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Water and Wastewater Accelerator Toolkit

1. CFP1 at Max Speed CFP1 at Max Speed Timer CFP1Max DN Pump1 Max Speed Publication IASIMP QS014C EN P February 2013 195 Chapter 3 196 Chemical Feed Mixers These routines contain the P_Motor routines for the chemical mixers If the Influent Level and a chemical feed pump are on then the mixers are turned on L001_Chemical_Feed_Setpoint_Strategy_LDR amp FBD This routine will contain the set point strategies of your system In our case it contains an operator manually set point and the FBD routine contains a simple calculated set point Y001 Status LDR amp FBD This routine contains all the user pertinent Status bits used for the programming of the Chemical Feed system All pumps running level status and pump sequence selected are examples of Status bits Status bits INTERLOCK THAT TELLS THE CHEMICAL FEED PUMPS THAT THE Chemical Feed Pumps CHEMICAL TANKS LEVEL Ok to Run IS OK TO RUN Bit Chemical Tank Levels OK Chemical FeedP Ready INTERLOCK THAT TELLS THE CHEMICAL FEED PLIMPS THAT THE INFLLIENT TANK LEVEL IS OK TO RUN Influent_Tank_Level_OK Chemical Feed Pumps Ok to Run Bit Chemical_FeedP_Ready Chemical_FeedP_TkLvl_Interlock_OK Any Chemical Feed Pump Running Chemical_FeedP1_P_ SD Sts_Running Chemical_FeedP_Running ANY CHEMCIAL FEED Chemical_FeedP2_P_YSD Sts_Running PUMP IS RUNNING Used for Chemical Chemical FeedP3 P VS
2. Chapter 3 Application Engineering Chapter 2 Hardware Design Process Library System Architecture Drawings Add on Instructions CAD Figures CAD Figures Website Resources Publications Website Resources Publications Chapter 4 Install and Start Website Resources Publications Installation and Setup Drawings Chapter 5 Maintenance Website Resources Publications Maintenance and Repair Drawings Water and Wastewater Quick Start Guide Chapter Organization Once you ve identified which section pertains to your role read that section Each section contains information on the existing documents content usage and location All of this material is provided to help you get started on your project This guide answers questions such as e What hardware do I need e How should it be programmed e What software standards should I use e How do I install this hardware See Appendix A for further resources and updates to existing information Publication IASIMP QS014C EN P February 2013 Required Software Publication IASIMP QS014C EN P February 2013 Preface To utilize the applications provided in this Accelerator the following software is required Rockwell Automation Catalog Number Version Required For Software RSlogix 5000 9324 RLD300RNE 17 or later All Water and Wastewater Controller Control Flash Applications BootP DHCP Utility EtherNet IP RSLinx Classic FactoryTa
3. By latching on the Program Acquire Command the application will default to Program Control of the application in the absence of a request to switch to Maintenance or Hand modes When one of these modes is requested the program will switch to these modes However when the request is no longer active the application reverts to Program Control Unlatching the Program Command Clear bit determines the style of mode control With this bit set to zero a level type of control is required for mode selection This means that to remain in a particular mode the request for that mode must be maintained For example to select Program mode the Program request command bit must remain 1 Latching this Program Command Clear bit would select an Edge type of control where setting the Program bit once on a one shot will trigger the transition to Program mode Once the transition occurs the command bit is turned off The command to change the mode is called a command acquisition bit Within the application modes change by manipulating these PCmd_Acq or OCmd_Acq bits PCmd is the request for program control or automatic OCmd is operator control In general the change of mode with the Program Command Clear bit latched is sensitive to the change of state of the mode acquire bit whereas with the Program Command Clear bit unlatched the state is determined by the state of the mode acquire bit itself This application is using the program command clear bit
4. A02 BatrScreenO01 FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Bar Screen 01 motor This routine is provided as a Function Block Diagram A03 BarScreenO01 Auto contains the Cycle Timer including the U_RepeatCycTmr AOT and High Differential Alarm code This routine is provided as a Ladder Diagram A04 DiffLevel contains the Analog Input AOI that monitors the preliminary treatment flow channel No 1 s differential pressure level This routine is provided as a Function Block Diagram BarScreen02 Controls the motor and manages cycle times and flow channel differential levels for the Bar Screen 2 system as described for BarScreen01 e GritTank01 Controls the motor and manages cycle times for the GritTank01 system including Main routine calls the other routines in this program A01 GritTankDrive LDR contains the code to monitor and control the Bar Screen 01 Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram Publication IASIMP QS014C EN P February 2013 201 Chapter 3 A02 GritTankDrive FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Grit Tank 01 motor This routine is provided as a Function Block Diagram A03 GritTankDrive Auto contains the Cycle Timer including the U_RepeatCycTmr AOT code This routine is provided as a Ladder Diagram A
5. Sheet 2 contains the ALMD function blocks for the high and low level faults of the P AIn block Using the ALMD blocks automatically inserts the fault message into the alarm banner if you choose to have an alarm banner in your HMI application and it contains a P AIn block that converts the actual level of the tank to a percentage 0 100 that is used to animate the chemical tank level on the HMI application For a detailed explanation of how to set up your alarms please refer to the FactoryTalk Alarms and Events System Configuration Guide Publication IASIMP QS014C EN P February 2013 181 Chapter 3 Typical P_Aln instruction used for the HMI tank level animation and the ALMD blocks used to display alarm messages on the alarm summary page if used THIS IS USED TO ANIMATE THE CHBMICAL TANK LEVEL IT CONVERTS LEVEL TO A VALUE BETWEEN 0 100 IT IS USED IN THE FILL ANIMATION IN FTSE Chemical Tank 1 Lewel P Aln FILL P Aln Analog Input 12 0 Chemical_Tank_1_Level_ value Inp P vBad Val InpP Ty val HiHiLim D 1 50000000e4038 1 50000000e4038 1 50000000e4038 1 50000000e4038 Signature ID 792 E8730 THESE ALARMS WILL PRODUCE MESSAGES THAT WILL SHOW UP IN THE ALARM SUMMARY PAGE IN FTSE E Digital Alarm Chemical Tank 1 Lewel HiHi ALMD AMD In AMD Digital Alarm Suppressed f Disabled 5 Chemical Tank 1 Lewel LoLo ALMD AMD Digital Alarm
6. 6 Once the scaled values have been entered the scaled value of the analog input displays in the Analog Input Scaled Value area 7 The second analog Input 1 1 1 is the same as input I 1 0 If the second analog input is not being used it does not need to be set up Configuring Analog Outputs 1 From the Main screen press Analog Outputs Config to display the configuration screen 1 21 2013 10 52 55 Aty Analog output selections The analog outputs can be used to retransmit the process variable from the analog inputs or to transmit the pump speed reference Analog Output Out 0 Usage Analog Output Out 1 Usage 0 1 0 0 1 1 Process Variable Process Variable Pump 1 Speed Reference Pump 2 Speed Reference AY Xe Ay 2 Set the Analog Output Out 0 Usage O 1 0 to retransmit a 4 20mA signal from the process variable the analog signal connected to one of the analog inputs ot to set the pump 1 VFD speed reference 4mA 0Hz 20mA 60Hz Publication IASIMP QS014C EN P February 2013 243 Chapter 3 3 Set the Analog Output Out 1 Usage O 1 1 to retransmit a 4 20mA signal from the process variable the analog signal connected to one of the analog inputs or to set the pump 2 VFD speed reference 4mA 0Hz 20mA 60Hz TIP Note The process variable can be the signal from analog input I 1 0 or input I 1 1 The default process variable is 1 0 but can be changed from the Measuri
7. A02 Drive FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Secondary Tank 01 motor See the Using Add On Instructions section above for more information This routine is provided as a Function Block Diagram e SecTank 02 Drive Controls the motor for the Secondary Clarifier Tank 2 system as described for the Secondary Clarifier Tank 1 Aeration Blower Controls the motor for the Blower system including Main routine calls the other routines in this program A01 Blower LDR contains the code to monitor and control the Blower motor and Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram A02 Blower FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Blower motor See the Using Add On Instructions section above for more information This routine is provided as a Function Block Diagram e SecTank01 RAS Pump Controls the Variable Speed Drive for the RAS Pump including Main routine calls the other routines in this program A01 Pump LDR contains the code to monitor and control the VFD for the RAS Pump Reset Alarms Interlocks and Faults associated with the pump This routine is provided as a Ladder Diagram 138 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 A02 Pump FBD contains the Variabl
8. OR THE INTERLOCK NEEDS TO BE DISABLED PRESSURE MODE ALL PUMPS TURNED OFF DUE TO HIGH PRESSURE Alarms Screen Alarm Message Time INACTIVE ALARM VFO ALARMS From the Alarms screen you can view a list of active and or inactive alarms Active alarms are shown in white against a red background and inactive alarms are shown in blue against a white background The newest alarms Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 appear at the top of the list Alarms remain in the list until the Clear All Alarms button is pushed on the maintenance screen Because this list contains past alarms history use the UP DOWN and PAGE UP PAGE DOWN buttons to scroll through the list From this screen you can also Press View Warnings to go to the Warning screen Refer to Warning Screen on page 256 Press Alarm Output Config to go to the Alarm Output Configuration screen Refer to Alarm Output Configuration on page 261 Press View VFD Alarms to view PowerFlex 4 alarms if a PowerFlex 4 VFD is being used Refer to VFD Faults PowerFlex 4 VFDs only on page 260 List of available alarms System Interlock I 0 19 Not Energized Pump 2 Failed To Run High Level PowerFlex VFD 2 Comm Loss Low Level Pump 2 OL Tripped VFD Fault High Pressure Pump 2 Over Temp Low Pressure Pump 2 Seal Fail Analog Input I 1
9. P1 Flow Switch Argen ua Process Value Raw Input in use indicator Raw Use raw input Command EAE Button Value 4 Use substitute process Value P ommand Substitute eer Button Process Value 1 0 Status indicator 62 Publication IASIMP QS014C EN P February 2013 Interlock Instruction P Intlk Chapter 3 The following table describes the Interlock Instruction P Intlk parameter and its usage Interlock Instruction P Intlk AOI Interlock P_Intlk Description This AOI collects sums up the Interlock conditions which stop a running energized open piece of equipment or prevent it from starting Interlocks are always evaluated to de energize equipment For permissive conditions such as those that must be made to start the equipment but which are ignored once the equipment is running use the P_Perm Permissives AOI Use This Instruction When e You have multiple interlock conditions or cascaded interlock conditions an interlock hierarchy which stop some equipment motor valve drive or keep it from starting Link the P_Intlk Status bits to the Inp IntikOK and Inp_NBiIntlkOK inputs of the motor valve or drive You need a first out indication of which interlock condition shut down the equipment You want configurable text descriptions of shutdown conditions and other features of the P Intlk Faceplates Do Not Use This Instruction When e You have conditio
