Development of Distributed Mains Monitoring and Switching
Contents
1. command to the transmission of response This implies that AC mains power status of 25 subsystems can be updated at this baud rate in 1 second Hence the system has improved Indus machine operation The system will provide information of status of electrical phases in terms of R Y and B in real time A graphical user interface GUI is developed which is helpful in observing the status easily Status of control outputs ensures working of field modules System is efficient and has low cost Power consumption of system is less This system can be used for monitoring and control of industrial and home appliances This system can be used in restricted and prohibited areas where human being is not allowed In future the system can be upgraded to monitor input power status of more than 32 subsystems This can be done by using repeaters Other parameters of subsystems like temperature can also be shown at control room System can be made wireless using W1 Fi technology Acknowledgements I express my profound sense of gratitude to Mr A M Gupta Scientific Officer F Accelerator Control Section ACS Raja Ramanna Centre for Advanced Technology RRCAT Indore Mr Pravin Fatnani Head Accelerator Control Section RRCAT Indore and Mr Preet Jain Head EC department SVITS Indore for their invaluable guidance persisting encouragement perceptual motivation everlasting patience and excellent expertise in discussion benefited me to proceed I sincerely wis2. table 5 Table 5 Function codes Function Code Function Code Working of Function Code Name Read Coil Status It reads all ports PO P1 P2 P3 of microcontroller bit wise Read Input Status It reads all ports of microcontroller byte wise It gives the information about the SFR of microcontroller Registers 05 Force Single Coil It writes the user defined hex value to the desired port of microcontroller ae a It echoes backs the transmitted frame in response function Exception Codes of Modbus protocol 2 implemented for P89C51RD2 microcontroller are shown in table 6 Table 6 Exception codes Exception Code Exception Code Name Working of Exception Code 01 Illegal Function Function Code not supported Illegal data address Address not available wrong address Illegal data value Data value out of range wrong data value 3 3 Server Application Server application running at server PC polls the Microcontroller field modules one by one and records the status of AC power MCBs in the database which can be referred for offline analysis It provides information about communication link between server PC and microcontroller field modules status of AC power MCBs in terms of electrical phases R Y and B module enable disable response indication checksum response string length poling count port number and baud rate at which the serial communication is established between server PC and field modules DOI 10 9790 2834 1
3. 0610109 www iosrjournals org 4 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex Response frame indicator Command Frame a ae esos fick Fisslcommand Response Module Faghle Disable Stopserver application baud rate setting Communication link indicator hecksum and ponse string length R Y B indicators and ON OFF buttons Ghee wae fa f fu fe gt fe fer os oe fo fo oe rv emmeemcmcrwre Loa Vecogo og ee les A wht Fig 3 Server Application front panel GUI YES Convert the address field of the frame from ASCT to hex YES Convert other frame fields to hex Add all the frame fields except start and end chars CRLF NO Is sum 07 YES Prepare response frame and transmit it to master PC Fig 4 Microcontroller firmware flow chart DOI 10 9790 2834 10610109 www iosrjournals org 5 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex write the complete frame to serial port Fig 5 Server Application flow chart 3 4 Client Application Client application running at client PC is connected with server application running at server PC over Ethernet Client application provides information about server to client communication link MCBs status in terms of electrical phases R Y and B communication link indication of server and field microcontroller modules ON OFF button is provided in the client application fo
4. 5 communication interface is chosen for the development of the system because large number of subsystems is present in the Indus complex As shown in comparison table 3 standard RS 485 transceiver supports 32 nodes on one physical network with the maximum length of the communication link 4000 feet The number of nodes can be further increased by using RS485 repeaters Any Microcontroller can be programmed and set up to communicate on standard Modbus network using two types of serial transmission modes 1 ASCII and 2 RTU This system is developed using ASCII mode because of its advantage that it is easier for debugging if any problem occurs during communication Table 3 Comparison between serial communication interfaces Specifications RS 232 RS 422 RS 485 Multidrop Communication Mode Simplex or full duplex Simplex or half duplex Simplex or half duplex or full duplex or full duplex Mode of Operation Single Ended Differential Total Number of Drivers and 1 Driver 1 Driver 32 Drivers Receivers on One Line 1 Receiver 10 Receivers 32 Receivers Maximum Cable Length 50 feet 2500 pF 4000 feet 4000 feet Maximum Data Rate 40 feet 4000 160 Kbits s can 10 Mbit s 10 Mbit s feet for RS 422 RS 485 be up to 1 Mbit s Table 4 ASCII command frame START ADDRESS FUNCTION DATA LRC CHECK CHAR LENGTH 1 CHAR 2 CHARS n CHARS 2 CHARS 2 CHARS 2 CHARS CRLF Function codes of Modbus protocol 2 implemented for P89C51RD2 microcontroller are shown in
