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1. 2005 Schneider Electric All Rights Reserved Applet AtvMeter started Schneider 120 ES Electric Plant truxure 6 Operation TeSys T Controller of the Gs1_Mot3 motor of the Grease amp Sand Removal unit In a Web browser type the Gs1_Mot3 TeSys T controller IP address 172 20 1 25 in the address bar di http 172 20 1 25 Microsoft Internet Explorer Eak Ele Edit wiew Favorites Tools Help x Q Badii s x a A J2 Search 57 Favorites e z I pw bi im rel 3 4 Links Address amp http 172 20 1 25 w EJ cc Sc neider TeSys T Motor Management System ectr i c ome ocumentation m Borna Monitoring Product status Product Status 0000009 E system Ready LI1 LIZ LIS LI4 LIS LIG LO4 Metering f Fault Reset Authorized a Power Cycle Required Be System ON LTMROBEBO 1111 i e Hp a Motor starting co Test Reset E Motor Running t3 Direction 1 e e e e e e wiring Faut Direstion2 system Faut o e System Warning lo Average Current FLC Minimum Wait Time 0 s 4M Time To Thermal Fault 9999 S 2000 2008 Schneider Electric All Rights Reserved Applet thinlet AppletLauncher started 4B Internet Schneider E ES Electric Plant truxure 6 Operation 6 2 3 Software Tools PowerSuite Diagnostic Tool From a computer with the PowerSuite tool installed you can access the different starters An example with the Lf1_PmpD1 AT
2. z a a 4 Configuration es Vijeo Citect Client FactoryCast HMI E M 1 Internet via GPRS 3G ADSL Pere gt Viso Cec Engineering Web Client a ene 1 pm e E HMI XBTGT remium T SE Sl A 1 i Ze M E Ethernet NP 1 Profibus DP i ses id bed bo amp For our application the Device names are allotted as described in the table below Advantys STB NIP 2311 Lifting amp Screening Unit Advantys STB NIP 2311 Grease and Sand Removal Unit TeSys T Air Compressor Grease and Sand Unit ATV61 Pump 1 lifting wastewater tank ATV61 Pump 2 lifting wastewater tank ATV61 Pump 3 lifting wastewater tank PRM Primary Clarifier Unit ETG3021 wastewater station O1 Schneider i d Electric Plant amp truxure 4 Configuration Clients Configuration By default each device has a Device name that can be customized if necessary In our case the default names are used for the devices equipped with rotary switches Advantys STB NIP 2311 The default Device name is formatted as follows STBNIP2311 xxx where xxx is defined by the rotary switches located on the STB NIP 2311 front panel For the first STB Lifting Screening the Device name has to be set to STBNIP2311 020 Set the Tens switch on 2 and the Ones switch on 0 For the second STB Grease and Sand Removal the Device name has to be set to STBNIP2311 021 Set the Tens switch on 2 and the Ones swit
3. 6 3 2 ATV 61 The following table describes the steps to replace the VSD of the pump Lf1_PmpD1 From the menu COMMUNICATION ETHERNET select the sub menu DEVICE NAME and type the same device name ATV61_PmpD1 Note IP parameters IP Card IP Mask IP Gate and IP Master must be set to 0 0 0 0 to allow the DHCP service to run Activate the FDR service From the menu COMMUNICATION gt ETHERNET select the menu FDR validation and select Yes to activate the FDR service Schneider lind Electric Plant truxure 6 Operation EN Turn the drive off and then back on again to have the device name taken into account Connect the drive to the Ethernet network 125 Schneider Electric Plant amp Z truxure 6 Operation Schneider Electric Plant truxure 7 Performance 7 Performance The following performances are measured using a 1 ms FAST task This chapter comprises the results for the following performance measurements e ART e FDR 7 1 Application Response Time ART of Devices The ART is determined by measuring the time delay from when the request for Run Motor command is issued by the IO Scanning to when the PAC receives Running status back from the starter Premium PAC Status Word Running Motor Via IO Scanning Command Run Motor via IO Scanning The following table summarizes the ART measurements performed on our architecture ATV 61 Ethernet TeSys T Et
4. General Management of build messages Build settings Project autasaving on download Comments PLC embedded data Animation tables PLE diagnostics H Variables Program Hl Languages Common FEL El LD Med display Hl SFC Data dictionary Upload information Upload information management Automatic Optimize data on line change az ST Operator Screens Controlled Screen lt D mot E eot M ess Schneider a ES Electric Plantf Ztruxure 4 Configuration 4 3 3 Importing tags in Vijeo Citect In Vijeo Citect from Citect Explorer menu click on Tool gt Import Tags Select the Premium I O Device and then select the Unity SpeedLink via OFS database type Import Variable Tags Destination LO Device Premium Source Database type Unity SpeedLink via OFS External database Schneider Aut OFS5 2 Browse Connection string ServerMode Branch Premiurn Options Add prefix to imported tag Tag prefix r Iv Purge deleted tags not found in data source cm m Click the Browse button to connect to the OFS server OPC Data Access Server Parameters Machine name blank local Select server and branch to import Schneider 4ukb OFS 2 e Premium Tag Sen Configuration W Enable Configured aie IM rae template saved as Tagen Import Premium sml anfigure Logging Log File Path C OF5ImportLogs Browse t Summary Log Level i Detail So Log
5. 1 kW to 10 kW Dosing pumps are frequently used to inject fluids Dosing pump that may be difficult to mix efficiently in batch tank lt 10 kW Constant gt system because of their low volume Screw pumps are also known as Archimede s screw Screw pump They are used for lifting large volumes of fluid or 4 kW to 50 kW Contant material to a limited height They are driven through a speed reduction gear Mixers are used to give homogeneity to fluids ieee is ic is also used to speed up chemical 4 KW to 50 kW nee Mixing is performed by a propeller rotating in the fluid driven by a speed reduction gear Moving devices systems such as rotators scrapers shields 1 kW to 10 kW Constant Moving devices drive various types of mechanical compressors conveyors Air blowers or fans are used to provide air or oxygen for ventilation or aeration tank Air blower and Quadratic or fan Flow can be adjusted using a mechanical system TO ro Lu constant fixed speed or variable speed drive Energy savings are possible by operating at reduced speed Mills and crushers are used to grind materials Mill and crusher 50 kW to 2 MW Variable They are typically high torque Schneider d Electric Plant truxure 2 Selection 2 4 2 Control Starter Functions Depending on needs it is necessary to be able to control some or all functions of a starter The principal function grou
6. Plant truxure 3 Design 3 Design 3 1 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 e Description of global application operating modes e Description of hardware design e Description of software design 3 2 Operating Modes 3 2 1 Principle Application operating modes are important structuring elements in the automation system definition phase They act on all architecture components SCADA PAC and motor control device wiring Operating modes described below are rather general and can be easily adapted to the specific requirements of a project The modes defined in our project are summarized in the following table Off Local buttons MODE Remote Local PAC ACTOR TENT Local buttons Application SCADA HMI logic Run Stop Run Stop ACTION en ee Eon Actuator powered off 3 2 2 Description Remote Mode In Remote mode the command to the actuators is always sent from the PAC Nevertheless we differentiate two sub modes e Auto mode The PAC application logic directly controls the actuators e Manual mode The operator controls the actuators via SCADA HMI e 33 Schneider Electric Plant truxure 3 Design Local Mode Off Mode When switching from the Auto to Manual mode using SCADA HMI actuators maintain their states they continue to run ifthey were running pre
7. Bandwicth HTTP modification Locked in operation Password Client Server address table MAC address Hame IP address Netmask Gateway TCSEGRPA223F4FO01 172 20 1 22 255 259 0 0 0 0 0 0 2 IDEE HEN REN Premium PAC specificities To run and use a PRM in Premium PAC architecture it is necessary to declare an XWAY profile Click on Messaging tab Select an XWAY profile on the PAC Ethernet module and an XWAY connection 1 122 in our case associated with IP address 172 20 1 22 corresponding to the PRM Note XWAY station number must be greater than 100 IP Configuration Messaging i0 Scanning snmp Address Server Bandwidtn AWA profile Imi Network i Station n Connection configuration zxwATY address 1 1122 MULTI 2 MULTI MULTI MULTI MULTI MULTI MULTI MULTI MULTI MULTI MULTI MULTI Mode Access IP address i 1r2 20 1 22 Access Control Adele EE EE lee EE CREE EE CE Vel lt 1 lt 1 lt 1 lt 1 lt 1 lt 1 lt 1 lt 1 STATI BEERERRRRRN Scbneider E ES Electric Plant amp truxure 4 Configuration Click on Validate to accept the network settings To start the PRM the PRM MGT block must be called in the application It activates the I O exchanges on Profibus Create a new section called PRM Management Instantiate the DFB PRM MGQGT P in this section There is one DFB for each type of PAC PRM MGT P for Premium PRM MGT M for M340 and PRM MGT Q for
8. diagram below RDY NET 00Hz OA 1 DRIVE MENU 1 1 SIMPLY START 1 3 SETTINGS 1 4 MOTOR CONTROL 1 5 INPUTS OUTPUTS CFG Code lt lt gt gt Quick 1 6 COMMAND 1 7 APPLICATION FUNCT RDY NET 0 00Hz OA MAIN MENU ENT 1 8 FAULT MANAGEMENT ENT 1 DRIVE MENU 1 9 COMMUNICATION 2 ACCESS LEVEL 1 10 DIAGNOSTICS 3 OPEN SAVE AS 1 11 IDENTIFICATION 1 12 FACTORY SETTINGS 1 13 USER MENU 1 14 PROGRAMMABLE CARD Schneider gt d Electric Plant amp truxure 4 Configuration From the Ethernet menu the following actions are performed Select the menu DEVICE NAME and type ATV61 PmpD1 to set the Device name Select the menu FDR validation and select Yes to activate the FDR Service From the menu FDR autosave select Yes to save the configuration automatically Note The IP Card address must be set to 0 0 0 0 to run the DHCP service Proceed in the same manner for the 2 other ATV 61s using Device names ATV61 PmpD 2 and ATV61 PmpD3 PRM The format of the Device name is TCSEGPA23F14Fxxx where xxx is defined by the rotary switches located on the back panel of the PRM For the PRM to set the Device name to TCSEGPA23F14F001 set the Tens switch top one on O and the Ones bottom one switch on 1 e 60 Schneider Electric Plant Ztruxure 4 Configuration FactoryCast Gateway ETG3021 The configuration can be done either from Web Designer or from the ETG3021 web
9. gt Advanced Diagnostic p I O Values Extend Diag N amp Advanced Diagnostic Configuration F ault gt I O Values Master Lock Slave Deactivated Ext Diags Overflow Parameter Fault Reserved Reserved Sync Mode Reserved Freeze Mode Reserved Watchdog On Reserved Slave Device Reserved Station Not Ready Static Diag Reserved Station Not Existent Re parameterization needed Reserved Extended Parameters GSD Diag Decode gt lt DiagAlarm Slot 0 Specifier No further differentiation Type reser lt RawBuffer Value lt DiagAlarm gt lt GSD Diag Decode gt 6 2 4 Local Panel Interface ATV 61 graphic display terminal provides a quick view of the equipment status and allows local command operations on the starter Schneider d Electric Plant truxure 6 Operation 6 3 Faulty Device Replacement FDR Operation This chapter details the maintenance procedures to replace the TeSys T ofthe Gs1_Mot3 motor of the Grease amp Sand Removal unit and the ATV 61 of the pump Lf1_PmpD1 of the Lifting unit The FDR service has previously been configured on these devices see chapter 4 2 1 on Page 56 6 3 1 TeSys T The following table describes the steps to replace the TeSys T of the Gs1_Mot3 motor Use the rotary switches on the front of the replacement TeSys T controller to assign it the same Device name TeSysT001 by setting the Tens switch on 0 and the Ones switch on 1
10. s content meet the expectations of our users All STGs are illustrated with industry specific applications to give more concrete examples of the methodology The STGs are not intended to be used as substitutes for the technical documentation related to the individual components but rather to complement these materials and training Development Environment Each STG has been developed in one of our solution platform labs using a typical PlantStruxure architecture PlantStruxure the process automation system from Schneider Electric is a collaborative system that allows industrial and infrastructure companies to meet their automation needs while at the same time addressing their growing energy management requirements In a single environment measured energy and process data can be analyzed to yield a holistically optimized plant Schneider Table of Contents 1 1 1 1 2 1 3 1 4 1 5 2 2 2 2 2 3 2 4 2 5 3 3 f 3 2 3 3 3 4 4 1 4 2 4 3 4 4 5 1 Introduction NEUTRA FEROS P 7 Customer CRANEN OCS unse ame 7 F VCTCOLNSIOS u EEE EEE 8 PLOJECH MENOJ V ur en einteilen era 8 FTOIGCUCEIOSCHDIUOR ren Er ee 10 Selection Phase eere eren nnne enne nneneses ID INILOQUCHON Pm Tc g 13 SEIECHON PHNEIDIE 22 eL 13 Seleeling Starter MOGO iii EE ed ue E ee M 16 Selecting
11. The operating modes described above require a wiring design for an emergency stop circuit and motor control device The following sections provide recommendations for developing a consistent wiring solution Safety requirements impose constraints to protect people and the environment We recommend safety measures for electrical risks that are defined in IEC 60204 1 This standard specifies in particular emergency stop operations 3 3 2 Emergency Stop Circuits Recommendations Emergency stops are located in cabinets close to the machines and close to the operators As the use of intermediate relays is prohibited the solution of a safety function block is essential in the case of multiple stop commands To cover most situations three basic diagrams are proposed Electric e 36 Schneider Plant truxure 3 Design TH Conventional Diagram Generally it comprises a contactor a variable speed drive or a soft starter optionally associated with thermal protection A second contactor KM_A in series with KM_1 and 2 makes it possible to cover all categories conforming to EN ISO 13849 1 The PAC receives information from the safety XPS block and acts on the starter contactors variable speed drive via the application Whatever the mode local remote or off the XPS retains priority Resetting cannot be performed if KM_1 and KM_2 are closed This diagram covers the structures including the products e ATS 48 AT
12. 10 input words and 1 output word for the command They are directly accessed via IO Scanning through the TSX ETG100 Gateway Refer to chapter 4 2 6 on Page 77 for more details Input Status Output Output Ctrl 256 INT 257 INT 258 INT 259 INT 260 INT 261 INT 262 INT 263 INT 264 INT 265 INT 752 INT e Scbneider d Electric Status Register Phase 1 current Phase 2 current Phase 3 current Voltage Logical Inputs status Logic output relays status Frequency Control Register 108 Plant truxure 5 Implementation ren 5 2 6 ATV 61 ATV 71 Variable Speed Drives on Ethernet Data Type MOT_ATV61_71 Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Bool Real Bool Bool Bool Bool Bool Bool Int Output Ctrl Int Int E Output RPM Int ARRAY 0 1 OF INT MOT PARAM SPEED HMI MOTOR A The communication with the ATV 61 and ATV 71 use 5 input words 1 reserved and 3 output words 1 reserved for the command They are directly accessed via IO Scanning Refer to chapter 4 2 7 on Page 78 for more details Note As this DFB controls a variable speed drive an input pin named ASpeed has been added so the PAC can specify a speed setpoint for the drive when it runs in automatic mode Reserved INT Input Status 3201 INT Status Register Input RPM 8604 INT Actual speed 3204 INT Motor Current Loeb 3211 INT Motor Power Reserved INT Output Ctrl 8501 INT Control Register Output