10. Suppressed 5 Disabled 3 Chemical Tank 1 Lewel Lo ALMD AMD Digital Alarm Disabled fa Chemical Tank 1 Lewel Fail ALMD AlMD Digital Alarm Cast de 1 03 Suppressed 9 Disabled 3j oo o B00 Chemical Tank 1 Level LDRand C00 Chemical Tank 2 Level LDR In this example program these routines are left blank X00 Auto Control LDR This routine examines the LoLo alarm bit of the P Aln instruction for chemical tanks 1 and 2 If the tanks are not at a Low Low condition the Chemical Tank Levels OK bit is set high and used as an interlock for the chemical feed pumps 182 Publication IASIMP QS014C EN P February 2013 Chapter 3 P_Aln alarm bits analyzed for the chemical tank level ok interlock INTERLOCK THAT TELLS CHEMICAL TANK 1 THE CHEMICAL FEED LEVEL 1 Analog Input PUMPS THAT THE is below Low Low CHEMICAL TANKS LEVEL limit IS OK TO RUN Chemical Tank 1 Level P amp ln Sts LoLo Chemical Tank Levels OK CHEMICAL TANK 2 LEVEL 1 Analog Input is below Low Low limit Chemical Tank 2 Level P amp ln Sts LoLo Influent Tank Level Program Main This program contains the JSRs to all the routines in this program BOO Influent Level FBD This routine contains the P AIn AOI function block that calculates the influent tank level on sheet 1 Sheet 2 contains the ALMD function blocks for the high and low level faults of the P AIn block and it contains a P
11. ACCELERATOR TOOL KIT RAW WATER INTAKE PS Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Chapter 5 Process Flow Diagram Raw Water Intake System Process Flow Diagram Number Title Description E 1110 System The flow diagram depicts a Raw Water Intake System with Process Flow particular 1 0 Any changes to the 1 0 for the Raw Water Diagram Intake System should be reflected on this diagram For example if additional pumps are required in an application you should update this sheet with those pumps and their associated 1 0 The Raw Water Intake System Process Flow diagram shows a general overview of the Raw Water Intake process controlled by the system in this drawing set It provides a quick summary of the controls involved and of the process that is being controlled Publication IASIMP QS014C EN P February 2013 307 Chapter 5 308 Network Diagram Raw Water Intake System Network Diagram E 1120 Network For details see page 23 Diagram Publication IASIMP QS014C EN P February 2013 Chapter 5 Panel I O Layout Sheets Raw Water Intake Panel 1 0 Layout Sheets i 1 Number Title Description E 1130 Panel I O Layout The Raw Water Intake Panel I O Layout Sheets depict Sheet 1 of 2 inputs
12. AND THE STOP PUMPS SET POINT IS SET LOWER THEN THE DESIRED PRESSURE SET POINT HAS ITS OVER TEMP INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OVER TEMP OR THE INTERLOCK NEEDS TO BE DISABLED PRIMARY MEASURING IS SET FOR FLOATS A PUMP IS ASSIGNED TO LAG1 AN INPUT NEEDS TO BE ASSIGNED TO LAG START OR THE PUMP NEEDS TO BE IN OFF PUMP 2 HAS ITS SEAL FAIL INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO SEAL FAIL OR THE INTERLOCK NEEDS TO BE DISABLED PUMP 3 HAS ITS OVERLOAD TRIPPED VFD FAULT INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OL TRIPPED VFD FAULT OR THE INTERLOCK NEEDS TO BE DISABLED PUMP 3 HAS ITS OVER TEMP INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OVER TEMP OR THE INTERLOCK NEEDS TO BE DISABLED Publication IASIMP QS014C EN P February 2013 257 Chapter 3 258 PUMP 3 HAS ITS SEAL FAIL INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO SEAL FAIL OR THE INTERLOCK NEEDS TO BE DISABLED PUMP 4 HAS ITS OVERLOAD TRIPPED VFD FAULT INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OL TRIPPED VFD FAULT OR THE INTERLOCK NEEDS TO BE DISABLED PUMP 4 HAS ITS OVER TEMP INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OVER TEMP OR THE INTERLOCK NEEDS TO BE DISABLED PUMP 4 HAS ITS SEAL FAIL INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO SEAL FAIL
13. Chapter 1 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e Each specific site must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Headworks System Add more drives as needed e The Ethernet Switch has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP devices in the system P addresses and node numbers are unique to your application and you must include them on this drawing Publication IASIMP QS014C EN P February 2013 Chapter 1 Secondary Treatment System Architecture Drawing This is a typical Secondary Treatment System Architecture Drawing Secondary Treatment System Architecture Drawing The following table describes the key design points of the Secondary Treatment System Architecture Drawing Hardware ControlLogix Processor Description Controls the Secondary Treatment System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the pumps EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the pla
14. If you want to return to the WWTP Overview screen click the Overview button Selecting the High Service Pump Station WTP Overview Screen RAW WATER INFLUENT CHAMBER GRIT CHAMBER TANK RAPID MIX FLOCCULATION SEDIMENTATION INTAKE amp PUMP amp BAR SCREEN BA ASIN STATION ni 4 f SI SLUDGE LAGOON CLEARWELL AND HIGH SERVICE PUMP STATION DISTRIBUTION SYSTEM RESERVOIR I Publication IASIMP QSO014C EN P February 2013 221 Chapter 3 High Service Pump Station System Overview Screen 163 c1 connection 0 open rejected Error 2040101 on route CompactLogi i slot O of the chassis at 10 16 3 232 Hp d The status information on the High Service Pump Station Overview screen includes Clearwell Level LIT 1302 Clearwell Level LIT 1303 e High Service Pump 1300 e High Service Pump 1301 e Elevated Tank Level LIT 1305 Clearwell High High Float Clearwell High Float e Clearwell Low High Float 228 Publication IASIMP QS014C EN P February 2013 Chapter 3 Control Description High Service Pumps The High Service pumps ate variable frequency drive controlled which allows their speed to be throttled The flow of drinking water is controlled by varying the speed of these pumps The system only requires one pump for peak demand plus elevated tank filling Hand Mode Select Hand on the Hand Off Auto selector switch located at
15. Out Reset gt L T3 PI Reset t5 n inp Reset ing ResetReqd oe oe Once a reset is initiated and the P_Reset sends its Reset command all devices that are to receive this reset must be mapped to the proper Reset bit This is done in a distributed manner Each device that is to receive the reset will have a branch on the rung mapping this Reset command to its Reset input See the Lift Station Reset Command with a Digital Input Object illustration for an example with a Digital Input object The idea is the same for all other objects that accept a reset Each rung for an object that requires a reset will require a branch like the one shown below Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Lift Station Reset Command with a Digital Input Object DEVICE ALARM O CONTACT D OK target 1 at oll times 1 Alarm ALWAYS checked Gate 1 at all times Lift Station 1 Pump 1 Motor Overload Contact input Signal Purnp 1 process variable Overload Fault from Sensor Device AmO Input Device1 AlmO inp PV Locatr1 1 Dsta 0 LST1 P1 Overlosadanp PV E Lift Station 1 Pump 1 Motor Overload Contact Target State of Input Alarm If not in Target State Device1 AlmO Inp Target LST1 P1 Overload Inp Tsrgets Lift Station 7 Pump 1 Motor Overload Contact Gate Condition 1 to enable Alarm Device1 AlmO Inp Gate
16. View the current system pressure and set point View the flow rate readout if Analog Input In 1 is assigned to Flow on the Measuring Setup screen or if Digital Input 0 1 0 0 on the Digital Inputs Assign 1 screen is set for Use For Pulse Counter View pump status mode and sequence information as shown below Pump Pum A p run sequence set Auto selected a ALT to Alternate ou eee gt H RUNNING Pe Pump run sequence set to Lead Pump Off selected gt r3 STOPPED LG1 Pump run sequence set to Lag 1 Pump stopped Publication IASIMP QS014C EN P February 2013 249 Chapter 3 Pump Down Overview Screen From the Pump Down Overview screen you can View the 20mA scaled value View the current level scaled value View the 4mA scaled value View pump status mode and sequence information as on the Pressute Overview scteen Pump Up Overview Screen From the Pump Up Overview screen you can view pump status mode sequence and level information 250 Publication IASIMP QS014C EN P February 2013 Chapter 3 Maintenance Screen Enter the desired speed for each PowerFlex VFD VFD SPEED PRESSURE FOLLOWER MODE Enter the desired speed for each VFD when the pump is placed into HAND manual mode D Vr From the Maintenance screen you can Press Clear All Alarms to clear all of the alarms from the alarm history Refer to Alarms Screen on page 258 Press VFD
17. 1 E1 C mtkok er l Inp_IntikOK Val_Faut p e __ Sts_Stonped _ 1 D2 C NBlntlkOK Je e inp NBIntikoK Sts Stopped 5 J 4 A2 1 E3 Pump 1 amp LM IOFLT p Inp_lOFault Sts Starting 5 a Sts Starting Pune 1LOCAL Ee I S SS SSS SSS SS SS eet amp Inp Hand Sts Running p 1 4 B1 0 C Inp_OvrdCmd Sts_Stopping Po e Sts Ruming C Alarm Reset jn r 0 amp jInp Reset Sts Jogging P4 4 42 4 B2 2 E4 Cfg PCmdClear Sts ActualDir CjPSet SpeedRef Sts Alarm D C OSet SpeedRet Sts_AtSpeed 5 amp PCmd Start Sts SpeedLimited 5 i amp PCmd Stop Sts Available D m amp jPCmd amp cq Sts Err D 1 amp PCmd Lock Sts Prog Bs r ALM FTSTART Alm FailToStart 3 B2 er Ax Alm IntlkTrip Po Ed ALM INTLKTRIP 3 B2 o1 3 53 i eC ALMJOFAULT _ Rdy Reset e ALM_DRIVEFAULT _ 3 55 3 B4 Signature ID 53EEDF50 A001 Chemical FeedP1 LDR The following routine contains most of the logic that controls Pumpl1 It will be examined and explained rung by rung RUNGO The following rung is where the programmer would put all the conditions that would make Pump not available Pump available logic CFP1 Auto Available Chemical FeedP1 P VSD Sts Prog Pump_1 REMOTE Pump 1NP ALARM Pump1 Available M fe mm OR This rung contains the start pump logic 192 Publication IASIMP QS014
18. Chapter 2 Panel I O Layout Sheets Pump Controller Station Panel 1 0 Layout Sheets Publication IASIMP QS014C EN P February 2013 49 Chapter 2 As et ey ee mm ntm iXX tek nar AXXd tek Sree Sess rr Number 8 11 1 0 Layout Pump Control Drive and PLC 1 0 Drawings Sheets CAD Figures The WWWAT CD contains both AutoCAD and Adobe PDF formatted hardware template files that you can use when designing your application Template files are available in dwg dxf and pdf file format 50 Publication IASIMP QS014C EN P February 2013 Chapter 2 Additional Resources Publication ASIMP QS014C EN P February 2013 Accessing the CAD Images from the WWWAT CD WWWAT Common Tools Le 1 i Lift Station W System Architecture Dosing Pumps a Controller Application J Supervisory System HMI Application s Help L2x Controller Information gt J PanelView Plus Information M Selection Guide 5 Stratix Switch Information gt User Manual pa Wireless Modem Information P Installation Instructions PowerF lex 70 Information gt Popular Configuration Drawings par E3 Overload Information Point 1 0 Information gt y 14 D CompactBlock Information The CAD files can be imported into your AutoCAD project for use in the development of drawing packages for your water and wastewater application Download additiona
19. Click the Enable button to place the unit back in service Solids Transfer Pump STP The STP is controlled manually by plant operators The pump discharges to a Belt Filter press which removes water from the sludge Hand Mode Select Hand on the Hand Off Auto selector switch located at the MCC to operate the pump locally The operator uses the buttons located at the MCC to operate the pump Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the MCC to put the pump in the Remote mode Operator Mode Manual Click the STP section of the Solids Overview screen Selecting the STP on the Solids Overview Screen The system displays the Tank Drive Faceplate Publication IASIMP QS014C EN P February 2013 161 Chapter 3 Solids Tank to Filter Press P 602 Faceplate Solids Tank 1 to Filter Press P 602 h EEUN Enabled Stopped gt m zj amp e e Comm OK For manual Operator Control select the Operator mode on the Solids Tank 1 to Filter Press P 602 Faceplate The Faceplate shown is used to control the pump The operator starts and stops the STD remotely from the Solids Tank 1 to Filter Press P 602 Faceplate The available Faceplate commands include Press the Play button to start the pump Press the Stop button to stop the pump Click the Disable button to remove the pump from service Click the Enable button to place the unit back in service Al