5. IOSR Journal of Electronics and Communication Engineering IOSR JECE e ISSN 2278 2834 p ISSN 2278 8735 Volume 10 Issue 6 Ver I Nov Dec 2015 PP 01 09 www iosrjournals org Development of Distributed Mains Monitoring and Switching System for Indus Complex Neeraj Chandnani A M Gupta Pravin Fatnani Preet Jain Department of Electronics and Communication Engineering Shri Vaishnav Institute of Technology and Science Indore India Accelerator Control Section Raja Ramanna Centre for Advanced Technology Indore India Abstract Indus Complex at Raja Ramanna Centre for Advanced Technology RRCAT has two synchrotron radiation sources Indus I and Indus 2 Microtron is injector to both the machines which sends electron pulses to the Booster A new microcontroller based distributed mains monitoring and switching system is developed for Indus complex It facilitates remote monitoring and switching of AC power switches to various subsystems It includes interfacing with power switches Miniature Circuit Breakers MCBs of Indus machine subsystems This work involves development of hardware firmware for microcontroller implementation of communication protocol LabVIEW based server and client application The developed system allows remote monitoring and switching of MCBs from main control room Keywords Microcontroller LabVIEW Protocol MCB Power I Introduction In RRCAT Indus complex is having many subsystems associate
6. d with Microtron Booster Indus 1 and Indus 2 During machine startup and shut down operation crew needs to switch many MCBs and when machine operation is interrupted because of any fault these MCBs are needed to be checked as a procedure for debugging If the status of all MCBs is made available in the main control room it will be helpful and will improve operation activity To fulfill the requirement an AC power status monitoring and switching system has been planned Fig 1 shows the block diagram of complete system It consists of server client and microcontroller based field modules interfaced with MCBs Real time database storing facility is also provided for offline analysis Server communicates to field modules over RS 485 network Communication between server and client is implemented over Ethernet The system senses line phases R Y B through optical fiber to provide physical as well as electrical isolation A distributed AC mains power monitoring and switching system is developed which allows remote monitoring and controlling of power input to various subsystems Indus complex is distributed over large area there are so many subsystems whose input AC power status is to be checked for debugging At present operation crew checks the status of various MCBs manually It takes a lot of time to check for the various MCBs So a system is developed which provides the status of MCBs at one place hence it saves time II Literature Survey The Litera
7. eceived data of response frame by server 0A89016C r n Table 7 Command Response frame timing analysis Command Frame time in ms Response Frame time in ms Enable pulse Processing Total time time ms time ms ms 7D0100800003FF r n 17 55 7D0101077A r n 13 45 405 3325 7F0300E0000896 r n 17 55 7F0301002B52 r n 15 55 25 010500A000FF5B r n 010500A000FF5B r n 17 55 1 2 15 37 45 17 55 17 55 11 45 From table 5 1 it has been noted that total frame time for function codes 01 03 and 05 are 33 25 ms 35 25 ms and 37 45 ms respectively The result is analyzed with the help digital Oscilloscope Agilent Technologies The command and response frame length for function code 02 and 08 is same as the function code 01 and 05 respectively So the timing analysis for function code 02 and 08 is same as function code 01 and 05 respectively The timing analysis for exception code 01 is shown in the table Since the command and response length for all the implemented function codes are same so their timing analysis is also same V Conclusion The system is developed in the Accelerator Development Lab ADL at RRCAT This system enables automation thereby improving the operation activity Heat on test carried out for four days to check performance of the system The system is tested at the baud rate of 9600 bits sec It is observed that for communication at Rs 485 interface it takes around 40 ms from reception of
8. er database and starts communication automatically All connected Microcontroller modules are in listening mode therefore as command sent by server to a particular module then only addressed module sends response The communication mode is half duplex and single master type hence at a time only one field module communicates with server In case if two modules addresses matched due to human mistake then server receives check sum error and tries multiple times to get the response from the module and finally declares that address faulty and blocks communication with the particular address addresses Field module Inputs Outputs details are as follows DOI 10 9790 2834 10610109 www iosrjournals org 2 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex Table 2 Microcontroller module I O signal description rR Input R Electrical Phase status CB input B Electrical phase status RE2 dt Output__ Potential free relay contact RL Output Potential free relay contact Fe me I I l l I l l l f 1 Y l l I ae l l l 7 B l I l l I l Fig 2 Schematic block diagram DOI 10 9790 2834 10610109 www iosrjournals org 3 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex 3 2 Communication Protocol Communication between server PC and microcontroller field modules is done over RS 485 network using Modbus protocol RS 48