13. 860 Actual speed value Parameter 3 v 1320 Motor current Drivecom state register Parameter 4 Parameter 5 Parameter 6 Parameter 7 Parameter 8 Parameter 9 Parameter 10 iE amp Ex gt Ay dn z ATY61 O Modified parar O Access level O Simply Start Input summary H Settings Motor contic inputs 7 Out f Command fy Applicative I EE f Fault manag Communicati 1 Comm sce O Modbus c eteme Password E PO Input scar Faulty De IP config Email am omms Enable Input and Output ID scanner Enable 10 scanner Output I0 scanner Code Address Description Parameter 1 CMD vw 850 DrivecomCmdReg Parameter 2 LFRD 8602 Parameter 3 Parameter 4 Parameter 5 Parameter 6 Parameter 7 Parameter 8 Parameter 9 Parameter 10 3 Standard profile en Not connected 3 Standard profile en Not connected Then in Unity Pro from the Network configuration window gt IO Scanning tab configure the IO Scanning line as follows Health Repetitive IP address Device Mame Unit ID Timeout rate E RD Ref i on d s eius EE Ref yntaz ms ms ones Slave eng Input Object ave eng 172 20 1 50 index 500 50 Set to 0 mj woe For the ATV 61 IO Scanning configuration the first register is always reserved e Reading length 1 reserved word 4 words configured registers 5 words for reading e Writing length 1 reserved word 2 words configured regi
14. Module Status Re ee 0000 E Warning Register 461 E Mechanical and Power PEW Response Obisc m PKW Response Data mm E Control of the System em O Mot3CmdSystem E Control of Communicati 0 Mot3CmdEom 7 E Output Control 700 POM tome PKW Request Obiect Mt PW PKW Request Data P em D_Motapkiwi2 Module Help Configure the process image area Configure Ready and Tripped bits of the Status Register item to visualize them on the SCADA Electric view amp 2 TeSys U Sc Mu R V1 xx Segment 1 Slot 13 Node ID 10 1 13 10 General ID Image Options LO Mapping Hexadecimal Data Item M ame Current Value User Defined Label Memory Address dec BE Status Register 455 _ hot tahlasitt FE Mat 45422 01 ENNIUS 1 45422 02 45422 03 All warnings he 45422 4 15472 nh Fault Reset Author ss 45422 06 41 42 terminals po 4542 0r Motor Running 454278 Average motor curr 45422 09 Average motor Curr 464210 Average motor curr 45422 11 Average motor curr 4542212 Average motor curr 45422 13 Average motor Curr 45422 14 L m e SttinPrgess 4542216 O Module Status Re Mot3StatuslO 45473 Module Help Configure the process image area EE Click on OK and close the Advantys application Schneider e d Electric Plant ftruxure 4 Configuration Click on Yes to start the update Unity Pro creates new variables correspon
15. Motor Control Devices eee esses enne s nhan aan nnns s sana aa assa nnns 24 el eiepsimalicei m P 28 BIS Le p t 3 MTOA CUON ae EE E ENE 33 ODeraling Modes 22 ae X PH 33 Hardware DESIGN E M M 36 SOMAS DES OM P re ee ee Meere 45 Confngurallol aneignen POO CHOR ke nee IHRER nee 55 PAC and Motor Control Device Configuration eeeeeesssseseees seen 56 SCADA System CORIIQUFallOr 2 aiuto eoe en nna eee ee hanes 89 EPG IOO COnMGUIAUON m M M 92 Implementation Hardware Implementation 95 Schneider Electric 5 2 5 3 5 4 6 1 6 2 6 3 7 1 7 2 DFB Implementation in the PAC esere aiaia R EEEn EE E E EAA E EERE Un PrOXP FOOL Strae UNN 2 eine nee SCADA ImblemenlatiOH e ioi eR du mM ML E I EE Opera O cessere xexu sa asu P ERU L AE Hus Ree Sn pss aes uEuasusasEsskase A PAU VON P qr E Process Control and Diagnosis un ox v beet a m a een a cU eds Faulty Device Replacement FDR Operation eoe ees sessi sees PertormaliCO nn Ve Application Response Time ART Of Devices u0020200022200nnennonnnnn nenne nennen nnn nnns Faulty Device Replacement FDR cccscccccseseccseeeccseeecsseeecsseeecsusecseeeessus
16. PAC or in local mode with buttons or panels Hardware Specific wiring design is required depending on the previous operating modes This part presents solutions notably for emergency stops and motor control devices Software Motor control applications require the design of objects located in different devices using various software This section shows how to design applications in Vijeo Citect for SCADA Unity Pro for PAC Schneider Electric Plant truxure 1 Introduction Configuration The aim of this phase is to provide key information for configuring the various system components PAC motor control devices SCADA applications The main purpose is to build a consistent system configuration with the description of all of the data exchanged between key components This phase comprises the following parts Configuration of data to be exchanged periodically between PAC application and motor control devices Configuration of data and data types to be used both in PAC and SCADA applications Implementation The main purpose of this phase is to explain how to implement the various components introduced in the Design phase PAC and motor control devices Unity Pro program SCADA Operation In this phase available operations for process control and related motor control diagnoses are described Performance This phase describes system performances Application Response Time ART of devices on
17. Pool Size 10 100 Verbose Detail e oe Select the displayed OPC group Premium corresponding to the Alias previously created under the OFS server and click on OK Back in the first window select Purge deleted tag not found in data source to avoid variables list overload EN Finally click the Import button to start the import process Schneid j cpneider d Electric Plant truxure 4 Configuration 4 4 ETG100 Configuration 4 4 1 Connection to the Gateway The ATS 48 and ATS 22 are connected to the Ethernet network via an ETG100 gateway The communication becomes transparent between the Ethernet network and Modbus serial line Thus the IO Scanning service can directly access the data of the devices To configure this gateway for the first time use a web browser and log on to the default IP Address Use login Administrator and password Gateway to log in Ethernet Parameters configuration Stieler ConneXium TSXETG100 Home Logout Monitoring Maintenance Ethernet amp TCP IP Ethernet amp TCP IP Serial Port Device List MAC Address 00 30 67 80 AB 89 pL Frame Format Ethernet II v User Accounts Media Type 10T 100Tx Auto v p Modbus TCP IP Filtering N IP Address 172 SNMP Parameters Subnet Mask 255 Default Gateway T 5 e F OININ elo er Firmware Version 2 700 2005 2008 Schneider Electric All Rights Reserved User Administrator Modb
18. RPM 8602 INT Speed setpoint lt 109 Schneider d Electric Plant amp Z truxure 5 Implementation 5 2 7 ATV 32 Variable Speed Drive on Profibus DP Data Type MOT_ATV32_Pfb Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Bool Real Bool Bool Bool n Bool Bool Ext ClearFault Bool ARRAY 0 3 OF BYTE Input Status Output Ctrl ARRAY 0 3 OF BYTE ARRAY 0 3 OF INT Input Meas MOT PARAM SPEED HMI MOTOR E During the configuration of the ATV 32 in the FDT Field Device Tool Container PRM configuration tool in Unity Pro the GSD offers a choice among 4 telegrams In our case the telegram 102 is chosen it allows for communication with 6 input and 6 output words However the DFB developed for the ATV 32 with Profibus DP does not use all the words see table below The input and output words are automatically generated with Unity Pro FDT Container during the configuration phase Refer to chapter 4 2 8 on Page 80 for more details Note As this DFB controls a variable speed drive an input pin named ASpeed has been added so the PAC can specify a speed setpoint for the drive when it runs in automatic mode 3201 MSB BYTE Status Register 3201 LSB BYTE Status Register Justa 8604 MSB BYTE Actual speed 8604 LSB BYTE Actual speed 3204 INT Motor current 3208 INT Motor voltage Input M incu Free INT Free INT 8501 MSB BYTE Control Register 8501 LSB BYTE Control Register DUE 8602 MSB BYTE Speed setpoint 8602 L
19. Schneider Li Profibus Remote Master Configuration Tool P Electric PRM Master Configuration F General Settings Factory IP Address uU Profibus Master Configuration Factory IP Address is derived from the MAC Address printed on the PRM label mp Basic Settings s Advanced Settings Factory IP Address gt IO Scanning ae o eo ra FF o o0 0 27 This IP Address will be used if the PRM Master DTM cannot connect to the PRM via the dedicated IP Address Dedicated IP Address Dedicated IP Address will be the primary Address used to connect to the PRM This Address will be also stored in the PRM configuration file IP Address mE 72 20 1 2 Subnet Mask 255 255 0 0 Default gateway Do 5n DHCP FDR Server Parameters of this section need to be filled if you want to use a DHCP FDR server IS v Create an entry for this device name in the DHCP server Device Name TCSEGPA23F14F 001 Extension 000 159 rotary switches value d Profibus baud rate in the Basic Setting menu is set t01500 kbits s The others parameters are left with default values Click on OK to validate the modifications and close the window The PRM of the Clarifier unit is now declared and configured Schneider d d Electric Plant truxure 4 Configuration Definition and configuration of the ATV 32 slave device From the DTM Browser window right click on the PRM Master Clarifier device and select Add to open the device
20. Speed Drive The Altivar 32 drive is a frequency inverter for 200 to 500 V three phase asynchronous and synchronous motors rated from 0 18 to 15 kW Up to 4 kW the ATV 32 is available in a book format In this power range it can be installed side by side saving a considerable amount of space Modbus and CANopen protocols are integrated into the ATV32 as standard Additional communication cards handle MODBUS TCP PROFIBUS DP DeviceNet and EtherCat protocols The Altivar 32 drive also offers the following functions e Safety function guarantees a high level of safety IEC 61508 SIL 2 e Logic function offers simple control system functions Boolean arithmetic operations comparators and so on e Bluetooth connectivity The SoMove Mobile software transforms any compatible mobile phone into a remote graphic display terminal by offering an identical Human Machine Interface SoMove Mobile software can be used to print out and save configurations import them and export them to a PC or a hard drive equipped with Bluetooth ATV 61 Variable Speed Drive This is a frequency inverter for 3 phase asynchronous motors rated between 0 37 and 800 kW It has been designed for the most common fluid management applications in industrial and commercial buildings and infrastructures The Altivar 61 includes specific functions for pumping and ventilation applications e energy saving ratio 2 or 5 point quadratic ratio e automatic
21. Unity Pro Refer to chapter 4 2 3 on Page 65 for more details DFBPin Input StatusO 455 INT Input Status1 458 INT Output CtrlO 704 INT Output Ctrl1 703 INT Output _Ctri2 700 INT e Scbneider d Electric Switch Status Contactor Status Control of the system Control of communication module Output Control 100 Plant truxure TeSys U Standard on Profibus DP Data Type String 20 Bool Bool Bool Bool Bool Bool Bool ARRAYI0 7 OF BYTE MOT_PARAM_2D HMI_MOTOR_TU_DP_2D MOT TESYSU s Pfb Input Status FbAuto FbManual FbLocal FbOff Output Ctrl 5 Implementation Data Type Bool Bool Bool Bool Bool Bool Bool Bool Bool ARRAY 0 3 OF BYTE The communication with this device uses 8 input bytes and 3 output bytes These bytes correspond to the variables automatically generated during the PRM configuration performed with Unity Pro Refer to chapter 4 2 3 on Page 65 for more details Input Status Output Ctrl 455 LSB BYTE 455 MSB BYTE 457 LSB BYTE 457 MSB BYTE 458 LSB BYTE 458 MSB BYTE Reserved BYTE Reserved BYTE 704 LSB BYTE 704 MSB BYTE 700 LSB BYTE 700 MSB BYTE e Scbneider d Electric Switch Status Switch Status Mechanical and power status Mechanical and power status I O Module Status I O Module Status Control of the system Control of the system Output Control Output Control 101 Plant truxure 5 Implementation le TeSys U A
22. Vijeo Citect Client Server Vijeo Citect Engineering Web Client kka JeF S o Profibus DP Profibus DP TET EIE IT IM IT t imi Ad la ULT F T Profibus PA Ethernet 5 va An Ethernet network 5 connects all process steps in order to enable effective diagnostics and performance Because of the Ethernet communication the SCADA systems and HMI can easily access all process data Embedded web diagnostic services which are available from any standard web browser facilitate the maintenance phase The motor control devices are distributed across the plant with connections to the Ethernet network Inthe same way Advantys STB islands 16 communicate with the controller via Ethernet and Profibus DP 17 These islands also connect DOL starters and other starters through various fieldbuses Electric e 30 Schneider Plant truxure 2 Selection Advantys STB islands 16 and the TeSys T 14 controller are connected to an Ethernet daisy chain loop The following list describes the motor starters used in the architecture ATV 61 6 They are directly connected to the Ethernet network All monitoring functions and controls are allowed An embedded web server can be used for maintenance Only the ATV 61 is presented in this guide but the ATV71 can also be used for the same purposes The configuration and implementation steps are the same as for the ATV 61 ATS 48 7 A Transparent Ready gateway E
23. catalog A device property window opens Modify the starter name In our case it is named lO PC1 Pmp1 Click on OK to confirm Note Once the slave device is added a Profibus address by default is assigned This address can be modified in PRM Master DTM see step 7 Double click on the Profibus slave to open its Profibus configuration window In the list on the left select Modules Configuration 4 module types are available to communicate with the ATV 32 Choose Telegram 102 by clicking on the button Add Note The DFB provided with this guide is configured to be used with Telegram 102 El IO PC1 Pmp1 fdtConfiguration ER ATV32 from GSD Schneider Electric Profibus Remote Master Generic Device DTM Schneider Electric ATV32 Device Information Modules Configuration GSD View P Device Parameters Information P4 Modules Configuration Input Size 0 244 9 Telegram 102 6PZD Output Size 0 244 Total 1 0 Size 1 488 Number of Configured Modules 1 1 Modules in GSD Name Output Configuration Telegram 1 PROFIdrive 4 O C3 0 C1 0 C1 0 FD x Telegram 100 4PKWw 2PZD 12 OxF3 0 F1 Telegram 101 4PKw BPZD 20 20 OxF3 0 F5 Telegram 102 BPZD OxF5 I Configured Modules Name Input Output Configuration Telegram 102 BPZD 12 12 OxF5 Le sno Br Be gt OK Cancel Apply Help x Disconnected 0 Data set Schneider gt d Electric Plant amp truxure 4 C
24. e Operational constraints The project characteristics impose constraints such as Plant productivity Traceability environmental constraints Process quality Diagnostic information required application standards Operational cost Operator profiles energy monitoring Schneider d Electric Plant truxure 2 Selection These functional and operational constraints are the inputs for the three following selection steps 2 2 2 Selecting Starter Type Three solutions are proposed to perform a motor control function e Direct On Line DOL starter This is the simplest solution appropriate for low and medium power motors that do not require frequent start up Depending on requirements elaborate protection and monitoring devices can be incorporated here e Soft starter For more powerful motors the use of a soft starter allows reducing the load and torque of the motor during startup and shut down if necessary This reduces the mechanical and electrical stress on the system e Variable Speed Drive VSD This is the most powerful solution allowing permanent control of the speed of a motor It is used for example to regulate flows in pump applications It can also help to optimize energy consumption The starter structure is detailed on Pages 17 to 23 A selection guide is provided on Page 24 2 2 3 Selecting Motor Control Devices The most appropriate device is selected based on the requested contr
25. value 2 WR Ref Glave length Input ans Glave Object 5331 100 Hold last ow w300 To refine the read and write register number click again on the button in the Device Name field to open the Property window Write down the values in the Data Exchange Required area for this island 55 input words and 30 output words Property Device Type Device Name ste fs Data Exchange Required Input words Output words Launch Advantys Contiguration Software Close the window Set the RD and WH lengths values to 60 and 35 respectively RD Ref RD Last value vr WR Ref WR Glave length Input z Slave length a Hold last v etw Ton Note The values entered are slightly more than necessary to be able to add a module without reloading the network configuration in the PAC Schneider a d Electric Plant amp truxure 4 Configuration The Lifting and Screening Advantys STB is now configured and ready to communicate with the PAC The table below summarizes the mapping created in the IO Scanning for this Advantys STB island Modbus Register Item RDSlaveindex RD Master object Length Note The configuration files of this Advantys STB island generated by the Advantys software are located in a directory defined in the Unity Pro options Therefore to use the Unity Pro application on another computer and make some modifications concerning the STB island mapping it is necessary to cop