20. Diagram Description The Dosing Pump System Process Flow diagram depicts a two pump alum addition process You make any changes to the number of pumps or I O for this process on this drawing For example if you require additional pumps in an application update this sheet with the appropriate pumps and their associated I 0 information The Dosing Pump System Process Flow diagram provides a general overview of the process controlled by the system a quick summary of the controls involved and the process that is being controlled Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 4 Network Diagram Dosing Pump Network Diagram or vn _ r TuT y an eari Ehan IET EUN MERIIUS V E E 170 Network For details see page 14 Diagram Panel I O Layout Sheets Dosing Pump Panel I 0 Layout Sheets ates TT d HHHH 1 i E ru e SE 219 Chapter 4 280 Number Title Panel I O Layout Sheet 1 of 3 Panel I O Layout Sheet 2 of 3 Panel I O Layout Sheet 3 of 3 Description The Dosing Pump System Panel O Layout Sheets show the 1 0 to the controller The format uses three cards per sheet This drawing depicts inputs to the card with the input device to the left of the input card It also shows output devices to the right of the output card You must add a new sheet for each
21. February 2013 313 Chapter 5 314 1 3and5 Power Layout Sheets Description Pump Control Power Distribution 480VAC Power and 24VDC Power Drawings Publication IASIMP QS014C EN P February 2013 Chapter 5 Panel I O Layout Sheets Pump Controller Station Panel 1 0 Layout Sheets Publication IASIMP QS014C EN P February 2013 315 Chapter 5 T MGR 8 11 1 0 Layout Pump Control Drive and PLC 1 0 Drawings Sheets 316 Publication IASIMP QS014C EN P February 2013 Chapter 5 Notes Publication IASIMP QS014C EN P February 2013 317 Chapter 5 318 Publication IASIMP QS014C EN P February 2013 Appendix A Additional Resources Website Resources This table describes the numerous websites where you can go to find useful and up to date information for all phases of a Water and Wastewater project Each website is categorized on the WWWAT CD and contains a link to that specific website For See Integrated Architecture Productivity tools to help you save time in the development of your water or wastewater system http rockwellautomation com solutions integratedarchitecture resources html General information about Rockwell Automation offerings in the water and wastewater industries http www rockwellautomation com industries water Components Time saving accelerators centered around Rockwell Automation component
22. High Service Pump Station System Architecture Drawing This is a typical High Service Pump Station System Architecture Drawing High Service Pump Station System Architecture Drawing The following table describes the key design points of the High Service Pump Station System Architecture Drawing Hardware ControlLogix Processor Description Controls the High Service Pump Station System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the pumps EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the plant network Publication IASIMP QS014C EN P February 2013 2 Chapter 1 Pump Controller Station Architecture Drawing 28 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application Each specific site manager must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis The number of PowerFlex 700 Drives may change based on the number of pumps in the High Service Pump Station System Add more drives as needed The Ethernet Switch has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP de
23. LST1 P1 Overload Inp Gete Lim Station x1 Pump 1 Motor Overload Contact Input Comm Statue or Quality 1 Bad 0 OK Device1_Alm0_input_ JOF aut Device1 _Alm0 Inp_PYBad Locak1 1Fault 0 LST1 P1 Overload Inp_PYBad gt a Lit Station 1 Litt Station 1 Pump Pump 1 Motor 1 1 Reset received Overload Contact for this P Reset s 1 Reset Alarm scope requiring reset Device Reset Out_Reset Device1 AlmOnp Reset lt LST1_P1 Reset Out_Reset LSTT P1 Overload Jnp Reset Litt Station 1 Pump 1 Motor Overload Contact P Din Discrete Input P Di Devicet Ama Ing Pv Inp Target Ino Gete Mode Selection Routines for Pump 1 and Pump 2 include a rung that handles mode operation of the routine This rung is shown in the Lift Station Pump 1 Pump 2 Mode Selection Rung illustration 107 Chapter 3 Lift Station Pump 1 Pump 2 Mode Selection Rung M DEVICE PROG MODE M6594242142423522322244222304442520222424242 220 245202422429222 009 When operator mode is unlocked enable automatic control POmd Acq Unistch PCmdClear to accept maitaned verses momentery command signals for prog mode Lift Station 1 Pump 1 Program Command to Acquire ownership Oper OOS to Prog Device Motor PCm d Aca LST1 P4 Motor PCmd Aco Lift Station 1 Pump 31 1 Cieor Program Commands on receipt OrLeave Set Device Motor Cfg POmdOear LSTI F1 Motor Cig POmdOear W
24. P Alarm Alarm or P Din Discrete Input AOI instead You need synchronized time stamping features or other FactoryTalk Alarm and Event features not supported by P Alarm Instead use the ALMD built in instruction Once the system initiates an alarm the alarm displays change color according to their severity A small bell appears in the upper right hand corner of the display to indicate that an alarm is active If you must acknowledge the alarm this bell blinks Alarm AOI Publication IASIMP QS014C EN P February 2013 Color indicates sever ity Blinks when acknowledge required E a A a Acknowledge button 57 Chapter 3 Analog Input basic Instruction P_Aln The following table describes the Analog Input Basic Instruction P Aln parameter and its usage Analog Input Basic Instruction P_Aln AOI Description Use This Instruction When Do Not Use This Instruction When Analog Input This instruction monitors one e You want to display a temperature e The analog input signal works with P_Aln analog value typically from an flow pressure level or another another instruction For example the analog input I O module and signal from a field instrument on your Speed Feedback for a variable speed provide alarms when the analog HMI drive is completely handled by the value exceeds user specified e You need any of the Scaling P_VSD Instruction Itis not necessary limits high and low Alarming
25. See the Customization of the Solids Application section for an example of how to add Single Speed Motor AOIs in a FBD routine 212 Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Separation Application The WWWAT CD contains the Separation application Refer to the Separation System Application Controller Organization illustration to view the application s organization within the Controller Separation System Application Controller Organization E C MainProgram ID Program Tags E Main ey A01 MiscDiscreteInputs By A02 MiscAnalogInputs wy A03_MiscDiscreteOutputs 4 A04_MiscAnalogOutputs 0 SedBasin01Drive A Program Tags Eh Main Bl A01 Drive LDR 4 A02 Drive FBD 2 7 FlocBsn01_M1202 K Program Tags Main Bj A01 Pump LDR ij A02 Pump FBD This task resides in a PLC in the main facility of the plant that contains the Separation application and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other plant systems 213 Chapter 3 The organization of this application is similar to that of other applications in this toolkit Specifically the functionality for each program and routine is e Main Program handles general separation application and functionality Main routine calls the other routines in this pr
26. Speed Hz to enter the desired speed for each VFD The VFD Speed Hz button is visible only if PowerFlex 4 VFD ot Other VFD is selected in the Motor Control Setup screen Press PowerFlex VFD Parameters to open the PowerFlex 4 VFD Parameters screen Refer to PowerFlex 4 VFD Parameters on page 253 The PowerFlex VFD Parameters button is visible only if PowerFlex 4 VFD is being used Press Pump Statistics to open the Pump Statistics screen Refer to Pump Statistics Screen on page 252 The Pump Statistics button is only visible after an application has been assigned Press PID Tuning to access the PD Tuning screen Refer to PID Tuning Screen on page 252 The PID Tuning button is visible only if Pressure Follower mode is selected Press PanelView Config to close the running Panel View application and open the PanelView configuration screen Publication IASIMP QS014C EN P February 2013 251 Chapter 3 Pump Statistics Screen From the Pump Statistics screen you can Select a pump to view the statistics for that pump The number of pumps visible depends on how many are in use The flow totalization is only visible if digital input I 0 0 is set to totalize or if analog input 1 1 1 is set for flow Reset the run time and cycle count shown in yellow View the motor current and voltage if a PowerFlex series 4 VFD is in use View the flow totalization if digital input I 0 0 is set to totalize or if analog input I
27. inp NOIintmHor 1 Xie TCtopping gt Ste E n2 St_Hand gt St Opec Lift Station 4 Pump 1 4 Rer Motor Pump 1 Qe Stop Motor Gtan Step Device Motor Qut Run Dewioetd Out Run lt LST1_P 4 Motor Out Run 87 Chapter 3 AOls Add On Instructions populate their own folder in the Controller Organizer AOls amp Add On Instructions QJ P AIn I P Alarm ig P DIn x iz P Intlk I P Mode G P Motor G3 P Perm I P Reset i P ResInh P RunTime 5 U Heartbeat Iz U_MotorAvailable Q U_MotorDemand Iz U_MotorStartOrderRotation These applications contain two AOI classes Process Library Modules identified with the prefix P_ and User Modules prefix U_ The applications included in the WWWAT include AOIs from both the Process Library and those created specifically for these applications 88 Publication IASIMP QS014C EN P February 2013 Chapter 3 Using the Process Modules The Process Modules are included in this Toolkit and can be imported into your application as required These modules are distributed as XML L5X and must be imported into your application as AOIs To import an XML file into your application 1 Click File gt Import Component gt Add On Instruction Select Import AOls BG Edt Vew Search Log Communications Tools Window Heip ga New Open off Chose No No ld seve Save As Page Setup CB Progra
28. of this chapter Refer to this section before customizing any application including the Separation This section describes customization specific to the Separation application 222 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template e MainProgram A04 AnalogOuput as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine See the Customization of the Solids Application section the Solids application for an example of how to add Single Speed Motor AOIs in a FBD routine 223 Chapter 3 224 High Service Pump Station Application The High Service Pump Station application is provided on the WWWAT CD Refer to the High Service Pump Station System Application Controller Organization illustration to view the application s organization within the Controller High Service Pump Station System Application Controller Organization C MainProgram A Program Tags En Main dy A01 MiscDiscreteInputs 4 A02 MiscAnalogInputs 4 A03 M
29. 0 Out Of Range Pump 3 Failed To Run Analog Input I 1 1 Out Of Range PowerFlex VFD 3 Comm Loss Power Failure Pump 3 OL Tripped VFD Fault Generator Running Pump 3 Over Temp Generator Fault Pump 3 Seal Fail General Fault Pump 4 Failed To Run Pump 1 Failed To Run PowerFlex VFD 4 Comm Loss PowerFlex VFD 1 Comm Loss Pump 4 OL Tripped VFD Fault Pump 1 OL Tripped VFD Fault Pump 4 Over Temp Pump 1 Over Temp Pump 4 Seal Fail Pump 1 Seal Fail 259 Chapter 3 VFD Faults PowerFlex 4 VFDs only POWER FLEX 4 VFD FAULTS SCREEN The VFD Faults screen shows faults for each PowerFlex 4 VFD in use in this example four VFDs are in use The fault information comes from the PowerFlex 4 VFD via the Modbus communication Press RESET VFD FAULT or the stop button on the VFD to reset the VFD fault List of available PowerFlex VFD faults NO FAULTS 39 PHASE V TO GROUND SHORT 2 AUXILIARY INPUT 40 PHASE W TO GROUND SHORT 3 POWER LOSS 41 PHASE UV SHORT 4 UNDERVOLTAGE 42 PHASE UW SHORT 5 OVERVOLTAGE 43 PHASE VW SHORT 6 MOTOR STALLED 63 SOFTWARE OVERCURRENT 7 MOTOR OVERLOAD 64 DRIVE OVERLOAD 8 HEATSINK OVERTEMPERATURE 70 POWER UNIT FAILED 12 HW OVERCURRENT 30096 80 AUTO TUNE FAILED 13 GROUND FAULT 81 COMMUNICATION LOSS 29 ANALOG INPUT LOSS 100 PARAMETER CHECKSUM ERROR 33 AUTO RE