9. h to express my gratefulness to all the members of staff of ACS RRCAT and Electronics and Communication Engineering Department SVITS who have extended their cooperation at all times DOI 10 9790 2834 10610109 www iosrjournals org 8 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex References 1 MCB Trip Monitoring Module http www starkstrom com assets Uploads MCB Trip Monitoring Module pdf 2 Modicon Modbus Protocol Reference Guide http modbus org docs PL MBUS_300 pdf 3 Microcontroller P89C51RD2 datasheet http netmedia com siteplayer docs 001212 Philips P89C51RD2_6 pdf 4 Muhammad Ali Mazidi Janice Gillispie Mazidi Rolin D Mckinlay The 8051 Microcontroller and Embedded Systems using Assembly and C second edition 5 LabVIEW User Manual http www ni com pdf manuals 320999b pdf 6 Rick Bitter Taqi Mohiuddin Matt Nawrocki LabVIEW Advanced Programming Techniques second edition 2007 7 Barry E Paton Sensors Transducers amp LabVIEW Prentice Hall PTR 1999 DOI 10 9790 2834 10610109 www iosrjournals org 9 Page
10. mmand frame response frame and Enable signals for Function Code 03 Transmitted data of command frame by server 7F0300E0000896 r n Received data of response frame by server 7F0301002B52 r n ua aaa al i T Command frame sent by server Echo of response frame 7 0 DN eal I IN mia iii b Ml 1 gt A 17 55 ms gt Response frame received by server 4 17 55 ms _ gt _ Enable Signal q AX 37 45000000ms 17 AX 26 702Hz AY 1 9 9225V gt Mode gt Source x b g es x1 gt 2 D gt 14 8000ms_ 22 9560ms x1 x2 Figure 9 Command frame response frame and Enable signals for Function Code 05 Transmitted data of command frame by server 010500A000FF5B r n Received data of response frame by server 010500A000FF5B r n DOI 10 9790 2834 10610109 www iosrjournals org 7 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex uo S 00Vv7 BSB W 00V we 7 2008 6 00087 Trigo d f WB Command frame sent by server Echo of response frame 17 55 ms Response frame received by server mM 11 45 ms gt 2 gt Enable Signal 30 900000 00ms aA E 9 9225 Miode Source ae EE 6 211 3500ms M 19 5560ms x1 x2 Figure 10 Command frame response frame and Enable signals for oe Responses Transmitted data of command frame by server 0A0900A000FF4E r n R
11. r remotely switching the status of MCBs MICROTRON BOOSTER INDUS 1 INDUS 2 SERVER TO CLIENT LINK Fig 6 Client Application front panel GUI DOI 10 9790 2834 10610109 www iosrjournals org 6 Page Development of Distributed Mains Monitoring and Switching System for Indus Complex IV Results The real time analysis of signal is carried out with the help of digital Oscilloscope Agilent Technologies The length of command frame 1s fixed for all function codes The duration of command frame for all function codes is 17 55ms The command frame response frame and Enable signals waveform are taken at RX TX and EN pin of microcontroller respectively for the implemented function codes are as follows a A Command frame sent by server Echo of response frame _ 17 55 ms gt Response frame received by server 13 45 ms Enable Signal Mod Source ne sogres CENERI arro 19 8000ms lt 1 x2 Figure 7 Command frame response frame and Enable ETE for Function Code 01 Transmitted data of command frame by server 7D0100800003FF r n Received data of response frame by server 7D0101077A r n Trig d a oe frame sent by server Echo of response frame 7 Sal 55 ms ia Response frame received by server 15 55 ms r Enable Signal 3 ne 25000 T AX 28 369H 2 ded ee t 1 Te hv ode yo Sevres SC a S boms M 0 7550ms x x2 Figure 8 Co
12. ture survey is done to collect information about other systems available in market One similar type of system developed by Starkstrom Company UK named as MCB Trip Monitoring Module MTMM 1 Comparison between this system and developed system is shown in table 1 Table 1 Comparison between developed system and similar systems NO Developed System MCB Trip Monitoring Module MTMM Modification is easy Modification is not possible Firmware is developed in such a manner that it can Firmware is copyright be used for other applications as well 7 Only monitoring available DOI 10 9790 2834 10610109 www iosrjournals org 1 I Page Development of Distributed Mains Monitoring and Switching System for Indus Complex Microcontroller Microcontroller Microcontroller field Module 1 field Module 2 field Module 32 Fig 1 Block diagram of complete system HI System Descriptions The system consists of microcontroller field modules firmware for microcontroller server and client application 3 1 Microcontroller field module As shown in fig 2 addressable Microcontroller based field modules communicates with server Eight bit DIP switch is used to set address of field modules and addresses are settable from 1 to 255 Auto module detection and registration feature is incorporated in the system As the field modules connected on the RS485 network server checks communication with field modules and registers address of it in serv
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