26. 1 Vlvi M Grease Sand G51 Mot2 eu Table e Grease Sand Gs1_Mot3 e Screen M Grease Sand G51 Vlvi ES PrimaryC PC1 INIT Program au PrimaryC PC1 Sequence er PC1 INIT T PrimaryC PC1 Cde Auto PCi1 Sequence ue Primary PC1 Moti 0 PCi Cde Auto E PrimaryC PC1_Mot2 e PC1 Moti M PrimaryC PC1 Pmp1 Pe PC1 Mot2 M PrimaryC PC1 Vlv1 M PC1 Vivi en Final e PC1iPmpi S PRM Management i Table ee E SR Sections B Screen Hmm FAST Hee y Diagnostic pec e Events E 3 Timer Events vu Qj 1 0 Events Scbneider 112 d Electric Plant amp Ztruxure 5 Implementation 5 3 2 Variable Naming Rules For the consistency of the project the names of the variables that are to be exchanged with the SCADA system are defined before developing the application In our project we use the naming rule described below The name of the variable is composed of 3 parts XXX_Yyy_Zzz e XXX is the variable group In our application the possible values of the variable group are HMI or INF These valus correspond to the variables exchanged with the SCADA system e Yyy is the identification of the functional unit to which the device belongs e ZZZ is the identification of the device type such as pump motor valve 5 3 3 DFB instantiation example The picture below shows an example of a MOT ATV61 71 DFB instantiated in Unity Pro Management of the A amp TV81 LS1 PmpD1 MOT ATV61 71 L81 P
27. AY 0 3 OF BYTE Output ARRAY 0 3 OF BYTE Input 2 INT Output 2 INT Input 1 ATS48 IOSCAN Input 2 ATS48 IOSCAN IM Output ATS48 IOSCAN O Input ATS22 IOSCAN Output ATS22_IOSCAN_O Input ARRAY 0 3 OF INT Output 1 INT Input 2 INT Output 3 INT Input ARRAY 0 7 OF BYTE Output ARRAY 0 3 OF BYTE Input 3 INT Output 3 INT Input ARRAY O 7 OF BYTE Output ARRAY 0 3 OF BYTE Input 4 INT Output 3 INT Input ARRAY 0 7 OF BYTE Output ARRAY 0 3 OF BYTE Input 6 BOOL Output 2 BOOL HMI MOTOR A HMI MOTOR E MOT PARAM SPEED HMI MOTOR C HMI MOTOR B MOT PARAM HMI MOTOR D HMI MOTOR TT HMI MOTOR TU s HMI MOTOR TU DP 2D HMI MOTOR TU a HMI MOTOR TU DP 2D MOT PARAM 2D HMI MOTOR TU m HMI MOTOR TU DP 2D HMI MOTOR 2D All the DFBs described here are provided with this document and are not locked As a result it is possible to open and analyze them using Unity Pro Schneider 98 Plant amp Ztruxure 5 Implementation 5 2 1 TeSys D Controller This section describes the MOT DIRECT DFB It controls a TeSys D contactor and a TeSys U Standard connected on a pre wired Advantys interface EPI2145 module Data Type MOT DIRECT Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool e Bool Bool Ext ClearFault Bool Input Switch Output Fwd Bool Bool Input Contactor Output Bwd Bool Bool Input CircBr
28. All AB COM Schneider ES Electric Plant amp truxure 3 Design 3 4 Software Design 3 4 1 Introduction Motor control applications require the design of objects dedicated to different devices using the following software e PAC application with Unity Pro e SCADA application with Vijeo Citect The main components of the architecture need to exchange data and data types during build in order to achieve a consistent application and to exchange data during run time in order to execute effective and complete process control 45 Electric Schneider j L 3 Design F Plant truxure Jl 3 4 2 Principle On PAC Application Unity Pro The management of each actuator is handled by Derived Function Blocks DFBs The cyclic exchanges between the PAC and the field devices are managed by IO Scanning On SCADA Application Vijeo Citect The HMI related to actuators is based on object oriented technology Genies and Super Genies The diagram below illustrates the data exchanges between the different components of the system Engineering Station Vijeo Citect Vijeo Citect Run time Build time Import Tags OFS OFS Using data dictionary Using data dictionary O m O x Z Joyjenjy Jojenjov e 46 Schneider Electric Plant truxure 3 Design 3 4 3 PAC Application DFB Design Introduction The exchanges between the PAC application and motor control devices are manage
29. C is no longer in the command circuit The Remote and Local positions of the lockable switch selector are transmitted to the PAC Indicator lights wired on the PAC or device outputs display Run Fault and Auto status on local panel Note To configure the I O of the starter PowerSuite for PC or Graphic pocket Pocket PC software are recommended Depending on the level of security required a wiring alternative is possible by using the Power Removal input on the variable speed drive see Paragraph 3 3 2 p 36 The picture below illustrates the several types of local commands found on the front panel 1 A Remote Off Local selector associated with an independent Run Stop selector 2 A Remote Off Local selector associated with Run Stop buttons integrated into the remote graphic display terminal LIFTING PUMP 1 LIFTING PUMP 2 o E DRY WEATHER DRY WEATHER NN DRY WEATHER LX M or man iita E wet ocu MEN R N gt b y d E b i rs 2 g u os LIFTING PUMP 1 RAIN WEATHER SCREENING MOTOR CONTROL VALVE 7 A 4 m E NN gt 1 io VN 5 I i BS E t e 43 Schneider Electric Plant amp Z truxure 3 Design The wiring of the ATV 61 is presented on the diagram below breaker and Command part contactor upstream of the upstream contactor 4a d w a KM x Re A Xy DR gu D TENTE T Fault Ae
30. Freq Threshold Hz 10 0 LI5 assignment Mot assigned Inactive LiB assignment Not esige ae F2D Frequency threshold2 Hz 50 0 ES LO ERE Na sexed Inactive _ F2DL 2 Frequency Threshold Hz 0 0 2 en Mrd Inactive _ TTD Motor thermal threshold 00 i 1 9 assignment Not assigned Inactive _ RTD High Freq Ref Threshold Hz 0 0 LIT assignment Not assigned Inactive _ RTDL Low Freq Ref Threshold Hz 0 0 E LITT assignment Nof assigned Inactive _ CTD Motor current detection A 12 3 L 72 assignment Mot assigned Inactive _ CTDL Low Current Threshold A 0 0 mnm Ld FLU Motor fluxina confiaure No Pre fluxina z Schneider d Electric Plant truxure 6 Operation Unity Pro Diagnostic Tool From Unity Pro some devices propose an advanced diagnostic tool The ATV 32 behind PRM Master DTM can be diagnosed directly from Unity Pro using PRM Diagnostic as described in the screenshot below J PRM_Master_Clarifier fdtDiagnosis TE 71 PRM Master Sch H neider i 1 Profibus Remote Master Configuration Tool Erz Electric PRM Master Diagnostic PRM Device Diagnostic Information gt PRM Advanced diagnostic PLC Connection Ident Number 0 0C95 Master Address Profibus Master gt Profibus Advanced Diagnosti Profibus Devices 510 Pci s Advanced Diagnostic gt I O Values Q 1010 PC1 Moti gt Advanced Diagnostic Invalid Slave Response gt I O Values Q 1110 PC1 Mot2 Not supported
31. How canl build a motor control application System Technical Guide Motor Control Management Develop your project o Disclaimer This document is not comprehensive for any systems using the given architecture and does not absolve users of their duty to uphold the safety requirements for the equipment used in their systems or compliance with both national or international safety laws and regulations Readers are considered to already know how to use the products described in this document This document does not replace any specific product documentation 2010 Schneider Electric All rights reserved Electric Schneider The STG Collection System Technical Guides STG are designed to help project engineers and Alliance System Integrators during the development of a project The STGs support users during the architecture selection and the project execution design configuration implementation and operation phases with an introduction to the system operating modes Each STG is a starter kit that provides users with e Technical documentation e Application examples e Object libraries Each STG addresses one or several customer challenges within the proposed solution using the offer from Schneider Electric All explanations and applications have been developed by both Schneider Electric experts and system integrators in our solution labs The contributions from the system integrators help the kit
32. INT Output Output Ctrl 2507 INT e Scbneider d Electric Mirror System Status Register 1 Mirror System Status Register 2 Mirror Logic Inputs Status Logic Ouput Status Control Register 106 Plant truxure 5 2 4 ATS 48 Soft Starter on Modbus Data Type String 20 Bool Bool Bool Bool Bool Bool ATS48 IO SCAN ATS48 IO SCAN IM MOT PARAM HMI MOTOR B 5 Implementation MOT ATS48 Data Type Bool Bool Bool Bool Bool Bool Bool Bool Bool Output Ctrl ATS48 IO SCAN O The communication with this device uses 7 input words 3 status words 4 measure words and 1 output word for the command directly accessed via IO Scanning through the TSX ETG100 Gateway Refer to chapter 4 2 5 on Page 76 for more details 458 INT Input Status 459 INT 460 INT 4062 INT 4063 INT Input Meas 4064 INT 4065 INT Output Output Ctrl 400 INT e Scbneider d Electric Status Register Status Register Extended Status Register Extended Motot current Motor torque Motor thermal state Phase rotation direction Control Register 107 Plant truxure 5 2 5 ATS 22 Soft Starter on Modbus ATS22 lO SCAN MOT PARAM HMI MOTOR B Input Status 5 Implementation Data Type MOT_ATS22 Data Type String 20 Bool Bool Boo Bool Boo Bool Bool Boo Bool Boo Bool a Bool Bool Ext_ClearFault Bool Bool Output Ctrl ATS22 IO SCAN O The communication with the ATS 22 uses
33. Premium I O Device Genies Pump vijen Cikeck TagPrefix Premium _ Starter L51 PMPD1 Type ATVEL Cancel Group Help Schneider ur Electric Plant amp truxure 5 Implementation In the Water project we have developed several pages for the representation of the whole process As an example the figure below presents the lifting unit page once every object has been instantiated x CS _Display_TitleQ G JT ES CS 65 s UserInfo 1 EEE Screening Vijeo Citect Js a3D pAnlInfo 2 2 rfe FE z Im r Time 1 Schneider i d Electric Plant amp Ztruxure 5 Implementation 116 Electric Schneider Plant truxure 6 Operation 6 Operation 6 1 Introduction In this chapter operations on process control motor control diagnostic and FDR devices maintenance are described 6 2 Process Control and Diagnosis The system architecture developed for this guide includes various control and diagnostic solutions The following interfaces are used for process control and diagnostic functions e The Vijeo Citect SCADA system which provides complete process monitoring and the ability to control it in Manual mode e The web diagnostic services which provide system diagnostics during the maintenance phases Products such as PAC ATV 61 Advantys STB and ETG100 gateway have an embedded web server with diagnostic pages that can be accessed from a standard
34. Quantum Note The Profibus library provided with the PRM must be installed before implementing this DFB PRM_MGT_P ENO SE IREG_FSTS VALID PRM Master Clarifier MSTR INFO MASTER INFO BUSY PRM Master Clarifier IN lMASTER STS ERROR RETRY STOP FSTSL PRM Master Clarifier FSTS To ensure that the PRM is ready to start the IO SCANNING REPORT REFRESH IO 9 IODDT bit associated with this device is used to activate the PRM MGT P DFB The MASTER INFO and MASTER STS inputs must be filled in to authorize the dialog between the PRM and the PAC MASTER INFO provides the communication path for the PRM In the case of a Premium PAC the XWAY path is specified This variable has been automatically generated during the PRM update performed in the IO Scanning Edit this DDT type variable to set the XWAY address configured in the previous step as the default one PRM Master Clarifier MSTR INFO T PRM INFO P Ae xw NW BYTE AWAY network A xw ST BYTE AWAY Station MASTER STS This input is connected to the PRM Master Clarifier IN variable This variable has been automatically generated during the PRM update performed in the IO Scanning Perform a Build All of the Unity Pro program and transfer it to the PAC Finally transfer the complete configuration in the PRM 15 From the DTM Browser right click on device PRM Master Clarifier and select Connect Schneider Electric 87 Plant amp truxure 4 C
35. S 22 e ATV 312 ATV 32 e TeSys T e TeSys D Starter Starter Note In the case of the ATV 32 we use a TeSys U to replace the contactor and circuit breaker Refer to the diagram on the next page for wiring details e 37 Schneider Electric Plant truxure 3 Design TH Diagram with TeSys U A TeSys U integrates a power switching function represented by KM_1 and KM_2 in the previous conventional diagram as well as protection functions short circuit protection thermal protection and so on The standard requires double power breakers contactor KM_A is mandatory Starter 1 Starter 2 TeSys U TeSys U e 38 Schneider Electric sy i An Plant amp Z truxure 3 Design HH Diagram with Variable Speed Drive ATV61 In the case of a requirement not exceeding level 3 in ISO 13849 1 a contactor between the GV and the starter is not necessary The power is shut down by the function Power Removal PWR directly wired on ATV 61 GV2 1 GV2 2 Starter 1 Starter 2 ATV61 ATV61 3 3 3 Motor Control Device Wiring Diagram This section provides a wiring diagram for the following starters e Direct On Line starting with starters TeSys U e progressive starting with soft starters ATS 48 e starting at variable speed with variable speed drive VSD ATV61 The proposed diagram re uses previously defined operation modes see chapter 3 2 Page 33 e 39 Schneider Electric Plant truxure 3 Design Direc
36. S1_PMPD1 Super Genie 2 Time managment 1 Daily Previous Day Working Time 6n4 mn onomn Nb Start E NN Delay to restart Om 0 s Time between start amp stop 5 5 A 53 Schneider Electric Plant amp Z truxure 3 Design Schneider Electric Plant Ztruxure 4 Configuration 4 Configuration 4 1 Introduction The aim of this chapter is to provide information for configuring the various components of the system PAC motor control devices and SCADA applications The main purpose is to build a consistent system configuration with the description of all data exchanged between key solution components The configuration of the system comprises the following stages e In our case the data exchanges between the PAC and the field devices require the configuration of the 2 following services configuration of the IO Scanning communication service configuration of the Faulty Device Replacement FDR service for the relevant devices The configuration of the FDR service is performed before the IO Scanning configuration because we want to first set up the device names and the associated IP addresses e Configuration of data and data types used both in PAC and SCADA applications A recommendation is provided to allow a unique configuration of data in both tools e 55 Schneider Electric Plant truxure 4 Configuration gt 4 2 PAC and Motor Control Device Configur
37. SB BYTE Speed setpoint i 110 Schneider d Electric Plant amp Ztruxure 5 Implementation xS 5 2 8 ATV 31 ATV 312 Variable Speed Drives on CANopen Data Type MOT ATV31 312 Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Bool Real Bool Bool Bool Bool Bool Bool Int 2 Output Ctrl Int Int 2 Output RPM Int MOT PARAM SPEED HMI MOTOR C The communication with these devices uses 2 input words and 2 output words These words correspond to the variables automatically generated during the configuration performed with Advantys associated with Unity Pro Refer to chapter 4 2 4 on Page 72 for more details DFB Pin CANopen register Type Description Input_Status 6041 INT Status Register Input_RPM 6044 INT Actual speed Output_ Ctrl 6040 INT Control Register Output_RPM 6042 INT Speed setpoint Schneider n d Electric Plant amp Ztruxure 5 Implementation 5 3 Unity Pro Program Structuring 5 3 1 Sections organization The Unity Pro program consists of several sections In Unity Pro the program can be represented in two ways e using a structural view directly related to the PAC application e using a functional view allowing greater readability of the process A good way to structure a program is by defining functional modules This method has multiple advantages the clarity of the program useful for maintenance or development and the ability to easily duplicate a process functional unit by e