30. 1 1 is set for flow PID Tuning Screen From the PID Tuning screen you can 252 Publication IASIMP QS014C EN P February 2013 Chapter 3 Select a pump to view or change the PID values for that pump The number of pumps visible depend on how many ate in use Press Enter Prop Gain Kc to enter the gain value for the PID Press Enter Integral Reset Ti to enter the reset value for the PID Press Enter Derivative Rate Td to enter the rate value for the PID Press Enter Deadband to enter the deadband value for the PID PowerFlex 4 VFD Parameters From the PowerFlex 4 VFD Parameters screen you can Save PowerFlex 4 series VFD parameters from the VFD to a database in the PLC Load saved PowerFlex 4 series VFD parameters from a database into the VFD If a PowerFlex 4 series VFD is being used you can save different sets of parameters under different recipe names If you save the parameters to an existing database recipe the previous recipe will be overwritten Once the parameters on the VFD are setup the way you want you can save the parameters to a database that resides in the PLC They can then be loaded into the VFD later To save a recipe Publication IASIMP QS014C EN P February 2013 253 Chapter 3 1 From the PowerFlex 4 VFD Parameters screen press Save PowerFlex 4 VFD Parameters Into Database to open the Save VFD Parameters screen SAVE VFD PARAMETERS SE
31. A procurement document can save you time by eliminating the need to create complex items such as the bid specification You only have to copy and paste the contents of these documents directly into the project specifications section instead of developing the content yourself Chapter 1 Customizing Procurement Documents Typically the procurement documents do not require editing However since all RFP s are unique in their requirements you many need to use the following procedure to make the necessary changes 1 Identify the section of the specification or RFP that is required For example is it a section on variable frequency drives or controllers 2 Locate the appropriate procurement specification on the WWWAT CD 3 Copy and paste the content of the procurement document into the specification or RFP 4 Check the introduction of the new section that you ve pasted into the specification It is possible that you will need to change the introduction to better integrate into the existing document The specification or RFP will already have a format and style but some adjustments will be necessary to adhere to this style 5 Check the format of the section numbering Ensure that the procurement specification that you included matches the section numbeting and does not disrupt the progression of section or page numbering 10 Publication IASIMP QS014C EN P February 2013 System Architecture Drawings Publication ASIMP QS014C
32. AIn block that converts the actual level of the tank to a percentage 0 100 that is used to animate the influent tank level on the HMI application For an example of how the function block diagram FBD is programmed see figures 3 and 4 For a detailed explanation of how to set up your alarms please refer to the FactoryTalk Alarms and Events System Configuration Guide B00 Influent Level LDR In this example program this routine is left blank X00 Auto Control LDR This routine examines the LoLo alarm bit of the P AIn instruction and if the alarm bit is off the Influent Tank Level OK and Mixer Lvl Interlock bits are set high and used as interlocks for the chemical feed pumps and chemical feed mixer interlocks Publication IASIMP QS014C EN P February 2013 183 Chapter 3 INFLUENT TANK LEVEL 1 Analog Input is below Low Low limit Influent_Level_P_Aln Sts_LoLo 184 P_Aln alarm bit analyzed and used by the chemical feed pumps and mixers as interlocks INTERLOCK THAT TELLS THE CHEMICAL FEED PUMPS THAT THE INFLUENT TANK LEVEL IS OK TO RUN Influent_Tank_Level_OK INTERLOCK THAT TELLS THE CHEMICAL FEED MIXERS THAT THE LEVEL IS OK TO RUN Mixer Lvl Interlock Influent Flow Program Main This program contains the JSRs to all the routines in this program B00 Influent Flow FBD This routine contains the P AIn AOI function block that calculates the influent flow on sheet 1 Sheet 2 contains the ALMD
33. Auto control perform the following 1 Select Auto on the Auto Off Hand selector switches located at the MCC for each equipment to place the GTD equipment in the Remote mode 2 Select Program mode from the HMI Equipment Faceplate When in Remote Program mode the system calls the GTD equipment to start when the accumulated time is equal to the Cycle Timer pre set Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Bar Screen Cycle Timer On Time Minutes Off Time 120 Minutes C ycle Now Alarms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Process Equipment Process Alarms Channel No 1 Differential Level High alarm Process Alarms Diff Pressure BITE he tego x wu Alarm Delay Time secon High 5 Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 High High wv High 4 e Low Low Low Device Fail Equipment Alarms These are the two types of Equipment Alarms 209 Chapter 3 Start Stop Faults If the system calls the Mechanical Bar screen and it is not running after 5 seconds he system generates a Start Stop Fail Alarm and displays it at the HMI Start Stop Faults If the system calls the GTD to start and is not running after 5 seconds the system generates a Start Stop Fail Alarm and displays it at the HMI 210 Publication IASIMP QS014C EN P Febru
34. Certifications Hardware Selection PowerFlex 70 User Manual 20A UMO01 PowerFlex 70 Information Installation Wiring Mounting AC Supply Grounding Fusing Power Wiring IP66 Nema 4X 12 Installations Input Output Contactors MOVs and CM Capacitors 1 0 Wiring e Speed Reference Control e Auto Manual Examples e EMC Instructions e Appendix A Supplemental Drive Information e Appendix B HMI Overview e Appendix C Application Notes Hardware Selection Installation and Start up Maintenance 320 Publication IASIMP QS014C EN P February 2013 Documentation Stored On the WWWAT CD WWWAT CD Folder E3 Overload Information Publication Number 193 UM002 Document Name E3 and E3 Plus Overload Relays User Manual Document Contents Product Overview Installation and Wiring Protective Trip and Warning Functions DeviceNet Node Commissioning Programmable Parameters Current Monitoring Parameters Diagnostic Parameters Logic Controller Application Example with Explicit Messaging Troubleshooting Appendix A Specifications Appendix B DeviceNet Information Appendix C PTB Compliance Appendix D CD Compliance Appendix E Accessories Appendix A Reference For Hardware Selection Installation and Start up Maintenance ControlLogix 1756 UM001 System User Manual ControlLogix System Overview Manage Controller Communication Place Configure an
35. Click on the Flocculation Mixer section of the Separation Overview screen The system displays the VSD Faceplate Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 VSD Faceplate Variable Speed Drive i egi x wa OO c c Enabled Drive OK Stopped gt m e NNI At Speed ze Actual Requested Operator Operator For manual Operator Control select the Operator mode on the VSD Faceplate The operator uses the faceplate shown to control the mixer The operator starts stops the mixer remotely from the VSD Faceplate The available faceplate commands include Press the Play button to start the mixer Press the Stop button to close the mixer Click the Disable button to remove the mixer from service Click the Enable button to place the unit back in service Sedimentation Plant operators control the Sludge Collection Mechanism SCM manually As the sludge settles to the bottoms of the basin a rack system collects the sludge for processing Sedimentation Basin Drive on the Separation WTP Overview Screen Torque Fault x 219 Chapter 3 220 Hand Mode Select Hand on the Hand Off Auto selector switch located at the MCC to operate the SCM locally The operator uses the buttons located at the MCC to operate it Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the MCC
36. DC This instruction multiple discrete speeds You will will also work with drives and other need specific logic for this motor variable speed motor control The P VSD Instruction is designed products via discrete 1 0 for the for motors with continuously start stop running signals and analog variable analog speed not multiple 1 0 for the speed reference and speed discrete speed selection feedback signals 80 Publication IASIMP QS014C EN P February 2013 Variable Speed Drive P_VSD Process Variable Faceplate Balanced Eccentric Energy Reducer Fee X ole i aj Program Enabled Stopped M Speed Drive OK co NEIJ Requested 60 00 Forward Forward v NEN 4s ab ej ej e i Tnbble Accumulator Wheep Frequency Output Datalink Overnde Comm OK Operator Tab Maintenance Tab Publication ASIMP QS014C EN P February 2013 BEL BENIJ o Balanced Eccentric nergy Reducer A 2u Um xj iR E o Enabled v ei interlocks and Pormissives Enabled D In Overnde Mode bypass interlocks and Permissmes that can be bypassed Speed Reference Limits Meson 000 Mane Time to pulse Out Reset to clear drive faul sec Use Run Feedback Burpless Program Operator Transition Bumpless Transdion from Override Hand 10 Program Operator Chapter 3 81 Chapter 3 Variable Speed Drive P_VSD Engineering Tab Process Variable Faceplate Balanced Eccentric Energy Reducer h2BET REUS Tag Forwa
37. EN P February 2013 Chapter 1 The system architecture drawings provide value in many stages of the project lifecycle While specifying a system these atchitecture drawings can be included in either the RFP or the proposal itself as an overview of the control system With one illustration they provide a summary of all the hardware components of the control system and the method of communication among all those components They also let control engineers quickly understand the scope of the control system and grasp the control technologies involved System architecture drawings are important eatly in the project life cycle because they efficiently summarize the control strategy Accessing System Architecture Drawings Go to the desired application and select the application of interest Selecting the System Architecture Application WWWAT Common Tooli Lift Station Dating Pumps Ld Controller Application i Supervisory System a HMI Application i Help Lal Lix Controller Information gt i a PanelView Plus information Customizing System Architecture Drawings System architecture drawings are intended to be used as a basis for your system design They require modifications to illustrate your application correctly Include the drawings in your RFP or the proposal itself 11 Chapter 1 Water and Wastewater The Water and Wastewater Treatment Plant documentation package contains Treatment Plant Drawings the following system
38. Eh Main B A01 Pump Alarms Bj A02 Pumpi Control Bj A03 Pump2 Alarms Bj A04 Pump2 Control Bj A05 Pump3 Alarms Bj A06 Pump3 Control E A07 Pump4 Alarms Bj A08 Pump4 Control B A09 PumpS Alarms Bj A10 Pumps Control Bj A11 Pumpe Alarms IB A12 Pump6 Control All these routines should be contained in the Pumps program and every routine must have a JSR instruction in the Main routine 109 Chapter 3 Lift Station Pump JSR Instructions Discrete Alarms In A02 Control of the Pump System Program configure the number of pumps total by setting Pump Demand CFG_PosTotal to equal the number of installed pumps 110 Publication IASIMP QS014C EN P February 2013 Chapter 3 Lift Station Pump 1 Pump 2 Mod MOTOR AVAILABLE Lift Station 1 Pump System Available AOI Total of Positions M Move Source PumpDemand CFG PosTotal LST1 PumpSystemDemand CFG PosTotal 2 Dest PumpAvailable CFG PosTotal LST1 PumpSystemAvallable CFG PosTotal 2 After making these changes map all the I O associated with the additional pumps Refer to the I O Assignment section of this document Changes to the HMI application can be summarized by explaining that adding pumps to the HMI simply requires duplicating existing animation on the screen and assigning the proper pump tags to each of the HMI components Be sure to not only add additional animations for the pumps but also for the discrete inputs located u
