function) Auto_Man Bool Command to set the block in Auto or Manu Run_Stop Bool Command to run or stop the pump Clear_Fault Bool Command to acknowledge internal and external errors indicated at the output Error. Acknowledgement is done with a rising edge. Clear_Warning Command to acknowledge starter warning.
5-Implementation PLC and motor control device implementation Soft starter ATS48 The ATS48 is connected to an Ethernet network via an ETG100 gateway. Communication is transparent between the Ethernet and Modbus serial line therefore the I/O scanning service can directly access the ATS48 data. The table below details the interface between the starter and the DFB into PLC application.
5-Implementation PLC and motor control device implementation ATS 48 DFB (cont’d) Input description FbStat ATS_Meas Starter status word. Feedback signal from I/O scanning Starter measures.
5-Implementation PLC and motor control device implementation ATS 48 DFB(cont’d) Functional description DFB behaviour is compliant with the previous description (see page 27), Type DI Number 4 Comment Operating mode selector switch in “Remote” position. Operating mode selector switch in “Local” position.
5-Implementation PLC and motor control device implementation ATV61 DFB (cont’d) This DFB is compliant with the description in page 27 design chapter, therefore only specific pins are detailed.
5-Implementation PLC and motor control device implementation ATV61 DFB (cont’d) Used structures HMI_MOTOR_A Auto_Man Run_Stop Rst_Fault Bool Bool Bool Speed_Setpoint Speed_Output Meas_1 Meas_2 Nb_start Min_time_stop Discrepancy_time Time_to_start Sts_Auto Sts_Manual Sts_Local Sts_Off Sts_Locked Sts_Error Sts_TimerProtect Sts_ATV_Ready Sts_ATV_Run Sts_ATV_Fwd Sts_ATV_Bwd Sts_ATV_Estop Sts_ExtErr Sts_NoVoltage_Err Sts_ATV_Err Sts_Discrepancy_Err Name Command to set the block in Auto or Manu Command to r
5-Implementation Unity program implementation UNITY program structuring The UNITY program comprises several sections, some of them with a transversal role such as PLC system monitoring or the process sequence. PLC system monitor the system state (alarms, status, communication...). Process sequences coordinate the process functions.
5-Implementation SCADA implementation SCADA principle Genies and Super Genies objects are defined to design the motor control application. They use structured variables that come from XVM files generated by Unity. For each type of graphical object (pump, motor,…) a genie is created. This genie can be pasted from a genie dialog box and added to the graphics page.
5-Implementation HMI implementation Principle Example Vijeo Designer 4.6 can not use the data structure from Unity, therefore the following recommendation are proposed. Example of HMI data mapping Two ATV61 manage two separate pumps. A Unity structured data type HMI-ATV is defined to create the variables used for HMI exchanges. In the example, two instances are created and link to the two ATV61 drives.
STG- Pumps and motors management 6-Operation Table of contents Introduction 56 Running a Process Control and Diagnostics 56 Architecture 56 Example 57 55
6-Operation Introduction Purpose In this chapter, available operations on process control and related motor control diagnosis are described. Process Control and Diagnostics Process control Process control requires information to monitor the different sections of the process and the functions related to motor control. It is necessary to be able to give commands and settings to the pumps and motors associated with the process equipments.
6-Operation Example Access to an ATV61 In this type of architecture, we can access a starter in several ways. From the SCADA Vijeo Citect (1), zoom to the functional unit and click on the corresponding motor starter. From a web client station (3) with Internet Explorer, type in the IP address of the motor starter. Note: Default login name "USER" and default password "USER".
6-Operation Example Example (cont’d) From a PC (5), we can access a starter using the PowerSuite tool. Type in the IP address of the motor starter. From the graphical terminal on the starter (4).
STG- Pumps and motors management Water application example Table of contents Objectives 60 Selection phase 61 Design phase 62 Configuration phase 70 Implementation phase 70 Operation phase 73 Components list 76 59
Water application example Objective Presentation The purpose of this chapter is to provide a real example of a process control application using the recommendations in the previous chapters. A waste water treatment plant is used to illustrate how to realize a pump and motor application. The first part of the process is implemented from the lifting to the primary clarifier using the solution platform introduced before.
Water application example Selection Motor control device selection The following table describes the selection criteria used to select the most appropriate motor control devices. DOL Lifting Screening Sand & grease removal Primary clarifier VSD Feed in pumps Redundant centrifugal pumps: Flow is controlled by changing the speed of rotation in order to better manage water flow variation. Rain water Centrifugal pumps: Flow is controlled easily by ATS48 pumps valves on the pump discharge manifolds.
Water application example Design Introduction Main control cabinet The water application architecture is designed using the solution platform introduced previously. The different process steps are split in three cabinets: -- Main control cabinet -- Lifting and Screening cabinet -- Grease & sand removal and primary clarifier cabinet. The main cabinet 1 contains the Modicon Premium P574634 PLC with the integrated Ethernet module.
Water application example Design 230 V AC Connexium 499 NES Clarifier PHASEO ABL7 iPC + VIJEO CITECT Sand and grease Multi 9 Lifting and screening Main control cabinet Control I/O Premium Emergency stop 63
Water application example Design Lifting and screening This cabinet integrates the lifting and screening sections. -- An Ethernet network connects each island section. Some products (VSD) are directly connected to Ethernet, the rest are managed across an Advantys STB I/O module. -- A HMI graphic terminal XBTGT is connected to Ethernet. It enables management of the local process and the process of other functions units (Sand & Grease and Primary Clarifier).