38. TG100 18 is used to connect this device to the Ethernet network ATS 22 8 A Transparent Ready gateway ETG100 18 is used to connect this device to the Ethernet network ATV312 9 The CANopen extension of an Advantys STB provides a cost effective connection to ATV312 with a high level of diagnostics Note that the CANopen port is embedded on ATV312 ATV32 10 Profibus Remote Master 19 is used to connect this device to the Ethernet network TeSys U with a Standard Advanced and Multifunction control unit 11 In order to reach a high level of monitoring and metering these TeSys U are connected to Advantys STB extension bus TeSys U with a Standard control unit 12 A cost effective solution is illustrated here with a pre wired solution using the Advantys 2145 EPI module TeSys U with a Standard and Multifunction control unit 13 These TeSys U are connected to a Profibus DP network and linked to the Ethernet network via a Profibus Remote Master 19 TeSys T 14 It is directly connected to the Ethernet network All monitoring functions and controls are allowed An embedded web server can be used for maintenance TeSys D 15 The selected solution is wired directly to the Advantys STB I O module or to the TeSys T 14 This architecture combines various motor control device solutions that are detailed in the following chapters A 31 Schneider Electric Plant amp Z truxure 2 Selection 32 Electric Schneider
39. TI2 MWw1152 EE LCR MW1153 4088 LTR MITTS n THR MW1155 EL M PHE MW1156 Outputdata 400 CMD MW1380 10_L81_0_PmpR1 Refer to the ATS 48 documentation for a description of the Modbus registers Schneider 2 ES Electric Plant tr uxure E 4 Configuration 4 2 6 ATS 22 Configuration As with the ATS 48 the ATS 22 is also connected to the Ethernet network through the ETG100 gateway Communication is transparent between the Ethernet network and Modbus Serial line Therefore the IO Scanning service directly accesses the ATS 22 The Unit ID identifies the slave address of the device on Modbus Serial In the following example of the ATS 22 10 status and measure registers are read and one command register is written Unlike the ATS48 the status and measure registers of the ATS 22 are ina contiguous area Thus a single line of IO Scanning is necessary Note All the ATS 22 registers are described in the ATS 22 Modbus user manual Health Repetitive RD WR Glave a ED Ref RO Last value wR IP address Device Mame Unit ID Timeout Master Master Sgntaz ms ms Object Slave length input Object length AWO 256 10 Note The IP address 172 20 1 15 set in the field IP address is the address of the ETG100 Modbus Serial Ethernet gateway The value 2 in the Unit ID field corresponds to the Modbus address configured in the ATS 22 The DDT variables used to communicate wi
40. V 61 drive of the lifting unit is shown below 4 PowerSuite ATV61 Lf1PmpD1 EIER Eile Display Configuration Tools Be BORE Ur EBS Display Setting parameters FRH Freq ref before ramp Hz 29 0 INRA Ramp increment tenths of seconds v RFR Output frequency Hz 230 ACC Acceleration ramp time sec 3 0 ULN Line mains voltage V 4198 ar 4l Ich Malorcurent A 03 DEC Deceleration ramp time sec 30 4 SPD Motor speed rpm 870 LSP Low speed Hz 5 0 E UOP Motor voltage Y 112 HSP High Speed Hz 150 0 P Aaa lereni se ITH Motor thermal current A 20 OTRA Motor torque A 39 IPHR Consumption kwh 154 SFC K speed loop fiter pb 4d TH8 BukeB fhemalsiale X 9 SPG Speed proportional gan a 8 THD Drive thermal state 83 SIT Speed time integral o o 4 a nee Er SDCI AutoDCinjectionlevell A he 4 RTH Motor run time h 2819 PIH Powerbn Bme h 13413 TDC1 Auto DC injection time 1 sec 0 5 E PET Process Operation Time h 2819 SDC2 Auto DE injection level2 A 11 1 TAC IGBT alarm counter sec D xi TDC2 Auto DC injection time 2 sec bo o a x SFR Drive switching freq kHz a0 a Inputs Outputs CLI Internal current limit A 127 gt removal TLS Low speed time out sec oo o o a LIT assignment Forward direction select Inactive _ SLP Slip Compensation x 100 amp LI2 assignment Reference 2 switching Forced local mode inactive _ UFR IH comperunon x fino a IR Nat assigned nes FTD Motor freq threshold Hz oo g ne ee mess FTDL Low
41. ab in the network configuration Property Device Type Device Name Data Exchange Required Input words l Output words E Launch Advantys DK Configuration Software Note The Device Name is used as a prefix to compose the variable names related to this island Click on the button Launch Advantys Configuration Software to run the Advantys software The Advantys software opens a blank configuration project named IO_LS1_ The island has to be configured at this stage with the I O modules either by selecting by hand the modules in odbc a T d u a EM the catalog or by uploading the configuration Refer to the Advantys software documentation for the different island configuration methods The Lifting and Screening Advantys island configuration is presented in the figure below DDO 3600 O 3600 cee maaan 00000 una 00000 17127 E mm A 93000 gt j DRA 3290 gt HHH DDO 3410 t t E E Gm m m mm m mm Once the configuration is done close Advantys software and return to Unity Pro 66 Schneider Plant truxure 4 Configuration 12 A dialog opens and proposes to update the symbols linked to this island lO Scanning Click on Yes to start the update Read and write reference registers of the island are automatically filled 5391 for the read register and O for the write register These values cannot be modified and are grayed FO Ref FAO Last
42. an Ethernet network Faulty Device Replacement FDR measurement of the time needed by the device to recover an operational state Schneider Electric Plant Ptruxure 1 Introduction 1 5 Project Description A process application has been developed to illustrate all explanations provided in this guide It corresponds to the pre treatment steps of a wastewater station which is separated into 4 units e lifting e screening e grease amp sand removal e primary clarifier Lifting Screening Grease amp sand removal Primary clarifier Schneider Electric Plant Ptruxure 1 Introduction The system architecture developed presented in the diagram below is based on a PlantStruxure control system with a centralized Premium PAC and a Vijeo Citect SCADA system The complete description of the architecture is given in chapter 2 5 3 on Page 30 Vijeo Citect Client FactoryCast HMI E p 7 amp S Internet via GPRS 3G ADSL Vii u ijeo Citect Vijeo Citect Engineering Web Client PN 11 Electric Schneider PlantPtruxure 1 Introduction Electric Schneider Plant f truxure l 2 Selection i 2 Selection Phase 2 1 Introduction This chapter presents the various steps required to select the most appropriate starter components as well as the automation architecture that performs the control 2 2 Selection Principle Each process contr
43. an be added to the power base The product can therefore be customized at the last moment i T Y n o Schneider Electric 18 Plant truxure 2 Selection TeSys T Motor Management System The capabilities of an over current relay are limited when problems associated with voltage temperature or special applications must be taken into account The TeSys T provides complete management of the motor and its load It incorporates these functions e Current and voltage sensors e Hybrid analog and digital electronic technology e Several communication buses available for data exchange and control e Powerful motor modeling algorithms e Application programs whose parameters can be set e 19 Schneider Electric Plant truxure 2 Selection 2 3 4 Soft Starter A soft start soft stop unit is a controller that is used for the torque controlled soft starting and stopping of three phase squirrel cage asynchronous motors It offers soft starting and deceleration capabilities along with machine and motor protection and functions for communicating with control systems These functions are specially designed for use in applications such as pumps fans and conveyors that are primarily used in Water and MMM industries ATS 22 Soft Starter This unit has a power range between 4 and 400kW It is designed to operate in standard applications The bypass function based on a bypass contactor is more convenient to use thanks to its
44. ation This chapter describes the configuration of the FDR and IO Scanning services 4 2 1 FDR Service Principle This service is based on identification of the device by a Device name Each Device name must be unique over the Ethernet network The FDR server controls duplication of Device names and does not assign an IP address that has already been assigned and is active The new device FDR client retrieves e its IP address and the FDR file path from a DHCP server e the FDR file from an FTP server if the device is not configured in local configuration Note The DHCP server and the FTP server are the same device TSX Premium or Quantum PAC The FDR file contains the Ethernet parameters configuration of IO Scanning FDR and so on and the device parameters 3 configuration steps are required prior to becoming operational e device name definition e clients field devices configuration e server PAC configuration Device name definition The device name allocations depend on the device configuration methods e rotary switches e graphic display terminal e Web server e PowerSuite tool In our architecture 5 types of devices handle the FDR service e ATV61 variable speed drive e Distributed I Os modules Advantys STB NIP 2311 e TeSys T controller e Profibus Remote Master PRM gateway module e FactoryCast Gateway ETG3021 e 56 Schneider Electric Plant f truxure
45. ation System Design Introduction During the SCADA application build Vijeo Citect objects have to be defined as well as the data and data type associated The following recommendations are provided to facilitate design readability and re use e Exchanges are mainly performed via DDT variables Derived Data Type e OFS server OPC Factory Server allows use of Unity Pro structured variables in unlocated format SCADA System Objects The application is based on Genie and Super Genie objects Genie and Super Genie are useful when there are many devices of the same type They can be re used many times without re configuring them for each device Once the common information is configured the device specific information is passed to the Genie and Super Genie at runtime Genies and Super Genies can be created in an another project and then re used easily by a new Vijeo Citect project using the function Included Projects e 52 Schneider Electric Plant truxure 3 Design SCADA System Example Genie and Super Genie objects are associated to each type of starter element A Genie represents a simple object such as the Ls1PmpD1 pump in the next figure A Super Genie is a dynamic page able to exchange tags related to the object it has been called from Generally a Super Genie is attached to a Genie Ls1PmpD1 Genie uM LS1 PMPD1 Control Speed Setpoint Auto Running Remote Super Genie 1 o L
46. bles the access to other variables is performed by explicit data exchanges VO SCANNING INPUT Input Status Starter status input Feedback signal from I O Scanning I O SCANNING OUTPUT Output Ctrl Starter control output Sent to the starter via I O Scanning Schneider d Electric Plant truxure ES 3 Design Parameters Assignment The input data type is a Derived Data Type DDT containing at least the following parameters Max time between the order and the order s feedback If max time is reached a discrepancy error is generated Nb_Start Day Number of starts authorized per 24 hours Min time Stop Minimum time between stop and restart These DFB input parameters are adjusted during the start up of the installation by assigning constant values to the variables In our case some of these parameters are sent to HMI or SCADA as read only As these parameters are not defined as constants they are not saved in the PAC memory All modifications applied to these parameters during operation are loston a cold start To overcome this loss the following procedure can be applied to save the current parameter values as initial values on a PAC cold start Action Using Unity Pro validate the save attribute of all device parameter variables 2 Adjust device parameter values using Unity Pro Using Unity Pro in the connected mode set the system bit S94 to 1 Initial values of all variables with th
47. catching of a spinning load with speed detection e adaptation of current limiting according to speed Electric e 22 Schneider Plant truxure 2 Selection e noise and resonance suppression due to the ability to adjust the switching frequency during operation preset speeds e integrated PID regulator with preset PID references and automatic manual Auto Man mode e electricity and service hours meter e fluid absence detection zero flow and limited flow detection e sleep function wake up function e customer settings with display of physical measurements bar I s C and so on Note The ATV 61 has been chosen here for its compatibility with pumping applications but ATV 71 can also be used without any modification of the application e 23 Schneider Electric Plant truxure 2 Selection 2 4 Selecting Motor Control Devices 2 4 1 Selecting devices The starter mode is closely linked to the load carried by the motor The following table presents several typical examples in process control applications such as water Direct on Soft VSD line starter of volume and pressure conditions Centrifugal pump Quadratic The flow can be controlled by using valves on the pump discharge manifold or by changing the 10 kW to 1MW e Q rotation speed treatment or cement production Type of Description comment Power range Torque actuator Centrifugal pumps are used to cover a wide range
48. cceleration and deceleration ramps Bypass by contactor at starting end Brake sequence Automatic catching a spinning load speed detection and automatic restart Energy saving ratio 2 point or 5 point quadratic ratio Noise and resonance suppression by switching frequency Electricity and service hours meter Detection of absence of fluid detection of zero flow rate limiting flow rate Sleep function wake up function Customer settings with display of physical values bar I s C etc Safety function integrated power removal SIL2 PI regulator and reference Fault statistics counters and history per type of protection Motor statistics storage of motor statistics values Diagnosis of faults affecting correct operation of the product Download and save configuration Schneider 2 Selection Motor management ATV 61 GUNT ATS 48 ATS 22 ATV 312 ATV 7A ATV 32 TeSys T By Upstream Circuit Breaker 27 Plant truxure 2 Selection 2 5 Selecting Architecture 2 5 1 Introduction The selection of starter mode and motor control device type was defined in the previous two steps It is now time to build the final architecture that allows all motor control devices to be connected to the PAC and SCADA system As described above the choice of architecture depends on the requested level of monitoring metering and diagnostics and also depends on the compatibility required with the other parts of the system It ha
49. ch on 1 Schneider Electric 58 Plant amp truxure 4 Configuration TeSys T controller The format of the Device name is TeSysTxxx where xxx is defined by the value of the rotary switches located on the front panel of the TeSys T Clear IP 1 o 15 1 9 Disabled Tens Ones e To set the Device name to TeSysT001 set the Tens switch on 0 and the Ones switch on 1 Then the PowerSuite software is used to configure the FDR service e From Settings Communication and HMI in Configuration Mode area select Configuration via Network port Faulty Device Replacement Enabled and Auto Backup automatic periodic backup of the FDR configuration file to the FDR server as described in the figure below Configuration Mode Configuration via Network port Local Configuration Faulty Device Replacement Enabled Auto Backup Auto Backup Period 120 Seconds Note By default the Configuration via Network port and Faulty Device Replacement Enabled parameters are selected allowing a replacement of the device without using PowerSuite software ATV 61 variable speed drive For the ATV 61 the Device name is set using the graphic display terminal Power Suite software can also be used but in that case a connection to the device is required The first wastewater lifting pump is used here as an example From the graphic display terminal access to the Ethernet menus as described in the