39. FeedPump2 A01 Alarms rungs 0 4 FeedPump2 A02 Control rung 5 for the motor related I O Additional Pumps To add additional pumps to the Dosing Pump application 1 Adjust A01 Control in FeedPSys to include for the additional pumps Modifying A01 Control in FeedPSys requires customization that is specific to the application You must use your judgment to determine how to incorporate these changes 2 Add additional pump programs as required These will be duplicates of FeedP1 and FeedP2 To add additional Feed Pumps 1 Copy and paste the existing FeedP1 or P2 program Both programs are identical so either one can be copied 120 Publication IASIMP QS014C EN P February 2013 Chapter 3 Feed Pump Program Folders C8 Feed Fr Program Tags Main Bj A01 Alarms Bi A02 Control E FeedP2 L Program Tags Main Bj A01 Alarms el A02 Control Program Tags Main B A01 Alarms B A02 Control 2 Create new controller scoped tags for the third pump Controller Scoped Tags Name Data Type WWTP_FeedP1 U MotorVSD WWTP FeedP1 FlowPacing U FlowPacing WWTP_FeedP1_OverLoad P_Din WWTP FeedP2 U_Moto VSD WWTP_FeedP2_FlowPacing U_FlowPacing WWTP_FeedP2_ OverLoad P_Din U_Moto VSD WWTP FeedP3 FlowPacing U_FlowPacing WWTP FeedP3 DverLoad P Din 3 Locate the program scoped tags for the new Pump 3 program 4 Define the Alias for Device and the other associated tags as this n
40. IASIMP QS014C EN P February 2013 Chapter 3 Alarms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Process e Equipment Process Alarms There are the fifteen types of Process Alarms Clearwell Level LIT 1302 High Alarm e Clearwell Level LIT 1302 Low Alarm e Clearwell Level LIT 1302 High High Alarm e Clearwell Level LIT 1302 Low Low Alarm Clearwell Level LIT 1303 High Alarm e Clearwell Level LIT 1303 Low Alarm Clearwell Level LIT 1303 High High Alarm e Clearwell Level LIT 1303 Low Low Alarm Clearwell Level Float Low Water Cutoff Clearwell Level Float LSH 1307 High Alarm Clearwell Level Float LSHH 1308 High High Alarm Elevated Tank Level LIT 1305 High Alarm e Elevated Tank Level LIT 1305 Low Alarm Elevated Tank Level LIT 1305 High High Alarm e Elevated Tank Level LIT 1305 Low Low Alarm 231 Chapter 3 232 Process Alarms Distribution Level 1 LIT 1305 hmm Alarm Delay Time secon High High High Low Low Low Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 v High High 4 vf High s v Low le vf Low Low i ua Device Fail Equipment Alarms These are the two types of Equipment Alarms High Service Pump 1 VFD Fault This is a messaged fault from the VSD drive unit Once the PLC receives the fault message it generates a VSD alarm at the HMI High Service Pump 2 VFD Fault This is a messaged fault
41. IASIMP QS014C EN P February 2013 303 Chapter 5 304 Panel I O Layout Sheets Dosing Pump Panel I 0 Layout Sheets Ee ee SE Number Title Description E 130 Panel I O Layout These diagrams show the I O to the controller The format Sheet 1 of 3 uses three cards per sheet This drawing depicts inputs to the card with the input device to the left of the input card E 131 Panel I O Layout It also shows output devices to the right of the output Sheet 2 of 3 card You must add a new sheet for each additional input or output card E 132 Panel I O Layout Sheet 3 of 3 This drawing package was designed with space reserved for all controller chassis card slots In this example drawing package slot 3 is empty This empty slot is represented on sheet E 131 with an empty area on the sheet and the text Spare If you add a card to slot 3 show it in this spare area If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a pre determined location in the drawing package for all the 1 0 modules Include 1 0 information specific to your application on this drawing We expect you to modify these sheets to fit your application Use these sheets as a template for use with many applications even though the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules The Dosin
42. Imissives OK to Pemissives OK tart motor can xtart Device Perm Stk NEPermmo e Dewioet Motor inp NEPemONM LETI P3 germ St NOlenmnOR L ST4 1 Motor Inp ND emm Ok Litt Station 1 Pump 1 Ow H Erte rico cts Litt Station 1 Pump Statue t OR to run o TeInterlocee OW Oe Step motor oah tarta Device intik Ste Intl Dewicet Motoring Inte LSTT P3 4t StI tke SLST IP 1 Motor dep to c Lift Station 1 Pump 1 Nom Bypastable Lam Station 1 Pump Interlock Status 8 1eNon ypaxr CIM AN NE Interlock Intero cke OK me Or te run oan tamen Device toti Ste NIIti e Dpewicet Motor inp NRIAIKOH lt LETI_FP 7 ye Ss NEL nte LSTI F1 Motoi inp Nen Op d a e y gt Litt Station 4 Pump 1 input Communioation Status Or OK tet Dewicet PFunrdbk HOT aut DewiceT Motor inp TOF ault TheocsabtiFault3z L TT P1 otorinp UOFault Devicet InaAuto IOF ault LeocabdihFaulttTs Litt Station 1 Pump Litt Station 4 Pump 1 InReset facelved 1 ImReset an taut tor this amp _Razat z conditions and ecope latched Alarme Device eset Out Reret Davica1 Moterinp Mexet ZLATI F1 Rocet Qut Recet LSTI P Motoring Retet Ct Station 7 Pump 17 Motor OM ote Single Spe Motor FP Motor Oewioe1 hdotosr Ps Out Run 2 LZTT 1 Motor Qut tart5 top Fun dp oe Qut Step gt Inp LP arpo o mte Stopped gt inp N P enn E fte Starting 2 bep Htec 1 Sts_Running gt
43. JE JE E _ fj p 1 pR 4 re lt Chemical Feed Pump CFPS Lead Sequence 5 1 2 3 4 Pump5_Lead Selected Sequence51234 Selected Pump1 Lagi Chemical Feed Pump Any Chemical Feed Sequence 5 1 2 3 4 Pump2 Lag2 Pump Running Selected 4 Chemical_FeedP_Running Sequence51234_Selected 4 Pump3_Lag3 gt CFP1 Auto Available Pump1_Lag4 Pump1 Available E The next step would be to add another pump to the not available section of logic Typical logic to indicate pump is not available Pump Lag NotAvailable CFP2 Auto Available Pump2 Lag4 Pump2 Available fr CFP3 Auto Available Pump3 Lag3 Pump3 Available FE CFP4 Auto Available Pump4_Lag4 Pump4 Available ir CFPS Auto Available PumpS Lag4 PumpS Available NE TE CFP1 at Max Speed Pump Lag4 Pumpi Max Speed ro Finally the following rung would need to be duplicated and changed to the new pump number The purpose of this rung of logic is to indicate when a pump is at max speed The max speed can be changed as explained in the A001 Chemical FeedP1 LDR routine There are some cases when the application or pump characteristics call for not waiting until the pump gets to 100 of is speed before the following pump is started In this example when the pump reaches 90 of its top speed the next pump in sequence is started Typical logic to indicate pump at max speed Pump To Max Speed Pump2 Lag4 Pum
44. MAPPING LAD 5 PF4 MSG LAD 7 PROC SETUP LAD 8 WARNINGS LAD 9 PID LAD 10 ANALOG LAD 11 RECIPELOAD LAD 12 RECIPESAVE LAD 14 STATISTICS LAD 15 PHPCNTRLVL LAD 16 PMPCNTRPRS LAD 19 PMP_RUN LAD 20 ALARMS Bip Bp Bip Be Day De ap De Be Dep Be ep ee Be 268 Publication IASIMP QS014C EN P February 2013 Chapter 3 Recipe Files The parameters for the PowerFlex 4 series VFD s are saved recalled into from RCP files Because a RCP file has a max file length of 32 there are 7 files required to hold all of the parameters 3 RCP Configuration Files E RCP File 0 PARAM E RCP File 1 PARAM Ci Rede E RCP File 3 PARAM E RCP File 4 PARAM E RCP File 5 PARAM E RCP File 6 PARAM E RCP File 7 PARAM Publication IASIMP QS014C EN P February 2013 269 Chapter 3 Notes 270 Publication IASIMP QS014C EN P February 2013 GChapter 4 Installation and Commissioning Important Installation and Commissioning Drawings Water and Wastewater Treatment Plant Hardware Drawings Installation and Commissioning This chapter contains valuable resources to help you install and begin using the Water and Wastewater system Use the following table to locate these resources To Access See Website resources for additional information including Website Resources on e Rockwell Automation product and knowledge base websites page 319 e Water and Wastewater industry websites R
45. Main screen do not display until the application has been set up So the first step is to go through the Application Config button Configuring the Application The functions available when you select the Application Config button include e Select the pumps and pump modes e Select primary and secondary measuring devices e Select control devices for all active pumps Assign digital inputs and their states Assign backup pumps Each of the configuration screens contains standard navigational tools Press Prev or Next to navigate between screens Press Up Down or Enter to navigate available choices on a single screen Press Exit to return to the Main menu To use the configuration controls 1 From the Main screen press Application Config to display the configuration screen Fi Pump Up Empty Pump Down Pressure Follower From the configuration screen you can Use the Up Down Enter buttons to select from the three available operation modes Publication IASIMP QS014C EN P February 2013 Chapter 3 Press Enter The Number Of Pumps to select the number of pumps 1 4 in use in the system View a description of the selected mode 2 Press Next to proceed to the Measuring Setup screen Hz Analog IN 0 From the Measuring Setup screen you can Use the Up Down buttons to select the primary measuring device TIP If Pressure Follower mode is selected then A
46. Reset button next to the appropriate pump SST Mechanism STP Single Speed Motor Run Time i EE Current running time this start 02 hours Maximum continuous running 02 c lime for a given start hours y 070 Total accumulated running 03 fe time hours i Total number of motor starts 33 A or attempts 10 0 164 Publication IASIMP QS014C EN P February 2013 Chapter 3 Customization of the Solids Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the Solids application This section describes customization specific to the Solids application 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template e MainProgram A04 AnalogOuput as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine Although the following specific example illustrates how to add a Solids Transfer Pump the procedure can be followed for many of the pumps motors in the toolkit using the Single Speed Motor AOI
47. Secondary Treatment System Hardware Drawings e Solids Handling System Hardware Drawings Chemical Feed System Hardware Drawings e Flushing System Hardware Drawings The Lift Station and Dosing Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings Publication IASIMP QS014C EN P February 2013 295 Chapter 5 Lift Station Hardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Lift Station folder and it contains the following drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e Panel I O Layout Sheets Device Wiring Schematics Title Page and Sheet Index Lift Station Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT aT rete Bak ee UT Tete F mu TUS nee Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application 296 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 5 Process Flow Diagram Lift Station System Process Flow Diagram Description E 160 System This diagram depicts a Lift Station consisting of two pumps Proce
48. Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT te ae Tt cee 1 Hs Ha M OCT aah C EUH Number Description Index Title Page and This is the Table of Contents Cover Sheet for the drawing Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Chapter 2 Communications Diagram Pump Controller Station Communications Diagram E 12 Pump Control Refer to Pump Controller Station Architecture Drawing on Communications page 28 for details Diagram Publication IASIMP QS014C EN P February 2013 45 Chapter 2 46 Panel Layout Diagram Pump Controller Station Panel Layout Diagram Number 13 E amim mri mi auLt Fi uo I ill iil Th oss Title Pump Description Controller requirements Station Panel Layout Diagram You can modify this as needed for your application Publication IASIMP QS014C EN P February 2013 Chapter 2 Power Layout Sheets Pump Controller Station Power Layout Sheets Publication IASIMP QS014C EN P February 2013 47 Chapter 2 Description 1 3and5 Power Layout Pump Control Power Distribution 480VAC Power and Sheets 24VDC Power Drawings 48 Publication IASIMP QS014C EN P February 2013