Water application example Design Lifting and screening Modbus STB extension rack Ethernet 24V DC 400/230V AC 400V AC XBT GT NSC 100 Multi 9 Phaseo ABL7 STB LU9GC3 TeSys T TSX ETG100 Preventa XPS GV2 TeSys U Lifting pump 1 Lifting pump 2 Rescue pump Dry weather pumps Lifting pump 1 Lifting pump 2 Rain weather pumps Control valve Tank level Emergency stop Tank level & flow ATS48 ATV61 65
Water application example Design Sand and grease removal and primary clarifier This cabinet has the same architecture with two Advantys STB automation islands In this example, the proposed motor control solutions are: bb For grease & sand compressor High power motor requires specific parameter control like phase reversing, diagnostics... A TeSys T multifunction relay is used. The product is linked to the Ethernet across the Modbus gateway of cabinet 2.
Water application example Design Modbus STB extension rack 24V DC CanOpen Ethernet Parallel outputs EPI 2145 400/230V AC Sand and grease NSC 100 Phaseo ABL7 Multi 9 STB STB From ETG GV2 ATV31 TeSys T Emergency stop Primary clarifier Valve for sand outlet Scraper 2 Air compressor directions Shield motor Tank level, outlet flow meter Oxygen sensor, sand & grit level TeSys U Sand pump Redundant pump Parallel outputs EPI 2145 Ethernet 24V DC 400/230 VAC 400V AC 24V DC STB Connexium 499 NES
Water application example Design Specific pump functions For applications like water treatment or pumping, some complementary functions are needed.
Water application example Design Detection of excessive or negative pressure Running Timer Operation sequences: 1 Alarm pressure 2 Pump running= Tempo increase 3 Pressure OK 4 Pump running 5 Alarm pressure = Stop pump Remark: Delaying allows pump start with pressure alarm 69
Water application example Configuration Introduction The configuration phase uses all elements described in chapter 4. Implementation Unity program The UNITY program comprises several sections, some of witch perform a transversal role such as PLC system monitoring or the process sequence coordination. bb PLC system monitoring manages the system state (alarms, status, communication...).
Water application example Implementation Unity program (cont’d) 1-Example of diagnostics for devices on the I/O scanner In this section, equipement status is monitored, an IODDT "T_COM_ETHCOPRO" dedicated to Ethernet is used IO_SCANNING_REPORT.REFRESH_IO_3 0 IO_SCANNING_REPORT.REFRESH_IO_5 0 IO_SCANNING_REPORT.REFRESH_IO_7 0 FBI 19 CU R PV FBI 17 CU R PV FBI 3 CU R PV Q CV IO_SCANNING_REPORT.REFRESH_IO_1 IO_SCANNING_REPORT.REFRESH_IO_2 IO_SCANNING_REPORT.REFRESH_IO_3 IO_SCANNING_REPORT.
Water application example Implementation Unity program (cont’d) 3-Example of starter type TeSys U with advanced control unit,, one block for the naming, one block for starter management and an optional block for time management There is an additional block allows Read or Write all TeSys_U parameters and data. LS1_MOT_1 IO_I_LS1_MOT_1.FbStart(1).8 IO_I_LS1_MOT_1.FbStart(1)0.9 OR Secu_Act_Lifting IO_SCANNING_ REREPORT.
Water application example Operation Introduction The water application can be operated either from a Vijeo Citect SCADA for complete process monitoring or from a Magelis HMI more dedicated to local monitoring and maintenance purposes. In Local mode, button panels can also be implemented to perform pump and motor management with no PLC control. In the general process view, a functional unit can be selected to visualize the pump to be controlled.
Water application example Operation Control pump example Using a web browser provides access to additional information. Faulty pump example When a fault is triggered, an alarm message is sent and the information appears in the general view. Click the area to access the defective element. An alarm message is sent.
Water application example Operation Faulty pump exampl(cont’d) The two popup levels below provide access to detailed information about the pump. Network faulty example Following sceen capture represent Ethernet architecture, Faulty communication is warned by a flashing red square.
Water application example Components list Part Number Control Room TSXP574634M V2.40 TCSESM083F23F0 SV1.03 MPCKT22NAN00N-PP SV1.0 ABL8RPS24050 76 Description PLC Processor with Ethernet port ConneXium managed Switch 8 x 10/100Base-T ports Magelis Compact iPC 12’’ Phaseo power supply 230 VAC,120 W, 5A 24V DC Lifting & Screening STBNIP2212 V2.14 TCSESM083F23F0 SV1.03 499NES25100 SV1.03 TSXETG100 V2.50 LC1D09BD LC1D18BD GV2-L08 GV2-L20 W3A3310 V2.1 ATV61HO75N4 V1.4 ATS48D17Q V1.
STG- Pumps and motors management 8-Glossary Glossary / Acronym Description Cicode is a Vijeo Citect programming language designed especially for plant monitoring and control applications. Using Cicode, you have access to all Cicode Function real-time data in the Vijeo Citect project and all Vijeo Citect facilities. Cicode can also be used as interface to various resources on computer. DDT (Derived Data Type) is a set of elements of the same type (ARRAY) or DDT of various types (Structure).