50. d using DFBs A single DFB is used for each type of starter and type of network interface It handles the management of e starter name e operating modes Local buttons e link between the sequences and the process status Process control sequence e interface with the starter I O Status and Control e adjustment of parameters Param e human machine interface HMI interface e status feedback DFB Structure The general structure of the proposed DFB interface is described below In order to have consistent interfaces the same general structure is applied to all device DFBs gt Starter Name FbManual Local Buttons FbLocal FbOff gt Status Feedabck gt ARun Process control Lock FbRun Sequence Ext Er Locked Ext ClearFault Ready 7 Error Control I O Parameters Assignment 2 2 gt Status and 2 HMI interface Note The detail of the parameters described below represents the general structure of the DFBs common for all starters Depending on the starter the groups may contain additional parameters speed setpoint forward backward control and so on Schneider M d Electric Plant amp Z truxure 3 Design Starter Name This input pin specifies the starter name used by the SCADA HMI Name of the starter directly used by SCADA HMI Local Buttons Operating mode selection between Remote Off Local selector switch
51. ding to the User Defined Label defined in steps 4 amp 5 The variables created by Unity Pro are summarized in the table below m Type Y Address Y Comment lO LS1 Mot3Status INT MW1030 IO LS1 R1 S13 TeSys U Sc Mu R Status Register 455 IO LS1 Mot3Ready BOOL MW10300 IO LS1 R1 S13 TeSys U Sc Mu R Ready Status Register 455 IO LS1 I Mot3Tripped MW1030 4 lO LS1 R1 513 TeSys U Sc Mu R_Tnpped Status Register 455 IO LS1 Mot3Status1 MW1031 IO LS1 R1 S13 TeSys U Sc Mu R_l O Module Status Register 458 IO LS1 Mot3Status2 MW1032 IO LS1 R1 S13 TeSys U Sc Mu R_Waming Register 461 lO LS1 Mot3Status3 MW 1033 IO LS1 R1 S513 TeSys U Sc Mu R_Mechanical and Power Supply Status Register 457 IO LS1 Mot3PKW1 MW 1034 IO LS1 R1 S13 TeSys U Sc Mu R_PKW Response Object PKW Service IO LS1 Mot3PKW1 WD2 MW1035 IO_LS1__R1_S13_TeSys U Sc Mu R_PKW Response Object PKW Service IO LS1 Mot3PKW2 MW1036 IO LS1 R1 S13 TeSys U Sc Mu R_PKW Response Data PKW Service IO LS1 Mot3PKW2 WD2 MW1037 IO LS1 R1 S13 TeSys U Sc Mu R_PKW Response Data PKW Service IO LS1 Mot3Ctle0 MW1318 IO LS1 R1 S13 TeSys U Sc Mu R Control of the System 704 O_LS1_Mot3Ctle1 MW1319 10_LS1_R1_S13_TeSys U Sc Mu R_Control of Communication Module 703 O_LS1_Mot3Ctle2 MW1320 IO LS1 R1 S13 TeSys U Sc Mu R Output Control 700 O_LS1_O_Mot3PKW1 MW1321 10_LS1__R1_S13_T
52. dvanced TeSys U Advanced on Advantys extension bus Data Type MOT_TESYSU_a Data Type String 20 FbAuto Bool Bool FbManual Bool Bool FbLocal Bool FbOff Bool Bool Bool Bool Bool Bool Bool Bool M Bool Bool Ext ClearFault i Bool Int Input StatusO Output Ctrl Int Int Input Status1 Output Ctrl1 Int Int Output_Ctrl2 Int MOT_PARAM_2D HMI_MOTOR_TU_a The communication with this device uses 3 input words and 3 output words These words correspond to the variables automatically generated during the configuration performed with Advantys associated with Unity Pro Refer to chapter 4 2 3 on Page 65 for more details Input StatusO 455 INT Switch Status Input Status1 458 INT I O Module Status Input Status2 461 INT Warning Status Output CtrlO 704 INT Control of the system Output Ctrl1 703 INT Control of communication module Output Ctrl2 700 INT Output Control lt 102 Schneider d Electric Plant truxure ARRAY 0 7 OF BYTE MOT_PARAM_2D HMI_MOTOR_TU_DP_2D String 20 Bool Bool Bool Bool Bool Bool Bool ER TeSys U Advanced on Profibus DP Data Type MOT TESYSU a Pfb 5 Implementation Data Type Bool Bool Bool Bool Bool Bool Bool Bool Bool Int ARRAY 0 3 OF BYTE The communication with this device uses 8 input bytes and 4 output bytes These bytes correspond to the variables automatically generated during the PRM configuration performed with Unity Pro Refer to chapter 4 2 3 on Page 65
53. e save attribute are replaced by their current values Save the application Note On a M340 it is necessary to set the system bit S66 to 1 or to transfer the RAM application to the memory card Schneider d Electric Plant truxure 3 Design HMI Interface The input data type is a Derived Data Type DDT containing at least the following variables These variables are exchanged between the PAC and SCADA HMI Aut Man 7 Set the block in Automatic true or Manual false mode Run_Stop Run true or stop false the actuator Clear Fault Acknowledge errors indicated at the output Error Nb Start Number of starts performed in the last 24 hours Time BStartStop Time seconds between start and stop of the actuator Max time between the order and the order s feedback If max time is reached a discrepancy error is generated Time to Start s Time seconds before the next start Time to Start m Time minutes before the next start Sts Status structure Automatic mode is activated The process sequence manages the actuator Manual mode is activated SCADA HMI manages the actuator Local mode is activated Hardwired selector switches manage the actuator Off mode is activated The starter power is cut off Starter ready to start Starter is running Starter in warning Starter in error Starter is locked by an interlock Lock input Starts number monitoring is activated and the max starts numbe
54. eSys U Sc Mu R_PKW Request Object PKW Service IO LS1 O Mot3PKW1 WD2 MW1322 IO LS1 R1 S13 TeSys U Sc Mu R_PKW Request Object PKW Service O_LS1_O_Mot3PKW2 MW1323 10_LS1__R1_S13_TeSys U Sc Mu R_PKW Request Data PKW Service IO LS1 O Mot3PKW2 WD2 MW1324 lO LS1 R1 S13 TeSys U Sc Mu R_PKW Request Data PKW Service Note All the variable names begin with the prefix IO LS1 corresponding to the Device name defined during IO Scanning configuration Unity Pro only generates a variable if a User Defined Label has been defined in Advantys The following table summarizes the mapping automatically created in Unity Pro for this Multifunction TeSys U connected on an Advantys STB island extension bus Item Status 455 Status 458 Status 461 Status 457 PKW Service PKW Service Control 704 Control 703 Control 700 PKW Service PKW Service 7 Schneider Plant truxure 4 Configuration 4 2 4 ATV 312 configuration The ATV 312 variable speed drive is integrated in the Advantys system using an STB XBE 2100 CANopen Extension Advantys module The configuration of motor starter used behind an Advantys STB is performed in two steps 1 The communication between the Advantys STB island and the PAC is configured in IO Scanning 2 The data of the selected motor starter is identified inside the Advantys STB Island IO Scanning configuratio
55. eak Bool Input FwdEcho Bool Input BwdEcho MOT PARAM 2D Param HMI MOTOR 2D HMI The communication with the device is performed with 6 digital inputs and 2 digital outputs directly accessed from the I O modules of an Advantys STB via IO Scanning Type Description 2 Input_Switch BOOL Switch Status Input_Contactor BOOL Contactor Status Input_CircBreak BOOL Circuit Breaker Status Input_FwdEcho BOOL Forward Feedback Input_BwdEcho BOOL Backward Feedback Output Fwd BOOL Command in Forward direction Output Output Bwd BOOL Command in Backward direction M 99 Scbneider d Electric Plant truxure 5 2 2 TeSys U controller 5 Implementation This section describes the DFBs for 3 instances of TeSys U Standard Advanced and Multifunction used with e Advantys extension bus communication modules e Profibus DP communication modules TeSys U Standard TeSys U Standard on Advantys extension bus Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Int Int MOT PARAM 2D HMI MOTOR TU s MOT TESYSU s Data Type Ext Err Ext ClearFault Input StatusO Input Status1 Bool Bool Bool Bool Bool Bool Bool Bool Bool Int Output Ctrl4 Int Output Ctrl2 Int HMI The communication with this device uses 2 input words and 3 output words These words correspond to the variables automatically generated during the configuration performed with Advantys associated with
56. ections offered by the motor control devices D O L starter Soft Starter Variable Speed Drive VSD Motor management system Motor circuit breaker Starter controller E TeSys U Contactor Dorf Standard Multifunction ATV 312 Hard wired Modbus SL CANopen Profibus DP Ethernet Modbus TCP Type of links EtherNet IP Advantys Pre wiring EPI2145 Advantys Internal bus Advantys CANopen On any TeSys U Ethernet connectivity can be provided using an additional TeSysPort module e Faulty Device Replacement FDR service The FDR service allows automatic configuration of the replacement device s IP address and parameter settings It makes the maintenance of devices connected on the Ethernet network easier The FDR service eliminates the need for service personnel to keep configuration records on hand and reduces the possibility of human error when entering a new configuration Schneider d Electric Plant truxure 2 Selection 2 5 3 Architecture Example The architecture example is based on a PlantStruxure control system with a centralized Premium PAC 1 a standalone Vijeo Citect SCADA system 2 and a Vijeo Citect Web Client SCADA System 3 A Magelis HMI XBT GT 4 is used for local control and monitoring this STG does not describe the implementation of this equipment Note Remote control rooms are not described in this STG Vijeo Citect Client FactoryCast HMI
57. efore the IO Scanning service directly accesses the ATS 48 data The Unit ID identifies the slave address of the device on the Modbus Serial line In the following example three status registers and four measure registers are read and one command register is written Because the status and measure registers are not in a continuous area two IO Scanning lines are required to configure the input data Note All the ATS 48 registers are described in the ATS 48 Modbus user manual Health Repetitive RD WR Timeout rate Master dim Ref T p inis Master ps Hef sit ms ms Object D ER Input Object ave eng 3 72 201115 1500 300 en 458 Set too eMwiseo 400 d Slave Unit ID Santar IP address Device Name i O MEME 1800 M E D sais 4062 siesta ste we Seien Om sonia ien co BEINEN Imnnununsnunnnunenanununsnunnnununnnunnn o RAAE EHE Note The IP address 172 20 1 15 set in the field IP address is the address of the ETG100 Modbus Serial Ethernet gateway The value 1 in the Unit ID field corresponds to the Modbus address configured in the ATS 48 The DDT variables used to communicate with the ATS 48 are presented in the table below Unlike for the TeSys U these variables have to be manually created in Unity Pro 00 ATS48 UNTYPRO Register Item Located address Variable DDT 00 ETA MW1150 000 049 00 ET MWST Ss E
58. elow Device Advantys STB NIP 2311 Lifting amp Screening Unit TeSys T Air Compressor Grease and Sand Unit ATV61 Pump 1 lifting wastewater tank ATV61 Pump 2 lifting wastewater tank ATV61 Pump 3 lifting wastewater tank PRM Primary Clarifier Unit ETG3021 wastewater station Open the project Water from Unity Pro and click on the Address Server tab from the Network Configuration window Type the previously defined Device names in the field Name and add the corresponding IP address Netmask and Gateway The screenshot below illustrates the procedure IP Configuration Messaging 10 Scanning Giobai Dats suve Address Server Bond r HTTF modification E Locked in operation Password rm Client l Serer address tabla mmm i r r 5 5 5 E MAC address IP address 3 EL ooo SIBNIP23H 0 a 255288000 0000 I mM STEMIP23n 021 fr220121 2682505800 0000 5 5 l MEE Te amp ysT OD i 220126 255 255 0 0 i 0000 fa MEM ATY PmpDi W220 7 25525500 5 0 2201 Bee ATWELL PmpD2 7 22015 1 255 255 0 0 i 220 116 I BENED ATW amp PmpD3 220152 i 25525500 i 220186 585 E d TCSEGPAZIFMFOO 220122 57 255 26500 i 0000 5 7 XN 1 ETG3021 WATER 17220116 5 25528500 i 0000 TE ee ee Nele ee s For the PRM of the Primary Clarifier unit the configuration of the IP address and De
59. essausessaesessesesaeeess Schneider Electric Plant truxure 1 Introduction 1 Introduction 1 1 Purpose The aim of this System Technical Guide STG is to provide recommendations guidelines and examples to help you integrate and manage motor control applications within PlantStruxure architecture Each process control project has specific requirements and constraints that influence the development of motor control solutions 1 2 Customer Challenges For customers in industries that require motor control solutions the challenges are to observe the Project specifications size of the plant process complexity level of monitoring metering and diagnosis and so on Functional constraints the process characteristics impose constraints in terms of power load types and power supplies Operational constraints plant productivity process quality design costs operational costs This guide suggests best practices to address these challenges and highlights specific areas including Mixed solutions for motor control devices The guide presents control solutions from the simplest to the most advanced to describe various monitoring and diagnostic capabilities Communication consistency in the global system The guide provides a solution that fits the requirements of the automation system control and start monitoring loads and management consumption operating time preventive maintenance Sub a
60. f communication module Output Control 104 Plant truxure 5 Implementation Emm TeSys U Multifunction on Profibus DP Data Type MOT TESYSU m Pfb Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool Bool ARRAY 0 7 OF BYTE MOT PARAM 2D HMI MOTOR TU DP 2D ARRAY 0 3 OF BYTE The communication with this device uses 8 input bytes and 4 output bytes These bytes correspond to the variables automatically generated during the PRM configuration performed with Unity Pro Refer to chapter 4 2 3 on Page 65 for more details Output Output Ctrl 256 INT 257 INT 258 INT 259 INT 260 INT Input Status 261 INT 262 INT 263 INT 264 INT 265 INT 752 INT e Scbneider d Electric Status Register Phase 1 current Phase 2 current Phase 3 current Voltage Logic Inputs status Logic output relays status Frequency Control Register 105 Plant amp Z truxure 5 2 3 TeSys T Controller on Ethernet Data Type String 20 Bool Bool Bool Bool Bool Bool ARRAYT 0 3 OF INT MOT PARAM 2D HMI MOTOR TT 5 Implementation MOT TESYST Eth Data Type Ext ClearFault Input Status Bool Bool Bool Bool Bool Bool Bool Bool Bool Int Int The communication with this device uses 4 input words and 1 output words They are directly accessed via IO Scanning 2502 INT 2503 INT Input Status 2504 INT 2505
61. for more details Input Status Output Ctrl 455 LSB BYTE 455 MSB BYTE 457 LSB BYTE 457 MSB BYTE 458 LSB BYTE 458 MSB BYTE Reserved BYTE Reserved BYTE 704 LSB BYTE 704 MSB BYTE 700 LSB BYTE 700 MSB BYTE e Scbneider d Electric Switch Status Switch Status Mechanical and power status Mechanical and power status I O Module Status I O Module Status Control of the system Control of the system Output Control Output Control 103 Plant truxure TeSys U Multifunction 5 Implementation TeSys U Multifunction on Advantys extension bus Data Type String 20 Bool Bool Bool Bool Bool Bool Bool Int Int Int Int MOT_PARAM_2D HMI MOTOR TU m MOT TESYSU m Data Type Ext ClearFault Input StatusO Input Status1 Input Status2 Input Status3 Bool Bool Bool Bool Bool Bool Bool Bool Bool Int Int Int The communication with this device uses 4 input words and 3 output words These words correspond to the variables automatically generated during the configuration performed with Advantys associated with Unity Pro Refer to chapter 4 2 3 on Page 65 for more details Input StatusO Input Status1 Input Status2 Input Status3 Output CtrlO Output Ctrl1 Output Ctrl2 455 INT 458 INT 461 INT 457 INT 704 INT 703 INT 700 INT e Schneider d Electric Switch Status O Module Status Warning Status Mechanical and power status Control of the system Control o
62. he following solutions e Direct on line DOL starter e Progressive start up with soft starters e Start up at variable speed with variable speed drive VSD The step for selecting and dimensioning the power part of the starter is not developed in this document Readers can refer to specific guides and Schneider Electric catalogs e 16 Schneider Electric Plant truxure 2 Selection 2 3 3 Direct On Line Starter TeSys D with circuit breaker This solution comprises a magneto thermal breaker and a TeSys D that covers a power range of up to 110 kW It provides the following basic functions e Protection against short circuit e Protection against overload e On Off switch e 17 Schneider Electric Plant truxure 2 Selection TeSys U Starter Controller This is an integrated Direct On Line starter up to 15 kW which performs the following functions e Protection and control of single phase or 3 phase motors breaker function overload and short circuit protection thermal overload protection and power switching e Monitoring protection function alarms application monitoring running time number of detected faults motor current values and so on logs last 5 detected faults saved with motor parameter values These functions can be added by selecting control units and function modules which simply clip into the power base Several communication modules are also available as an option and c