49. The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application The Dosing Pumps are assumed to be run by a third party supplied controller The ControlLogix interfaces to it via a remote chassis This scenario should be reviewed and adjusted based on the strategy for the specific dosing pump control e The input and output card configuration in the remote chassis must be determined based on the specific needs of the inputs and outputs located in the proximity of that chassis Publication IASIMP QS014C EN P February 2013 Chapter 1 Primary Treatment System Architecture Drawing The following is an example of a typical Primary Treatment System Architecture Drawing Primary Treatment System Architecture Drawing The following table describes the key design points of the Primary Treatment System Architecture Drawing Hardware Description ControlLogix Processor Controls the Primary Treatment System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the pumps EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the plant network Publication IASIMP QS014C EN P February 2013 15 Chapter 1 The WWWAT CD also contains System Architecture Dra
50. additional input or output card This drawing package was designed with space reserved for all the Controller Chassis card slots In this example drawing package slot 3 is empty This empty slot is represented on sheet E 131 with an empty area on the sheet and the text Spare If you add a card to slot three you should show it in this spare area If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a pre determined location in the drawing package for all the 1 0 modules Include I O information specific to your application on this drawing We expect you to modify these sheets to fit your application You use these sheets as a template for use with many applications even though the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules The Dosing Pump Panel 1 0 Layout Sheet contains one example of each type of module that will typically be used in a lift station application Note that these modules are 1756 style 1 0 modules Different I O modules will require changes to these sheets Publication IASIMP QS014C EN P February 2013 Water Treatment Plant Hardware Drawings Publication IASIMP QS014C EN P February 2013 Chapter 4 The Water and Wastewater Treatment Plant WTP Hardware documentation package contains the following system level drawing packages e Raw Water In
51. amp DosingApplication amp B MainProgram 9 Program Tags Main B A01 DiscreteInputs B A02 AnalogInputs BB A03 Outputs amp FeedPSys I Program Tags Main BB A01 Control C8 Feed A Program Tags Main Bj A01 Alarms B A02 Control C amp Feedp2 9 Program Tags Fi Main Bj A01 Alarms BB A02 Control This task resides in a Controller located in the main facility of the plant using the Dosing Pump application It is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other systems of the plant 113 Chapter 3 The organization of this application is similar to that of the Lift Station Specifically the functionality for each program and routine is e Main Program handles general Dosing Pump application s functionality including Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 DiscreteInput maps inputs that are relevant throughout the Dosing Pumps A02 AnalogInput maps analog inputs that are relevant throughout the Dosing Pumps A03 AnalogInputs maps inputs that are relevant throughout the Dosing Pumps e PSys determines how many pumps to run and which pumps to start This is a supervisor o
52. at the MCC to put the SCT in the Remote mode Operator Mode Manual Click the SCT section of the Secondary Overview screen Selecting the SCT on the Secondary Overview Screen The system displays the Tank Drive Faceplate Publication IASIMP QS014C EN P February 2013 147 Chapter 3 Tank Drive Faceplate Tank Drive hx ag DUET 05 Enabled Stopped p Wii _ eje For manual Operator Control select the Operator mode on the Tank Drive Faceplate The Faceplate shown is used to control the Tank Drive The operator starts and stops the drive remotely from the Tank Drive Faceplate selecting Tank Drive on the Secondary Overview screen The available Faceplate commands include Press the Play button to start the drive Press the Stop button to stop the drive Click the Disable button to remove the drive from service Click the Enable button to place the unit back into service Alarms The Supervisory Control and Data Acquisition SCADA system generates the following equipment alarms Start Stop Faults If the blowet is called to start and is not running after 5 seconds the HMI generates a Start Stop Fail alarm If the RAS pump is called to start and is not running after 5 seconds the HMI generates a Start Stop Fail alarm If the SCT center drive is called to start and 1s not running after 5 seconds the HMI generates a Start Stop Fail alarm Blower Fault This is a contact f
53. branch for the Reset button To remove a pump from this Reset group tie a different Reset button to this branch In general there are three important customizations that are required with this object Assigning all the Reset Required bits to the P Reset object Assigning all the devices such as buttons that can initiate a reset to the P Reset object Properly distributing the Reset command to all objects that will use its reset Lift Station Pump Control Rung 2 Lift Station 1 Pump 1 Reset Input 1 Reset from Site Wide Device pushbutton or Reset Push Button another object Device1_GroupReset Device1 Reset Inp Reset PLC Device ResetPB LST1 P1 ResetInp Reset _ _ _ _ C Assigning the Device That Initiates the Reset Assigning the device that initiates the reset is also done on the rung with the P Reset object Add branches here for all devices that can initiate a Reset command to this P Reset object These devices may include commands from the HMI hard wired reset buttons or other operator interfaces that provide a Reset command Assigning the Reset Required Assigning the Reset Required bits is done on the rung with the P Reset object All Reset Required bits from all objects that will receive the reset command must provide a Reset Required bit to this reset Add branches to this rung for each device that will fall within the group for this P Reset The illustration below demonstrates
54. contains the Cycle Timer including the U_RepeatCycTmr AOT and High Differential Alarm code This routine is provided as a Ladder Diagram A04 DiffLevel contains the Analog Input AOI that monitors the differential pressure levels of Preliminary Treatment Flow Channel No 1 This routine is provided as a Function Block Diagram BarScreen02 Controls the motor and manages cycle times and flow channel differential levels for the Bar Screen 2 system as described for BarScreen01 above GritTank01 Controls the motor and manages cycle times for the GritTank01 system including Main routine calls the other routines in this program A01 GritTankDrive LDR contains the code to monitor and control the Bar Screen 01 motor and reset alarms interlocks and faults associated with the motor This routine is provided as a Ladder Diagram Publication IASIMP QS014C EN P February 2013 125 Chapter 3 A02 GritTankDrive FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Grit Tank 01 motor This routine is provided as a Function Block Diagram A03 GritTankDrive Auto contains the Cycle Timer including the U_RepeatCycTmr AOT code This routine is provided as a Ladder Diagram A04 GritTankFlow contains the Analog Input AOI and U FlowTot AOI that aggregates the Grit Tank 01 flow This routine is provided as a Function Block Diagram e Wet well monitors Wet well level and gene
55. equipment in the this mode to use it from the HMI The operator can place the Mechanical Bar screen in the Remote mode by selecting Auto on the Auto Off Hand selector switches located at the MCC for each equipment In Remote mode the operator may select Auto or Manual mode to control the process from the HMI Publication IASIMP QS014C EN P February 2013 129 Chapter 3 130 Operator Mode Manual Click the screening equipment to display the Single Speed Motor Faceplate screen Single Speed Motor Faceplate Screen HMI Template Single Speed Motor Fen M8 Program al Enabled ELTTEN PON e e Comm OK For Manual Operator Control select the Operator mode from the HMI equipment Faceplate The Faceplate shown is used to control the screening equipment The screening equipment is started and stopped remotely from the HMI screen The available Bar screen commands include Press the Play button to start the Bar screen Press the Stop button to stop the Bar screen Click the Disable button to remove the Bar screen from service Click the Enable button to place the unit back in service Program Mode Auto To place the Bar screen in Program Mode Auto control perform the following 1 Select Auto on the Auto Off Hand selector switches located at the MCC for each equipment to place the Bar screen in the Remote mode 2 Select Program mode from the HMI Faceplate template When in Remote Program mo
56. from the VED drive unit Once the PLC receives the fault message it generates a VED alarm at the HMI Publication IASIMP QS014C EN P February 2013 Chapter 3 Reporting The SCADA system records Process The system will trend common signals and record them for future viewing including High Service Pump P 1300 Output Frequency Command Frequency High Service Pump P 1301 Output Frequency Command Frequency Equipment Runtimes e Runtimes are recorded for the blower and clarifier center drive mechanism by the SCADA system Depending on the user s security level the total runtime may be reset by clicking on the Total Reset button next to the appropriate pump High Service Pump 1 High Service Pump 2 Single Speed Motor Run Time ih EE Current running time this start 02 hours Maximum continuous running 02 1 lime for a given start hours 0 07 Total accumulated running 03 D time hours r 070 Total number of motor starts 33 A or attempts OU Publication IASIMP QS014C EN P February 2013 233 Chapter 3 Pump Controller Station 234 Customization of the High Service Pump Station Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the High Service Pump Station This section describes customization specific to the High Service Pum
57. icons are enclosed in the large red box on the WTP Overview screen If you want to return to the WWTP Overview screen click the Overview button Selecting the Separation WTP Overview Screen y RAW WATER INFLUENT CHAMBER GRIT CHAMBER TANI RAPID MIX FLOCCULATION SEDIMENTATION INTAKE amp PUMP amp BAR SCREEN BASIN BASIN STATION CLEARWELL AND HIGH SERVICE PUMP STATION lu j DISTRIBUTION SYSTEM RESERVOIR Doegiey WIP Overen Publication IASIMP QS014C EN P February 2013 Chapter 3 Separation Overview Screen There ate no tema to showin this view The status information on the Separation Overview screen includes e Flocculation Mixer Mechanism e Sludge Mechanism Publication IASIMP QS014C EN P February 2013 217 Chapter 3 218 Control Description Flocculation Mixer Mechanism Plant operators control the Flocculation Mixer manually A VSD powers the mixer which allows operators to adjust its speed Hand Mode Select Hand on the Hand Off Auto selector switch located at the VSD to operate the mixer locally The operator uses the buttons located at the VSD to operate it Selecting the Flocculation Basin on the Separation Overview Screen Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the VSD to put the mixer in the Remote mode Select the operating state On Off and set the speed on the VSD Faceplate Operator Mode Manual
58. n Comm Failure a MOV 1 09 1 0 Status Indicator Publication IASIMP QSO014C EN P February 2013 71 Chapter 3 Motor Operated Valve P ValveMO Maintenance Tab Process Variable Faceplate Motor Operated Inlet Exit Valve EA TONS tr Mode Indicator I g amp A 7 Requested Mode fo Operator _ amp D ro Maintenance Mode indicator Acquire and Release ndicator H M Command Buttons Valve Disabled D iS Valve Enable and Indicator 2 Enabled Ki Disable command wt Buttons Open and Close Permissives Open and Close Open and Close Permissives Enabled A Bl Permissive Bypass Bypassed Indicator nd In Override Mode bypass Open and Close Permissives that can be bypassed Use Valve Closed limit switch for failure checking Use Valve Open limit switch for failure checking After commanded time with no motion before Fault sec After command time to reach position before fault sec Time in seconds to pulse valve outputs 0 outputs maintained ON Publication IASIMP QS014C EN P February 2013 Chapter 3 Motor Operated Valve P ValveMO Engineering Tab Process Variable Faceplate Motor Operated Inlet Exit Valve Configure Valve Description Label and Tag Stop output can be used to break local seal in and stop valve motion 4 Clear Program Commands on receipt AP Perm object is connected to Inp OpenPerm AP Perm object is connected to Inp ClosePerm Valve provides a Cl