63. hernet ATS 48 Modbus via ETG100 TeSys U on Advantys STB island via EPI2145 TeSys U on Advantys STB extension bus TeSys U Profibus DP via PRM Profibus DP parameters Profibus BaudRate 1500 kbit s Profibus Cycle 8ms Electric Schneider Plant truxure 7 Performance 7 2 Faulty Device Replacement FDR These results are the measurement of the time needed by the device to recover an operational state To measure this time accurately the device is disconnected from the Ethernet network While the device is offline a configuration parameter is changed on the device When the device is connected back on the Ethernet network the FDR server sends the operational configuration to the device and sets all the parameters to their runtime values The monitoring of the parameter that has been modified offline allows detecting when the device recovers an operational state when the parameter turns back to its runtime value the device is declared operational Thus the recovery time is defined by the time needed by the device to get back to an operational state The following table summarizes the recovery times measured in our architecture ATV 61 Ethernet Schneider lini Electric Schneider Electric Industries SAS Head Office 89 bd Franklin Roosvelt 92506 Rueil Malmaison Cedex FRANCE www schneider electric com Due to evolution of standards and equipment characteristics indicated in texts and
64. images in this document are binding only after confirmation by our departments Print Version 2 0 07 2010
65. integration into the starter The integrated contactor operates at the end of the startup Sequence and deactivates once the stop command has been given to limit the starter s heat dissipation This also leads to significant wiring reduction This unit also features thermal protection for motors as well as a monitoring facility for machines Note Contactor and circuit breaker can be replaced by a TeSys U 20 Schneider Electric Plant truxure 2 Selection ATS 48 Soft Starter This unit has a power range between 4 and 1200 kW It is designed to operate in severe applications This unit also features thermal protection for motors as well as a monitoring facility for machines A contactor and circuit breaker can be replaced by a TeSys U controller associated with a specific module for a soft starter or variable speed drive Note In the above figure an external contactor is used to perform the bypass function of the ATS 48 21 Schneider Electric Plant truxure 2 Selection 2 3 5 Variable Speed Drive Starter ATV 312 Variable Speed Drive The Altivar 312 drive is a frequency inverter for 200 to 600 V three phase asynchronous motors from 0 18 to 15 kW The Altivar 312 is robust compact and easy to use Its integrated functions are particularly suitable for the requirements of applications involving simple industrial machines Modbus and CANopen protocols are integrated as standard ATV 32 Variable
66. iodic communication To define the IO Scanning service configuration in Unity Pro it is necessary to identify the data exchanged with each motor control device These data will be used by dedicated DFB see DFB list chapter 5 2 P 98 In the selected architecture described in chapter 2 5 3 P 30 4 types of communication are used The different characteristics in IO Scanning parameters are e Motor control devices connected on Advantys STB on Ethernet TeSys U TeSys D and ATV 312 e Motor control devices connected on Profibus DP with a PRM TeSys U TeSys D and ATV 32 e Motor control devices connected behind an Ethernet gateway to Modbus serial line Soft starter ATS 48 or ATS 22 e Motor control devices connected directly on the Ethernet network ATV 61 and TeSys T PA I O Scanning I O Scanning Ethernet Profibus DP mti STB Bus Extension I IR TeSys T fiel AG EPI2145 eu 5 EEE TeSys D TeSys dc 64 Electric Schneider Plant amp truxure 4 Configuration 4 2 3 TeSys U configuration In this case the TeSys U is connected to the Ethernet network through an Advantys STB island The connection can be done either using a pre wiring solution module Advantys STB EPI2145 or an Advantys extension bus communicator The configuration of motor starter used behind an Advantys STB requires two steps 1 The communication between the Advantys STB island a
67. low Yi PRM Master Clarifier fdtOfflineParameterize Sie PRM Master Schneider L i Profibus Remote Master Configuration Tool d Electric PRM Master Configuration my General Settings Profibus Master Configuration Basic Settings gt Advanced Settings amp IO Scanning IO PC1 Pmp1 Schneider Electric ATV32 from 1 05 3 126 IO PC1 Pmpi gt DPV1Settings gt Profibus Settings o Assign Station Addresses to Devices Address 0 126 12 Assign Address Directly Applied to the selected device OK Cancel Help Select the ATV 32 and assign a new address 12 in our case Note This address must be identical to the one configured on the ATV 32 Click on OK to finish On the ATV 32 device equipped with a Profibus DP communicator configure the Profibus DP address as follows Menu CONF FULL gt COM gt Cbd AddrC and set the address to 12 as defined in the PRM configuration Note This menu can be used only if the Profibus DP communicator is plugged The PRM Master and ATV 32 slave are now configured Schneider ES Electric Plant amp truxure 4 Configuration Add the PRM in the IO Scanning We can now start the IO Scanning configuration From the Ethernet network configuration window click on IO Scanning tab On a new IO Scanning line click on the button in the Device Name field to open the Property window Note The Device Type DTM is automatically selected in the Property
68. mgpD1 Ha FbAuto p O LS1 O PmpD1 AutaLight IO LS1 PmpD1Local FbManual IO LS1 I PmpD1Remote j FbLocal lur IMF L51 PmpD1 Day mn LS1 PmpD1 Speed IMF LS1 PmpD1 Day h Lock L 81 PmpD1 IO L81 EmergencyStop HMI GLOBAL CLEAR FLT IMF LS1 PmpD1 Prev day mn IMF LS1 PmpD1 Prev day h IMF LS1 PmpD1 Tatal mn IMF LS1 PmpD1 Tatal h IG LS51 I PmpDH Fhb Stat Output Ctril O LS1 O PmpD1 G Ctrl IO LS81 I PmpD1 Fb RPM _ RP Output RPM O LS1 O PmpD1 Q RPM IO LS1 I PmpD1 Measure Par L S81 PmpD1 HMI LS1 PmgpD1 All the DFBs are instantiated the same way For more details refer to the Unity Pro Water project provided with this guide Schneider He d Electric Plant amp Ztruxure 5 Implementation 5 4 SCADA Implementation 5 4 1 SCADA Principle Genie and Super Genie objects are defined to control and monitor the motor control process For each type of graphical object pump motor and so on a Genie is created This Genie can be copied from a Genie dialog box and added to the graphical page When the Genie is pasted in the graphical page a pop up window is activated to substitute the tags used in the Genie and Super Genie Each Super Genie is associated to a Cicode function This function e substitutes tags in the Super Genie e opens the associated Super Genie For example the screenshot below describes the instantiation of a Genie for the pump LS1_PMPD1 controlled by the ATV 61 The ATV 61 is piloted by the
69. n The Grease amp Sand Removal Advantys STB island 172 20 1 21 is used to illustrate the configuration steps To configure this island refer to the previous section describing the Lifting and Screening Advantys STB island as the principle is exactly the same However this island is named IO GS1 DDO 3600 DDO 3600 a lodos 10 100T oo mh Note ATV 31 and ATV 312 have not been dissociated within Advantys While ATV 312 does not exist in the Advantys catalog the ATV 31 profile is used for the ATV 312 configuration without any differences e 72 Schneider Electric Plant lF truxure 4 Configuration a The Grease and Sand Removal Advantys STB island is now configured and ready to communicate with the PAC The table below summarizes the mapping created in the IO Scanning for this Advantys STB island ee 7 Item RD Slave index RD Master object Length Define the data of the ATV 312 We use the ATV 312 of the Grease and Sand unit scraper named Mot1 as an example to illustrate the data definition Open the Grease and Sand unit Advantys STB island configuration to define the data exchanged with the ATV 312 From the IO Scanning service click on the button in the Device Name IO GS1 field to open the Property window of this device IP address Device Name 220120 lst L p Device Type Device Name EX wii Ve me ee 2 2 Data ERU Required Inpu
70. nd the PAC is configured in IO Scanning 2 The data of the selected motor starter is identified inside the Advantys STB Island IO Scanning configuration The Lifting Screening STB island 172 20 1 20 is used to illustrate the configuration Run Unity Pro and open the Water project Click on IO Scanning tab from the Network Configuration window On a new IO Scanning line type the island IP address 172 20 1 20 in the IP address field IP address I 1 1r2 20 1 20 On the same line enter the start address Master Object and the number of words length for the read and write registers e MW1000 and 100 words for read register e MW1300 and 100 words for write register AL RD Ref AO Last value we WR Ref WR Master 5l th Master sl th Object ave eng Input Object ave eng 100 0 100 f NIS Hald last MIO Note It is necessary to configure the RD length and WR length values before running the Advantys tool from Unity Pro but these values are not yet defined Therefore the read write word lengths are overestimated at first and are fine tuned in step 10 Click on the button in the Device Name field to open the Property window IP address Device Mame mm 1rz 20 1 2 e 65 Schneider Electric Plant amp truxure ss ton Select STB in the combo box Device Type and configure the Device Name to IO_LS1_ Note This Device Name is not the same as the Device Name set in the Address Server t
71. ocumentation for more information Definition and configuration of the PRM in the DTM Browser Run Unity Pro and open the Water project From the Tools menu select DTM Browser Select the PRM Master and click on the button Add DTM 4 Note To be able to select the PRM Master the PRM Master DTM must have been previously installed and the catalog updated and reloaded From the DTM Browser window right click on Host PC and select Add to open the communication devices catalog DTM Browser Check DTM devices 3 5 5 Result A confirmation dialog box opens confirm the modification e 80 Schneider Electric Plant truxure A t A device property window opens Modify the PRM name if necessary In our case it is named PRM Master Clarifier Properties of device General Device information DTM information Protocol information DTM name management Alias name PRIM Master Clarifier Tag name Default 1 0 vision management Default input 1 0 vision Variable name PRM_Master_Clarifier_IN Default output 1 0 vision Variable name PRM Master Clarifier OUT Cancel Help Click on OK to confirm From the DTM Browser window double click on the PRM Master Clarifier instance to open its properties Click on General Settings and fill in the PRM MAC address IP address and DHCP FDR parameters as described in the screenshot below FF PRM Master_Clarifier fdtOfflineParameterize i m
72. ol functions There are three types of functions e Motor protection overload and short circuit e Metering functions measurement of power current and so on e Monitoring functions alarms histories and so on A table on Pages 26 and 27 summarizes the various starter functions 2 2 4 Selecting Architecture All selected motor control devices have to be connected to the global system architecture Therefore the communication link of the device must be selected in a consistent manner and in compliance with the chosen global architecture Schneider t gt d Electric Plant truxure 2 Selection 2 3 Selecting Starter Mode 2 3 1 Motor Starter Basic Functions A motor starter unit has four basic functions e Isolation of the load from the main power supply e Protection against short circuit e Protection against overload e Control start stop speed Each motor starter unit can be enhanced with additional functions depending on its system requirements e Power speed controller soft starter phase reversal and so on e Control auxiliary contacts time delay communication and so on Starters are selected based on the power and control specifications 2 3 2 Power Specifications Related to the Load The choice of starter is determined by e Mechanical characteristics of the load torque inertia speed e Power and electrical motor characteristics e Necessary protections These criteria are used to define one of t
73. ol project has specific requirements and constraints that drive the selection of a motor control solution The project specifications present the characteristics that determine the selection criteria to be used in the selection steps The following diagram describes the selection procedure Project Specifications Complexity Physical dimensions Operational Constraints Plant productivity Process quality Operational cost Functional Constraints Power supply Network load ze D e oO Q T o u Selecting starter mode Direct On Line Soft Starter Variable Speed Drive Selecting starter and functions Selection steps Selecting Architecture PAC and Network Schneider d Electric Plant truxure 2 Selection 2 2 1 Project Specifications The size of the plant process complexity and other customer requirements define the PAC topology I Os architecture and connection types Project specifications also cover related constraints which can be divided into two groups e Functional constraints The process characteristics impose constraints in terms of power supply and network load that must be complied with These constraints are introduced in the following chapter without delving into the calculations or protection details of LV and MV networks Readers are advised to refer to the specific selection guides published by Schneider Electric for more details
74. onfiguration Click on Telegram 102 in the tree list on the left to define the registers that are used on the ATV 32 from the PAC IO PC1 Pmp1 fdtConfiguration ATV32 from GSD Schneider Electric Profibus Remote Master Generic Device DTM Schneider Electric ATV32 Device Information Module Parameters Uwe E DCA2 DCA3 DCA4 DCA5 OCA6 OMA1 OMA2 OMA3 OMA4 OMAS DM B P Device Parameters P Modules Configuration Value 9 Telegram 102 6PZD 1 Parameter type UNSIGNEDIE Min D Max 65535 Buffer 01 00 66 03 21 35 03 21 9A 03 00 90 03 00 90 93 00 00 03 00 00 05 0C 81 05 21 9C 05 00 00 05 00 00 05 00 00 05 00 00 IQ Disconnected Gj Data set In our case and to be consistent with the DFB MOT_ATV32_Pfb provided with this guide registers of this Telegram are defined as described below Module i Module Registers Parameters Parameters OCA1 8501 OMA1 3201 OCA2 8602 OMA2 8604 OCA3 0 OMA3 3204 OCA4 0 OMA4 3208 OCA5 0 OMA5 0 OCA6 0 OMA6 0 Registers Refer to the ATV32 documentation for a complete description of the register numbers EN Click on OK to finish the configuration of the Profibus DP slave Schneider ES Electric Plant Ztruxure 4 Configuration To modify the ATV 32 Profibus address double click on PRM Master Clarifier from the DTM Browser to open the PRM configuration window Select Profibus Devices in the list on the left as described in the screenshot be
75. onfiguration Once connected right click again on the PRM and select Store data to device to upload the configuration in the PRM At the end of the transfer the PRM disconnects and restarts The PRM of the Clarifier Unit is now configured and communicates with the PAC e 88 Schneider Electric Plant truxure 4 Configuration 4 3 SCADA System Configuration Without going into details about the Vijeo Citect programming this section outlines the principle stages The configuration of OFS which is used for the communication between the SCADA system and the PAC is also described 4 3 1 Principle Stages e Creating new Cluster From Citect Project Editor gt Servers gt Clusters create Cluster e Creating new Network address From Citect Project Editor gt Servers gt Network Addresses enter the computer name or IP address of the OFS server e Creating new Alarm Server From Citect Project Editor gt Servers gt Alarm Servers create Alarm Server called MyAlarms linked to Cluster1 e Creating new Trend Server From Citect Project Editor gt Servers gt Trend Servers create Trend Server called MyTrend linked to Cluster e Creating new I O Server From Citect Project Editor gt Servers gt IO Servers create I O Server called OPC linked to Cluster1 e Creating new I O Device Create a Premium I O Device by using the communication wizard and link it to the I O Server OPC previously created and select OFS comm