59. of Contents Iotroddetiots 5 sta IN acest dese adno he Oe At p dat acd ipn eal pp 5 Required Software Sos eoe WE e Head a ee eX PRS ENG 7 Chapter 1 Tntrod cton aise eaa po d un qo doe s dr e RW PP PER 9 Procurement Specifications es v eMe vo REUS me bia ga 9 Customizing Procurement Documents 00 0000 10 System Architecture Drawings i i eeu oes eese tertie bees 11 Accessing System Architecture Drawings 044 11 Customizing System Architecture Drawings lesus 11 Water and Wastewater Treatment Plant Drawings 12 Lift Station System Architecture Drawing 004 12 Dosing Pump System Architecture Drawing suus 14 Primary Treatment System Architecture Drawing 15 Headworks System Architecture Drawing 0 17 Secondary Treatment System Architecture Drawing I9 Solids Handling System Architecture Drawing 21 Water Treatment Plant Drawings ed Cadete p Eee KR 23 Raw Water Intake Pump Station System Architecture Drawing 23 Separation Station System Architecture Drawing 25 High Service Pump Station System Architecture Drawing 27 Pump Controller Station Architecture Drawing lesus 28 Additonal R s urces c eae e ter reed re oro ee een 29 Chapter 2 Tatroducton eu ue ac xti RD abo E Red CR Pubs eoo te 31 Hardware Dia Wiis ene Tere ar ltd parade ed RE Aci Kaos re 31 Water and Wastewater Treatment Plant
60. of the output Sheet 2 of 2 card You must add a new drawing sheet for every additional input or output card This drawing package reserves space for all the slots of a controller s chassis If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a pre determined location in the drawing package for all the 1 0 modules 1 0 specific to an application are shown here and it is expected that these sheets are heavily modified for each application These sheets provide a template for use for many applications though even if the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules This provides one example of each type of module that will typically be used in a Raw Water Intake System application Note This drawing depicts 1756 style 1 0 modules If you use different I O modules you must also update these sheets Publication IASIMP QS014C EN P February 2013 43 Chapter 2 Pump Controller Station Hardware Drawings 44 One of the System Architecture sub folders on the WWWAT CD is the Pump Controller Station folder and it contains the following drawings e Title Page and Sheet Index Communications Diagram e Panel Layout Diagram e Power Layout Sheets e Panel I O Layout Sheets Title Page and Sheet Index Pump Controller Station Title Page and
61. run time maximum run motor control center MCC time or start count information for bucket to show total motor run a piece of equipment on the time The time and number of operator display and you do not starts are variables used by have monitoring software that maintenance personnel to provides the information determine when to perform an maintenance activities on motor Your equipment monitoring or other equipment software expects the Controller to provide equipment run time and starts values rather than just a Running status 74 Publication IASIMP QS014C EN P February 2013 Chapter 3 Run Time P_RunTime Process Variable Faceplates Operator Tab Engineer Tab Run Time for Product Transfer Pump th amp Current running time this start hours Maximum continuous running k time for a gwen start hours y Total accumulated running time hours Reset Button Total number of motor starts or attempts Run Time for Product Transfer Pump Clear Program Commands on receipt Publication ASIMP QS014C EN P February 2013 15 Chapter 3 Motor Operated Valve P_ValveMO The following table describes the Motor Operated Valve P_ValveMO parameter and its usage Motor Operated Valve P ValveMO AOI Variable Speed Drive P_ValveMo Description This AOI operates open and close a motor operated valve in a variety of modes see below monitoring for fault conditions Us
62. that the plant is required to implement treatment steps Feeding Alum to the wastewater increases the amount of sludge generated which will result in larger quantities sludge in the secondary clarifiers The Alum is pumped from the two storage tanks by two metering pumps numbers 1 and 2 These pumps are paced by the plant flow rate WARNING Alum is a potentially dangerous substance and must be handled with care From the overview screen click the Alum button or the Alum Storage Tank icon to display the Dosing Pump Application screen 115 Chapter 3 Selecting the Alum Button COO OOE EMEC EE EOE EE EEE AAA ALAA AAA mceeemrergmemrrmnnm OOOO OEE EE EES m P xi Alum Storage tank oo Dosing Pump Alum Feed Screen aed Alum Feed n gt o aH vein nov MINER c Yearly Flow a MGAL Loni Years Flew Em MM Picton Pont Calibralion Chamber LL Shows the statusof the alum storage Stepp tank eo tp mn peream E or Com d o tee kaa The lower left of the Alum Feed screen shows the status of the Alum storage The Alum storage tanks are equipped with ultrasonic level sensors to measure the gallons stored Alum in each tank The tank volume and pump status are displayed on the Alum Feed Overview screen Selecting the Alum Storage 116 Publication IASIMP QS014C EN P February 2013 Chapter 3 Level display opens the Analog Input Faceplate for the Alu
63. these reset required bits and the branch required Publication IASIMP QS014C EN P February 2013 105 Chapter 3 Lift Station Reset Command M Tres ER eT ENTE TE NT EE ESN RR e RESET O DEVICE RESET Resets al alarms intetiods and lavit tor the P metor and related signals It also receives Lift Station 4 Pump 1 Motor OQvetioad Contact 1 Ready fo Operator Alam Reset Command Device AlmO R y Reset LST1 P1 Overoad Rdy Reset Lift Station 1 Pump 1 teRaset Required enable Reset button Device Reset inp ResetRaqd LSTt_P Reset inp_ResetReqd gt Reset Required Bits from other objects Litt Station 1 Pump 1 Motor High Temperature Sewteh t Ready for Operator Alarm Reset Command Device1 Alm Rdy Reset LST1 P1 MoterHiTemp R dy Reset Disorete Input Ready for Operstor Alam Reset Command Devicet Alm2 Rdy Reset LGT1 P4 Alm2 Rey Reset Lift Station 1 Pump M1 1 Ready to teceive OC md Reret enadies HMI button Device1 Motor Rdy Reset lt LST1_P1 Motor Rey_Reset gt Litt Station 1 Pump 1 Rasat Input Reset trom Site Wide Device Reset Push Button Device 1_GroupR eset PLC Device ResetPB Distributing the Reset Command Pushbutton or another object Device1 Rezet inp Reset LST 1 PA Reset Inp Reset Litt Station 1 Pump 1 Repat Reset Reset P Reset Device Reset
64. where pump control is based on the level of a wet well The Water and Wastewater sections of the WWWAT contain the Lift Station system application because of its general applicability Its Controller organization is shown below 90 Publication IASIMP QS014C EN P February 2013 Chapter 3 Lift Station System Application Controller Organization C MainProgram A Program Tags Main Bj A01 DiscreteInputs Bj A02 AnalogInputs Bj A03 DiscretOutputs B A04 AnalogOutputs amp Pumps Program Tags Main B A01 Pumpl Alarms B A02 Pumpi Control Bj A03 Pump2 Alarms BB A04 Pump2 Control Bj A05 Pump3 Alarms BB A06 Pump3 Control E A07 Pump4 Alarms E A08 Pump4 Control BB A09 PumpS Alarms E A10 PumpS Control Bj A11 Pump6 Alarms BB A12 Pump6 Control E PumpSystem Program Tags Main Bj A01_StartOrder Bl A02 Control The functionality for each program and routine is e Main Program handles Lift Station wide inputs and outputs Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 DiscreteInput maps inputs that are relevant throughout the Lift Station A02 AnalogInput maps analog inputs that are relevant throughout the Lift Station A03 AnalogInputs maps inputs that are relevant throughout the Lift Station A04 AnalogOutputs
65. 013 Chapter 3 Lift Station program for Pumps and its associated Main routine with a JSR to all other routines Program Example Publication IASIMP QS014C EN P February 2013 85 Chapter 3 86 Inputs and Outputs The philosophy for real world inputs and outputs are that they are mapped to tags in the Controller Each I O point occurs once in the Controller on the rung where it is mapped For example consider this rung Inputs and Outputs Wetwel Lo Level Float Alarm Lift Station 1 Low Level Float Alarm Input Signal Low Level Float process varisble Alarm from Sensor Local 11 Data 10 LSTI LoL vFloat np PV UR Station 1 Low Level Fiost Alarm VO Communication Status 1 Faut 0 OK LSTI LoL vFiost np IOF eut Locat 1 1Fout 10 Din Discrete Input with Alarm P D LSTI LoLvFiost ko Pv De iro Target 1e Ino Gate te inp JOF out 0e Oe In the Lift Station application the Wet Well Low Level Sensor has been electrically connected to the 10th input on the card in slot one of the Local Rack The mapping of physical I O to internal bits is good programming practice for the following reasons e If the electrical design changes you only have to make one change in the program e Keeping all this inputs and outputs together keeps your application clean and consistent This mapping should be done on the same rung as the object that uses the input for the following reasons e W
66. 04 GritTankFlow contains the Analog Input AOI and U FlowTot AOI that aggregates the Grit Tank 01 flow This routine is provided as a Function Block Diagram e Wet Well monitors Wet Well level and generates alarms including Main routine calls the other routines in this program A01 Wellwell contains the code to monitor Wet Well level and generates alarms utilizing the Analog P AIn and Discrete P Din Input AOIs This routine is provided as a Function Block Diagram AOI instructions are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P_ in their name The other AOIs have a prefix of U_ as shown in the AOI illustration AOls E S Add On Instructions m GJ P AIn i P Alarm w P DIn w P Intlk w A P Mode HR P Motor m iz P Perm iz P Reset P ResInh LS P RunTime U_CommFail U_FlowTot o U_Heartbeat U_RepeatCycTmr 5 U WallClock Process Description The Raw Water Intake application consists of Screening Influent Flow Measurement and Grit Removal From the inlet well the wastewater enters 202 Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 one or two preliminary treatment flow channels Each flow channel consists of an Inclined Bar screen with a mechanical ra
67. 8 D 1 50000000e 038 Alm Lo 7 2 C2 S Ly le Fail 5 2 C3 tate Signature ID 7928730 c Loo 2 C3 2 C4 B00 Chemical Flow LDR In this example program this routine is left blank X00 Auto Control LDR The routine is left blank in this application but should the programmer need to add any logic for this program it would be placed in this routine Chemical Feed System Program This is the main part of the chemical feed system as this program contains the five chemical feed pump and mixer logic Main This program contains the JSRs to all the routines in this program A000 CPP Availabily LDR The rungs in this program enable the operator to pick a pump sequence and it also checks the availability of the pump can it be used in our sequence if it is not ready it is skipped during automatic cycle Customization Should a pump need to be added the programmer can copy rung 4 paste it and change the tags to reflect new pump sequence Publication IASIMP QS014C EN P February 2013 187 Chapter 3 Typical logic to select pump sequence Chemical Feed Pump Any Chemical Feed CFP5 Selected As CFP2 Selected As CFP3 Selected As CFP4 Selected As CFP1 Selected As Sequence 5 1 2 3 4 Pump Running Lead From HMI Lead From HMI Lead From HMI Lead From HMI Lead From HMI Selected Chemical FeedP Running P5 Lead PB P2 Lead PB P3 Lead PB P4 Lead PB P1 Lead PB Sequence51234 Selected
68. ASIMP QS014C EN P February 2013 Chapter 3 Secondary Overview Screen Alam tame Cordtion Menag Thee ara no tees V6 show n Ber vmm Fem es sen SS ee uae gei The status information on the Secondary Overview screen includes e Blower BLR 400 e Secondary Clarifier Setting Tank 1 e RAS Pump P 401 e Return Flow Rate FIT 401 Publication IASIMP QS014C EN P February 2013 143 Chapter 3 Control Description Blower BLR 400 This section describes the BLR 400 Blower modes Hand Mode Select Hand on the Hand Off Auto selector switch located at the MCC to operate the blower locally The operator uses the buttons located at the equipment to operate the blower Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the MCC to put the BLR 400 Blower in the Remote mode Operator Mode Manual Click on the BLR 400 Blower section of the Secondary Overview screen Selecting Blower BLR 400 on the Secondary Overview Screen Blower Fault Stopped m Blower BLR 400 The system displays the Blower BLR 400 Faceplate 144 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Blower BLR 400 Faceplate Blower BLR 400 Aren Bg a Enabled Stopped gt m j amp e e Comm OK For manual Operator Control select the Operator mode on the BLR 400 Blower Faceplate The Faceplate shown is used to control the blow