76. port island on the Ethernet 7 Advantys STB island on the Profibus DP network network daisy chain loop controlled through the PRM gateway 2 TeSys T on the Ethernet network daisy chain loop 8 TeSys U Standard and Multifunction on the Profibus 3 TeSys U Standard on pre wired Advantys STB interface SE DeDwoecontoleodhreHghidieraVtd ate EPI2145 module 9 ATV 32 variable speed drive on the Profibus DP 4 TeSys D contactor wired on Advantys STB I O module Debo echt hed onda etn RSNA 5 ATV 312 on CANopen using an STB XBE 2100 CANopen Extension Advantys STB module 6 PRM e 97 Schneider Electric Plant truxure 5 2 DFB Implementation in the PAC 5 Implementation Each type of starter is associated with 1 dedicated DFB The table below summarizes the DFBs that we created for our application Modbus TCP MOT ATV61 71 Profibus DP MOT ATV32 Pfb Advantys CANopen MOT ATV31 312 MOT ATS48 Modbus via ETG100 MOT ATS22 Modbus TCP MOT TESYST Eth Modbus TCP via Advantys extension rack MOT TESYSU s Profibus DP MOT TESYSU s Pfb Modbus TCP via Advantys extension rack MOT TESYSU a Profibus DP MOT TESYSU a Pfb Modbus TCP via Advantys extension rack MOT TESYSU m Profibus DP MOT TESYSU m Pfb Modbus TCP via Advantys STB Prewiring Modbus TCP via Advantys STB I O Modules MOT_DIRECT Input ATV61_71_IOSCAN_ Output ATV61_71_IOSCAN_O Input 1 ARRAY 0 3 OF BYTE Input 2 ARR
77. position inputs Sets the DFB to Local mode The actuator is directly piloted by the local buttons the commands from SCADA HMI are ignored Sets the DFB to Remote mode The PAC manages the actuator The commands come from a process sequence in Auto mode or from SCADA HMI in Manual mode Process Control Sequence This group is the DFB inputs used by the PAC program sequence to control the device in Auto mode ARun A In Auto mode starts the actuator signal set to 1 Interlock input for actuator operation Actuator operation is stopped or inhibited when the input is set to 1 When signals returns to O the actuator is automatically restarted or ready to start depending on the ARun command in Auto mode or HMI command in Manual mode Input for external error signals emergency stop for example Actuator operation is stopped or inhibited when the input is set to 1 The error must be acknowledged Ext ClearFault Input for external error acknowledgement Note The pins Lock Interlock and Ext Err External Error inhibit or stop device operation The main difference is that the Ext Err needs an acknowledgement via SCADA HMI before authorizing a new start of the device Control I Os This group is the process data inputs and outputs I Os that monitor and control the devices IO Scanning based on periodic read write variables allows implicit data exchanges This functionality must be reserved for frequently used varia
78. process If the operating mode is changed from Remote to Local the motor stops but the local hardware command leads the stop or the run on starter terminal block If the operating mode is changed from Local to Remote the motor follows the commands from the process or from the HMI If the interlock input Lock is set to O the motor is running An active interlock signal inhibits the start of the motor or stops a running motor The motor restarts or is ready to start when the interlock signal returns to O The DFB sets the output Error signal to 1 if the error input Ext Err is set to 1 external error or in the case of an invalid operating mode a missing feedback signal or an internal error of the starter The errors are displayed on the HMI as alarms To reset the output Error an acknowledgement must be done by a rising edge on the input Clear Fault from the HMI structure or on the input Ext ClearFault from the PAC application A minimum stop time before a new start of the motor can be set using the Min time stop parameter The motor is then authorized to restart only when the Time to start O This function is disabled if Min time stop O Also a maximum number of starts per day can be set using the Nb Start Day parameter The motor is then authorized to restart as long as Nb Start lt Nb Start Day This function is disabled if Nb Start Day O A 51 Schneider Electric Plant truxure 3 Design 3 4 4 SCADA Applic
79. ps are listed below e Motor Control Performance Control over power torque speed reversing start time and risk of jamming are required e Motor Protection Its purpose is to avoid operating motors in abnormal conditions that could result in negative events such as overheating premature ageing destruction of electrical windings damage to coupling or gear box e Motor Metering and Monitoring Functions The purpose of implementing measurement devices is to provide continuous supervision of motor operating conditions The collected data can be used effectively to improve energy efficiency and extend motor lifetime Monitoring functions allow you to control costs schedule maintenance operations and keep historical information for legal requirements Schneider a d Electric Plant truxure 2 Selection The following tables present a synthesis of the different device functions DOL Starter Starter controller TeSys U Motor circuit breaker Contactor Standard Advanced Multifunction LC D or F control unit control unit control unit Schneider d Electric Plant truxure Monitoring functions Fault differentiation Remote or automatic thermal Local control with I O on product Local control with HMI terminal Accelerating decelerating torque control Linear S U or customized a
80. r is reached Monitoring enabled if Nb_start_day 0 Discrepancy monitoring is activated and the discrepancy time is reached Monitoring enabled if Discrepancy_time 0 Name Name of the starter Status Feedback These output variables indicate the status of the device They can be used in the PAC process application and also to connect a PAC digital output FbAuto gt Auto mode activated FbManual Manual mode activated FbLocal Local mode activated The actuator is managed by local switch selector FbOff I Powered off by local switch selector FbRun Starter is running Locked Starter is locked Ready 7 Starter is ready Error Starter in Error Schneider 2 d Electric Plant truxure 3 Design Operation DFBs support Automatic and Manual operating modes The Automatic and Manual modes are activated by the SCADA HMI when the mode is set to Remote The Manual mode is selected by default on aPAC cold start The Local mode information from hardware selector is connected on an input pin to inhibit the commands from the process and SCADA HMI This information is also displayed on SCADA HMI Inthe Automatic mode the motor is started and stopped via the inputs ARun in Remote mode only If the operating mode is changed from Automatic to Manual the motor continues in the same way run to run stop to stop If the operating mode is changed from Manual to Automatic the motor follows the commands from the
81. s also been chosen to use the Faulty Device Replacement FDR service for this architecture in order to make the maintenance easier and more efficient Other selection criteria such as cost and performance also influence the final choice 2 5 2 Architecture Definition We applied the following criteria to define the architecture example used to illustrate this guide This architecture is detailed on Page 30 chapter 2 5 3 e Mixed Solution of Motor Control Devices We have chosen several motor control solutions from the simplest to the most advanced in order to describe the various monitoring and diagnostics capabilities e Control and Management in the System A solution that fulfils the requirements of automation motor control and starting monitoring loads and so on and management consumption operating time preventive maintenance and so on is provided e Sub Assembly Modularity Thanks to Advantys STB distributed IO islands modularity and their ability to be connected to different fieldbuses we use these islands to communicate with several types of starters in order to facilitate process extension and reduce design cost e Evolution Facility The solution must be easily expandable beyond the initial design so that extensions can be integrated without having to reconsider the overall architecture Schneider d Electric Plant ftruxure 2 Selection The table below summarizes the different types of conn
82. server From the ETG3021 IP Configuration menu in the IP parameters area select Served from device name Then in the FDR parameters area type ETG 3021 WATER in the Device name field The replication period parameter sets the automatic backup of the FDR configuration file to the FDR server period to 5 minutes Configuration from Web Designer amp Properties for TSX ETG 3021 PLANT1 General Configuration Security Configuration IP Configuration Modbus IP filtering Modem PPP Security Phone 14 gt Ethernet parameters Ethernet frame Format Ethernet II Link speed and duplex 100 FD Auto IP parameters Served from MAC address Served from device name Local served IP address 172 20 1 16 Subnet mask 255 255 0 0 Default gateway 0 0 0 0 FDR parameters Device name ETG3021_WATER Replication period mn 5 v oma Configuration from the web server IP amp FOR AGENT CONFIGURATION Ethernet parameters Ethernet frame format Ethernet Il Link speed and duplex 100 FD Auto IP parameters Served from MAC address e Served from device name Local FDR parameters Device name ETG3U021 VATER Replication period mn Schneider P ES Electric Plant amp truxure 4 Configuration Server Configuration In the Water application the DHCP and FDR server are hosted in the Premium PAC TSX P57 4634 The IP address used for each FDR device is presented in the table b
83. ssembly modularity The developments have been made with a re use objective in order to facilitate process extensions and reduce design costs Schneider ES Electric Plant Ptruxure 1 Introduction 1 3 Prerequisites We recommend users have knowledge of the following software e Unity Pro e Vijeo Citect e PowerSuite 1 4 Project Methodology This STG explains the project methodology that includes the following phases Selection Design Configuration Implementation and Operation This document provides a step by step methodology to create motor control solutions based on PlantStruxure architecture Here is an overview of this method e Selection This phase presents the various steps required to select the most appropriate starter components as well as the automation architectures that perform the control From the project specifications to the functional and operational constraints the Selection phase helps to choose the starter mode the motor control devices and finally the whole architecture e Design This phase comprises three main parts Operating modes Application operating modes are the most structuring elements in the automation system s Design phase They define the application s hardware and software parts and act on all of the architectural components Here the objective is to propose operating modes that can address specific situations starter management in a remote mode with a
84. sters 3 words for writing Schneider es d Electric Plant tr uxure 4 Configuration The DDT variables used to communicate with the ATV 61 are presented in the table below These variables are manually created in Unity Pro ATV A WNITYPRRO Register Item Located address Variable DDT Refer to the ATV61 documentation for a description of the different registers Note All the configuration procedures described in this section are also valid for the ATV 71 variable speed drive e 79 Schneider Electric Plant amp truxure 4 Configuration 4 2 8 ATV 32 Configuration The ATV 32 is connected to the Profibus DP network thanks to the PRM which is a Profibus DP Master used as a gateway between the PAC on Ethernet and the ATV 32 Profibus The configuration of the motor starter used behind the PRM requires 3 steps 1 declaration and configuration of the PRM in the DTM browser 2 declaration and configuration of the ATV 32 as a Profibus DP slave in the DTM Master 3 Addition of the PRM in the IO Scanning Note The configuration of the PRM Master Ethernet and Profibus DP parameters and the associated slaves are entirely performed from the DTM Master Note The configuration of the PRM and the ATV 32 require that the PRM Master DTM is installed in the Unity Pro workstation Then ensure that the DTM catalog is updated with ATV 32 gsd file and PRM Master DTM Refer to the PRM d
85. t Online TeSys U Diagram The TeSys U is a starter that integrates sectioning protection overload short circuit and commutator functions The Remote Off Local selector switch allows the TeSys U to be controlled either by the PAC in the Remote mode or by a Run Stop switch in the Local mode The selector switch has a third position Off In this position the contactor is open and the coil is not powered Note The Off mode cannot be considered as a padlock function In the Local mode the starter is controlled via the Run Stop selector switch the Run command is wired directly to the starter In this mode the PAC is no longer in the circuit which is important in the event of spurious signals or for maintenance Remote and Local positions of the lockable switch selector are transmitted to the PAC Indicator lights wired to the starter display Run and Fault status on the local panel Note The TeSys U pre wiring accessories cannot be used in the case of a local command M f 3 _A Schneider d Electric Plant truxure 3 Design Soft Starter ATS 48 Diagram As described in the following diagram a KM4 contactor is placed upstream of the ATS 48 This contactor controlled by the Remote Off Local selector switch allows cutting off the power to the starter see diagram below Weaker and Command part tontactor of the upstream i a contactor KM Note The Off mode cannot be considered as a padlocking f
86. t words 51 Output words po Launch Adwantys ok Configuration Update Software i Click on the button Launch Advantys Configuration Software To be able to modify the ATV 312 configuration unlock the island configuration by clicking on the following icon 5 Double click on the ATV 31 to open its Advantys configuration window EN Click on the IO Image tab rememeber that only the ATV 31 profile is available in Advantys e 73 Schneider Electric Plant amp Ztruxure M t Set the User Defined Label fields for each item as follows Es ATV31 V1 xx Segment 2 Slot 9 Node ID 32 2 9 32 PR General IO Image Options Fall Mapping Hexadecimal Data Item M ame Curent Value User Defined Label Memon Address dec Status Word Mot Status 45442 Actual Speed Value rp O Matten 7 15443 a Mott Ct 40010 Nominal Speed Value ml MotlApm 40011 Control Word Module Help Cancel Apply Configure the process image area Ey Click on OK and close Advantys A dialog box opens and proposes to update the symbols linked to this island lO Scanning 1 2 Do vau want bo update your symbols now Click on Yes to start the update Unity Pro creates new variables corresponding to the User Defined Label defined in step 4 The variables created by Unity Pro are summarized in the table below Address Comment amp 0_GS1_ _MotiRpm zMWw1120 IQ GS1 R2 858 ATV31 Act
87. ted to alarms is located at the bottom On the general page the units with at least one alarm are surrounded by a blinking red box The following figures show the navigation sequence for accessing the control panel of the Lfi_PmpD1 pump in the Lifting unit 4 Es SCO Coo cue ShGGR HATETE ai ne in r um a em Schneider u d Electric Plant truxure 6 Operation 6 2 2 Web Interface Some products have an embedded Web server They only allow diagnostics with a Web browser ATV 61 Variable Speed Drive of the Lf1_PmpD1 pump of the lifting unit Ina Web browser type the Lf1_PmpD1 ATV 61 drive IP address 172 20 1 50 in the address bar Then enter the default login USER and password USER Fichier Edition Affichage Favoris Outils A Altivar 71 61 Microsoft Internet Explorer EIER a Qe x 2 GD P rehech Kran D 2 8 Adresse c http 172 20 1 50 Oo OK x Altivar amp 71 61 I Home Documentation Monitoring Monitoring ALTIVAR Altivar Viewer an 5047 R1 Device Name ATV61 PmpD1 Am pomo R2 Altivar Chart AI3 0 0 u Altivar State RUN m fo Device File RAMO ATV61 PmpL A01 0 0 A020 A030 Data Viewer FRH Freq Ref RFR Output Freq OTR Output Torque ULN Mains Voltage UOP Motor voltage LCR Motor Current THD Drive Thermal THR1 Motor Thermal OPR Output Power APH Power Used RTH Run Time 1 080 1 440 1440 ot OO Oe of OOO Motor Speed RPM
88. th the ATS 22 are presented in the table below Unlike for the TeSys U these variables have to be manually created in Unity Pro Register Item Status Refer to the ATS 22 documentation for a description of the Modbus registers LCr1 LCr2 LCr3 Voltage LI Lo 7 D I I 2 e 17 Schneider Electric Plant amp truxure 4 Configuration 4 2 7 ATV 61 Configuration Regarding the ATV 61 the input and output IO Scanning parameters can be configured in different ways using e PowerSuite software e ATV 61 graphic display terminal e ATV 61 Web server For the ATV 61 the addresses of the registers that are read and written by IO Scanning are defined in the device The following example shows the configuration of 4 input and 2 output variables directly in the device using PowerSuite software A PowerSuite ATV61 Lf1PmpD1 File Display Configuration Tools A PowerSuite ATV61 Lf1PmpD1 File Display Configuration Tools BS UC h be E ATY61 O Modified parar O Access level O Simply Start Input summar Settings Motor contrc id nam 7 Out j Command Applicative I ww manag Communicati i Comm sce O Modbus c gt Ghee Password Output sc O Faulty De IP config Email Am omis Enable Input and Output ID scanner Enable 10 scanner Input 10 scanner Code Address Description Parameter 1 ETA v 1320 Parameter 2 RFRD
89. ts introduced in the Design chapter 5 1 Hardware Implementation The different process steps of the pre treatment part of a wastewater station are split into three cabinets e Main control cabinet e Lifting and Screening units cabinet e Grease amp Sand Removal and Primary Clarifier units cabinet 5 1 1 Main control cabinet The main control cabinet contains the Premium PAC 1 CPU TSX P57 4634 with an integrated Ethernet module This PAC manages the distributed I Os and motor control devices located in other cabinets The standalone SCADA Vijeo Citect application connected to the PAC is run on a Magelis iPC computer 2 This application monitors and controls the global process Electric e 95 Schneider Plant amp Ztruxure 5 Implementation 5 1 2 Lifting and Screening units cabinet This cabinet integrates the Lifting and Screening hardware 1 Advantys STB islands on the Ethernet network 2 TeSys U Standard Advanced and Multifunction on the Advantys extension bus 3 ETG100 Modbus serial Ethernet gateway 4 ATS 22 Soft Starter on the Modbus serial line controlled through the ETG100 gateway 5 ATS 48 Soft Starter on the Modbus serial line controlled through the ETG100 gateway 6 ATV 61 Variable speed drives on the Ethernet network 96 Schneider Electric Plant truxure 5 Implementation TEE 5 1 3 Grease amp Sand Removal and Primary Clarifier units cabinet 1 Advantys STB dual
90. ual Speed Value rpm amp I0 GS1 I MotlStatus zMw1119 IQ GS1 R2 S8 ATV31 Status Word amp amp I0 GS1 O MotlCtil zMWw1348 10_GS1__R2_S9 ATV31 Control Word amp 0_GS1_0_MotiRpm zMW1349 l0 G51 R2 S3 ATV31 Nominal Speed Value rpm Note All the variable name begins with the prefix IO GS1 corresponding to the Device name configured in IO Scanning Unity Pro only generates a variable if a User Defined Label has been defined in Advantys Schneider i d Electric Plant ftruxure 4 Configuration The table below summarizes the mapping automatically created in Unity Pro for this ATV 312 connected on an Advantys STB island Enhanced CANopen module Item CANopen Modbus Register _ Located address Variable Note As for the previous island the configuration files of this Advantys STB island generated by Advantys application are located in a directory defined in the Unity Pro options Therefore to use the Unity Pro application on another computer and make modifications concerning the STB islands mapping it is necessary to copy the Unity Pro application as well as the Advantys configuration files into the proper directory of the new computer 75 Electric Schneider Plant truxure 4 Configuration 4 2 5 ATS 48 Configuration The ATS 48 is connected to the Ethernet network through an ETG100 gateway Communication is transparent between the Ethernet network and Modbus Serial line Ther
91. unction In the Local Mode the starter is controlled via the Run Stop selector switch the Run command is wired directly to the starter and the PAC is no longer in the command circuit The Remote and Local positions of the lockable switch selector are transmitted to the PAC Indicator lights wired on the PAC or device outputs display Run Fault and Auto status on local panel A bypass is implemented in order to reduce power consumption When the start sequence is terminated the starter is short circuited by a contactor In our case the bypass function is performed by the KM1 contactor this contactor is controlled via the R2 output of the ATS 48 Note To configure the I O of the starter PowerSuite for PC or ATS Display software are recommended The wiring of the ATS 48 is presented on the diagram in the next page 41 Schneider Electric Plant truxure 3 Design ey p Fault mi C 42 Scbneider Electric I Hm Plant amp Ztruxure 3 Design Variable Speed Drive ATV 61 Diagram As described in the diagram on following page a KM1 contactor is placed upstream of the ATV 61 This contactor controlled by the Remote Off Local selector switch allows cutting off the power to the starter Note The Off mode cannot be considered to be a padlocking function In the Local Mode the starter is controlled via the Run Stop selector switch the Run command is wired directly to the starter and the PA
92. unication protocol The SCADA I O tag database is created in Vijeo Citect from the Unity Pro variable database and thanks to OFS Vijeo Citect is able to communicate with unlocated PAC variables e 89 Schneider Electric Plant amp truxure 4 Configuration 4 3 2 OFS Configuration From OFS configuration tool Create an Alias whose type is Unity Pro and name it for example Premium Set the IP address of the PAC in the corresponding field Select Using Data Dictionary This option allows OFS to connect directly to the PAC to get the embedded database and be regularly updated amp OFS Configuration Tool Version 3 34 File Edit view Settings Help Schneider Electric al amp agasiume 9 Devices EA Device overview amp EU Default devices A Devices without Aliases EU OPC settings Premium EU Deadband EU OFS Server settings Diagnostic i 2 Simulation Device name Premium 3 Symbols Device name Premium EU PLC Software EU Communication Device address MBT 172 20 1 1 U ai Options E General Symbol table file PLC Embedded Data V Using Data Dictionary Preload settings G Dynamic consistency Consistency level 5 BE Option Read Only Schneider Electric OFS Configuration Tool 3 34 From Unity Pro In the Unity Pro project settings the Data dictionary option has to be selected in order to allow OFS to read the embedded database Project Settings Project Settings Property abet
93. us Parameters configuration sgl ConneXium TSXETG100 Home Logout Monitoring Maintenance Setup Ethernet amp TCP IP Serial Port mm Serial Pot 575 Device List Mode Master Physical Interface R5485 2 wire User Accounts Transmission Mode Modbus RTU Web Page Access Baud Rate 19200 Parity Even s lt lt lt lt Modbus TCP IP Filtering l Response Timeout SNMP Parameters Seconds Apply Firmware Version 2 700 2005 2008 Schneider Electric All Rights Reserved User Administrator Schneider d Electric Plant amp truxure 4 Configuration Note The I O Scanner sends several requests in parallel while the gateway sends them one by one on the Modbus serial line The time delay generated by this communication mode can trigger a gateway timeout if a Modbus slave communication is inoperative An I O scanner timeout can be triggered for all the slaves handled by the gateway To minimize this set a minimum time out 0 5 s on the serial port of the gateway 93 Electric Schneider Plant amp truxure 4 Configuration Schneider i Electric Plant amp Ztruxure 5 Implementation 5 Implementation The main purpose of this chapter is to describe the implementation of the componen
94. vice name are not done from the Address Server tab These parameters are set from the PRM configuration screen as described in the procedure on next page Schneider gt ES Electric Plant amp truxure 4 Configuration EM Open the DTM browser from the Tools menu From the DTM browser double click on PRM Master Clarifier to access the configuration tool From the menu select General Settings In the DHCP FDR Server area select the boxes Create an entry an Backup the PRM configuration Type 001 in the Device Name field to set the name of the PRM module to TCSEGPA23F14F001 This corresponds to the name defined with the rotary switches in the previous section DHCP FDR Server Parameters of this section need to be filled if ou want ta use a DHCPJFDE server W Create an entry for this device name in the DHCP server Device Mame TCSEGPAZ3F14F On Extension 000 159 frotary switches value w Backup the PRM configuration in FOR server on download Once the Ethernet configuration is done build the program and transfer it to the PAC Note It is necessary to restart the devices to finalize their FDR configuration Schneider d Electric Plant truxure 4 Configuration 4 2 2 IO Scanning Service On each scan time the PAC application exchanges input and output data with the motor control devices The IO Scanning communication service is used on the Ethernet network to perform this per
95. viously and keep the same speed for motors controlled by variable speed drives When the system comprises many control stations SCADA and HMI it is necessary to define an access rights policy in order to avoid conflicts when operating in the Manual mode In some specific applications Manual mode can be deactivated in order to suppress any human intervention on the process actuators In the Local mode the command to the actuator is sent directly from local controls Therefore actuators can be controlled even in the case of an inoperative PAC That means that local controls are hardwired directly to the pre actuators contactor variable speed drive and so on The commands are usually sent using switch buttons Depending on the drives a remote graphic display terminal can be used It is possible to switch an actuator to the Off mode for maintenance purposes This mode prevents any operations on the actuator For security reasons this mode requires an additional electrical padlocking Note Concerning all the modes the power can be switched off by emergency switches Schneider 9 d Electric Plant truxure 3 Design The following diagram presents the relation between the different parts of the system Remote mode PAC Auto Run Stop Manual Run Stop Local mode wiring Local Run Stop e 35 Schneider Electric Plant truxure 3 Design 3 3 Hardware Design 3 3 1 Introduction
96. web browser e Buttons and indicators on a local panel which provide immediate display of the equipment status and permit local command operations on starters e Dedicated software tools such as Unity Pro or PowerSuite which allow diagnosis of equipment and processes particularly in the Design and Implementation phases of the process Schneider ne Electric Plant truxure 6 Operation 6 2 1 Vijeo Citect SCADA Interface Pages A number of pages have been developed for the monitoring and control of the pre treatment part of a wastewater station Home page General page III ET d uf r 7 a ml CO Schneider me d Electric Plant truxure 6 Operation Navigation The navigation takes place through a graphic environment Once the Vijeo Citect project is launched the system opens a home page which situates the project in the whole water treatment plant A simple click on the home page leads to the general view which displays the project and its four pre treatment units Lifting Screening Grease amp Sand Removal and Primary Clarifier The mouse pointer highlights them within a square Clicking on the desired unit displays the equipment included in the unit as well as each control module related to the equipment The goal is to make the navigation intuitive unit gt element gt equipment gt control module and so on A navigation toolbar is located at the top of the screen and a page dedica
97. window if the new IO Scanning line has been left totally blank Device Type DTM Protocol OTM Name Profibus DPI FRM flaster Clarifier Data Exchange Required Input words Output words eae a ws Select the new PRM PRM Master Clarifier in the combo box DTM Name and click on OK A pre defined line is then added for this PRM in IO Scanning 172 20 1 20 PRIM Master a 255 Hold last m WO Note The Device Name field is written in red because Unity Pro asks for an update to finish the configuration On the same line fill in the start address Master Object word number length for the read and write registers e MW1170 and 100 words for read register e MW1400 and 100 words for write register Note It is necessary to configure the RD length and WR length values to start the PRM update but these values are not yet defined Therefore the read write word lengths are overestimated in the first step and are fine tuned later Validate to accept the IO Scanning settings e 85 Schneider Electric Plant truxure 4 Configuration Open the Property window using the button in the Device Name field and click on the Update button Result the Device Name field appears in black PRM and I O variables have been automatically generated and the Address Server has been configured Click on the Address Server tab to check the configuration IP Configuration Messaging 10 Scanning SNMP Address Server
98. xport import Project Browser Ta Structural view Project Browser x uidi Functional view EET Cy Waste Water Plant E Functional Station E Cx Configuration E Tee ay Simulation rm 0 Bus X EE e Process j Derived Data Types E Program E 3 Derived FB Types l See Scaling PID Variables amp FB instances v Xj Table tw 9 Motion Screen 5 Communication 2 Lifting Program Program Spee Mig Tasks eee L51 Init an 5 Mast Rig LS51 Sequence j 889 ew OOA M P L51 Cde Auto e Fes Diagnostic System manitor Pe L51 PmpR1i t Simulation Digital Inputs t LS1_PmpR2 Lon Simulation Analog Inputs P L51 PmpDi Process Scaling PID t LS1_PmpD2 gt Lifting LS1_Init en LS1_PmpD3 Pi Lifting LS1_Sequence Pf 5 eee L51_Mot1 E Lifting LS1 Cde Auto m Ls1 Mot3 Lifting L51 PmpR1 P LS1_Mot2 M Lifting LS1_PmpR2 Fe Lsi vivi er Lifting LS1 PmpD1 LX Table a Lifting LS1_PmpD2 B Screen T Lifting L51_PmpD3 i Grease Sand Lifting LS1_Mot1 Je Program Lifting L51 Mot2 E GS1 Init en Lifting L51_Mot3 f GS1 Sequence Lifting L51 Vlvi HD GSi Cde Auto Grease Sand GS1 Init Pe Gsi Moti M Grease Sand G51 Sequence Fe GS1 Mot2 Grease Sand GSi Cde Auto Pw Gsi Mots seven Grease Sand G51_Pmp1 m Gsi Pmpi t Grease Sand G51 Pmp 2 ep GS1_Pmp2 a Grease Sand G51 Moti M G5
99. y the Unity Pro application and also the Advantys configuration files in the proper directory of the new computer e 68 Schneider Electric Plant truxure 4 Configuration Define the data of the TeSys U We use the TeSys U Multifunction of the screening unit compactor named Mot3 as an example to illustrate the data definition Open the Lifting and Screening unit Advantys STB island configuration to define the data exchanged with the chosen TeSys U From the IO Scanning service click on the button in the Device Name IO LS1 field to open the Property window of this device Click on the button Launch Advantys Configuration Software IF address Device Name Pro pe tiy 3 Device Type Device Mame 2 20120 E jest 3 lata Exchange Required Input words Output words Launch Advantys Configuration Software i To be able to modify the TeSys U configuration unlock the island configuration by clicking on the following icon 5 Double click on the Multifunction TeSys U to open its Advantys configuration window EN click on the IO Image tab e 69 Schneider Electric Plant amp truxure 4 Configuration Set the User Defined Label fields for each item as follows TeSys U Sc Mu R V1 xx Segment 1 Slot 13 Node ID 10 1 13 10 PR General ID Image Options LO Mapping Hexadecimal Data Item Mame Current Value Memory Address dec Status Register 455 s LL 25422 E 0

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