69. Assign screens in total From the first Digital Inputs Assign screen you can Use Digital input I 0 0 as a pulsed input to totalize flow only or to totalize flow and calculate a flow rate 238 Publication IASIMP QS014C EN P February 2013 Chapter 3 As a flow totalizer this can be very accurate However using it to calculate flow rate is not as accurate as using analog input I 1 1 as a flow rate input Press Enter Gallons Per Pulse to set the appropriate gallons per input pulse 5 Press Next to proceed to the next Digital Inputs Assign screen From the remaining Digital Inputs Assign screens you can Press Normally Open or Normally Closed to set the state to match the way the digital input is wired on the field device Use the Up Down and End Home buttons to scroll through the list of selections Digital inputs I 0 0 I 0 17 are assignable to any of the 27 selections listed however depending on the application they may not all be applicable For example if you only have two pumps in your system selection 20 Pump 3 seal fail would not apply NOT USED Pump 4 Running Pump 1 Seal Fail Selection 0 of 27 Selection 9 of 27 Selection 18 of 27 Low Level Pump 1 OL Fault Pump 2 Seal Fail Selection 1 of 27 Selection 10 of 27 Selection 19 of 27 Pumps Stop Pump 2 OL Fault Pump 3 Seal Fail Selection 2 of 27 Selection 11 of 27 Selection 20 of 27 Lead Start Pump 3 OL F
70. C EN P February 2013 Chapter 3 Start pump logic CHEMICAL FEED PUMPS Chemical Feed Pump Any Chemical Feed AUTO START Start Required Pump Running Pumps Auto Start Chemical Feed StartReq Pump Lead NotAvailable Chemical FeedP Running Chemical FeedP1 P VSD PCmd Stop Chemical FeedP1 P VSD PCmd Start JE JE w P G UNNEEEEEEEEEEEEEEM CFP1 Lead Pump1 Lead Pump Lag NotAvailable Pump Lead MaxSpeed Pump1 Lagt Pump Lag2 MotAvailable Pump Lag MaxSpeed JE Pump1 Lag2 Pump Lag3 NotA vailable Pump Lag2 MaxSpeed Pump Lag3 Pump Lag4 NotAvailable Pump Lag3 MaxSpeed JE Pump1 Lag4 Chemical FeedP1 P VSD PCmd Start REL If the chemical tank and basin levels are OK we are calling for the pump to start and depending on what pump this is in the pump sequence we tell the pump to start Notice we do not start the pump unless the pump ahead of it in the sequence is at max speed RUNG 2 Conditions to stop the pump Since the CV is broken down into 20 increments 100 divided by 5 as the CV decreases the corresponding pump will stop Publication IASIMP QS014C EN P February 2013 193 Chapter 3 Stop pump logic Chemical Feed Pump Chemical Feed Pump Stop Required CFP1 Lead Start Required Chemical Feed StopReq LES Pump1 Lead Chemical Feed StartReq Chemical FeedP1 P VSD PCmd Stop Less Than A B j sam c Source A ChemicalFeedP P
71. CD01 Chemical FeedP3 LDR D001 Chemical FeedP4 FBD D001 Chemical FeedP4 LDR E001 Chemical FeedP5 FBD E001 Chemical FeedP5 LDR FO01 Chemical Feed Mixer1 FBD FO001 Chemical Feed Mixer1 LDR GD01 Chemical Feed Mixer2 FBD GODO1 Chemical Feed Mixer2 LDR HO01 Chemical Feed Mixer3 FBD HO01 Chemical Feed Mixer3 LDR LOO1 Chemical Feed Setpoint Strater LOO1 Chemical Feed Setpoint Strater YOO1 Status FBD vYOO1 Status LDR 2000_Sirm Simulation_FBD C amp Main_Program Program Tags Main 400_Simulation_FBD The functionality for each program and routine is as follows Main Program This program is used to display operator assist messages and pop ups on the HMI screen It can also be used for all user routines that do not specifically affect direct operation of the system Interlocks heartbeats to other PLCs are examples of this Chemical Tank Levels Program Main This program contains the JSRs to all the routines in this program The B00 Chemical Tank 1 Level FBD and C00 Chemical Tank 2 Level FBD routines contain the P_AIn AOI Publication IASIMP QS014C EN P February 2013 Chapter 3 function block that calculates the levels for chemical tanks 1 and 2 on sheet 1 Typical P_Aln instruction used for chemical tank level CHEMICAL TANK 1 LEVEL Chemical_Tank_1_Level_P_Aln P Aln Analog Input Chemical Tank 1 Level Value 2 B2 Chemical Tank 1 Level lNP P Chemical Tank 1 LevellO FAULT
72. D Sts Running red boat Chem Pump Running Interlock Chemical FeedP4 P VVSD Sts Running Chemical_FeedP5_P_YSD Sts_Running Publication IASIMP QS014C EN P February 2013 Chapter 3 HMI Description The following is a brief description of the HMI portion of this project HMI Overview screen m ChemicalFeedSystem FactoryTalk View SE Client START STOP CYCLE PB S m PV 249 95 GPM SCREEN EN BASIN 1 CHEM FEED FLOW PID SET POINTS AND E 249 96 GPM SELECT PUMP SEQUENCE PB S CHEMICAL SPRAY NOZZLES pon INFLUENT LEVEL Son 2000FT M m oo CHEMICAL FEED PUMP 1 4 2o See 2 10 00 E 33 92 o Running Forward p wa oa CHEMICAL FEED PUMP 2 CHEMICAL TANK 1 CHEMICAL TANK 2 gt 100 00 96 P CHEM TANK 1 LEVEL Y CHEM TANK 2 LEVEL Y Running Forw 1200FT M amp DFT M CHEMICAL FEED PUMP 3 3 100 00 iP Running CHEMICAL FEED PUMP 4 100 00 a Running Forward CHEMICAL FEED PUMP 5 99 93 D INFLUENT FLOW WP i 2500 0GPM M Se i T lt i gt Unable to initialize Alarm Historian Alarm server RNA Local HUB SFLD 20110708 FinalDWSD chem FTAE TagServer is unhealthy O Clear Clear All gix Emulate O Chemical Feed Pu i 000 C HMI 2 Paint Publication IASIMP QS014C EN P February 2013 197 Chapter 3 Chem
73. Flex 4 VFD S are being used the following parameters need to be set on each VFD 1 P36 start source 5 comm port 2 P38 speed reference 5 comm port 3 PowetFlex 4 40 A103 comm data rate 5 38 4k PowerFlex 400 C103 comm data rate 5 38 4k 4 PowetFlex 4 40 A104 comm node address 1 4 PowerFlex 400 C104 comm node address 1 4 The PLC is programed to control PowerFlex 4 VFD s at node address 1 4 If pump 1 is a PowerFlex 4 drive it must be set to node 1 If pump 2 is a PowerFlex 4 drive it must be set to node 2 and so on with the remaining pumps 5 PowetFlex 4 40 A106 comm loss time 10 sec PowerFlex 400 C106 comm loss time 10 sec The default time of 5 sec may work satisfactory however during parameter saving and loading the message instructions in the PLC may take longer than usual and the additional time may alleviate some nuisance communication faults 6 PowerFlex 4 40 A107 comm format 0 RTU 8 N 1 PowerFlex 400 C102 comm format 0 RTU 8 N 1 Panel View C600 2711C T6T Firmware version 1 60 1 IP address 192 168 1 3 2 Subnet 255 255 255 0 3 Gateway 0 0 0 0 not used 262 Publication IASIMP QS014C EN P February 2013 Chapter 3 4 DHCP Off not used r Protocol sena DF gt Ethernet Allen Bradley MicroLognyENI D PanelView Component Settings WweOnmuon No configurable properties at protocol
74. GJ U_Heartbeat U RepeatCycTmr EJ U_WallClock Process Description The Solids Treatment application includes e Waste Activated Sludge WAS Valve e Solids Storage Tank SST e Solids Storage Tank Agitator SSTA e Solids Transfer Pump STP Waste Activated Sludge Valve WAS is removed from the RAS discharge piping using a throttling valve The throttling valve is controlled to provide the operated selected flow rate to the WAS holding tank Solids Storage Tank The influent to the storage tank is comprised of primary solids PS and WAS The contents are mixed by mechanical agitators The Blending Tanks feed the dewateting system A transfer pump located in the basement of the Solids Building is used to transfer the contents of the tank to the Belt Filter Press BFP Solids Storage Tank Agitator A Paddle Agitator mixing mechanism is provided in the tank to continually mix the tank contents prior to pumping The mixing mechanism is used to minimize solids settling and to ensure that consistent feed solids characteristics are applied to the dewatering system 155 Chapter 3 Solids Transfer Pump A transfer pump transfers blended solids from the storage tank to the BFP Blended solids consist of PS and WAS A grinder is located upstream of the BFP feed pump and Pulsation Dampeners are located on the suction and discharge side of the pump A flow meter is located on the discharge of the pump to the BFP
75. Hardware Drawings 31 Lift Station Hardware Dra wines se sie te em Re d d 32 Dosing Pump Hardware Drawings 0 000 000 00008 36 Water Treatment Plant Hardware Drawings 00 40 Raw Water Intake Pump Station System Hardware Drawings 40 Pump Controller Station Hardware Drawings 00 44 CAD ETS as eekan v Rise e we My PETRI as Ca OO AA 50 How to Access Additional CAD Figures from the Website 51 Additonal RESOURCES onde AA o Set bate e Ages oae Sm ed Rs 51 Chapter 3 Additional Resongees uoo tus or amate e BOON tom eam 53 Process Library Mauule iari uii ba are oinnia Bett dedita 53 Using ihe Process Library Module bo ee eta es 55 Reuse Code ss ciani PE Te EC TER VOR EE Sua SF 55 Provide an Easier to Understand Interface 55 Intellectual Property Protection d rt wee iors ees 56 Using Add On TnStracuomesc o 2o tese REUS E e DER a ted gs 57 1 ako CP XA EET ito eatis b ea anh Ge Wei anh ee Me ya Bia old 57 Analog Input basic Instruction P_Aln 0044 58 Digital Input Instruction P_Dln seis ei A Air odd 61 Interlock Instruction P Tntlby oo ab te bl eb eR etis 63 Mode P MO 2 eite ended rick mar ios a bacs bcr e Da 65 Motor CEP ZMOTOE s oni hee s cnet NU e dA SC acute tity Ao 68 Permissive P Perm i2 iaa cc S er ee E rd o eO RA ws 71 Reset P R set wx aces pct C e RET n EO VIS TN 72 Reset Inhibit D ResetInB sod eb oed MEE ae 73 R n La
76. IDE CV 99 93977 Source B 1 LES Pump1 Lagi Less Than amp B Source A ChemicalFeedP PIDE CV 99 93977 Source B 20 LES Pump Lag2 Less Than A B Source A ChemicalFeedP_PIDE CY 99 93977 4 Source B 40 LES Pump1 Lag3 Less Than amp B Source A ChemicalFeedP PIDE CV 99 93977 Source B 60 LES Pump1 Lag4 Less Than amp B Source A ChemicalFeedP_PIDE CY 99 93977 Source B 80 Chemical FeedP1 P VSD PCmd Stop JE Is pump in local or remote Local or Remote Pump_1 LOCAL Pump 1 REMOTE JF TE RUNG 4 In this rung we examine the CV and the pump sequence number then we take the computed value of the speed and put it into the Pset_SpeedRef tag of the pump Customization To add delete a pump you would take the max CV 100 and divide it by the number of pumps this value would then be split evenly between the low limit of the LIM blocks then a new expression would be put into the CPT block to reflect the new number of pumps 194 Publication IASIMP QS014C EN P February 2013 Chapter 3 Pump speed calculation CFP1 Lead Chemical FeedP1 P VSD Sts Running mM Pump1 Lead CPT p Limit Test CIRC Compute PUMP RUNNING Low Limit 0 Dest Chemical FeedP1 vase sep J USED FOR SIMULATION i i IN THIS CASE Test ChemicalFeedP_PIDE CY Expression 100 100 ChemicalFeedP_PIDE CY 5 99 98525 High Lim
77. IN FTV SE Influent Flow HiHi amp LMD Influent Flow Fail amp LMD Ba ALMD CJ ALMD CJ Digital amp larm Digital amp larm 0 0 0 0 HiHi D In amp larm B Fai j2 gin In amp larm B 1 C2 1 C3 0 0 Suppressed 9 0 Suppressed 3 0 Disabled 2 Disabled 2 Influent Flow Hi amp LMD Influent Flow Lo ALMD ALMD LJ ALMD LJ Digital amp larm Digital amp larm 0 Hi n In amp larm 2 In amp larm 2 1 C2 Suppressed D Disabled 3 Suppressed Disabled 3 Influent Flow LoLo amp LMD ALMD CJ Digital amp larm In In amp larm 5 Suppressed 9 oo O Disabled D B00_Influent_Flow_LDR In this example program this routine is left blank X00 Auto Control LDR The routine is left blank in this application but should the programmer need to add any logic for this program it would be placed in this routine Chemical Flow Program Main This program contains the JSRs to all the routines in this program B00 Chemical Flow FBD P AIn FBD used in calculating the chemical flow out of the chemical feed pumps Note that in this application the Chemical Flow P AIn Val tag is used as our PV process variable in the ChemicalFeedP PIDE routine PIDE 186 Publication IASIMP QS014C EN P February 2013 Chapter 3 Typical P_Aln instruction used for Chemical Flow CHEMICAL FEED FLOW Chemical Flow P Aln P Aln Analog Input Inp PvBad D 4 50000000e 038 1 50000000e 038 1 50000000e 03
78. Inputs simulation bit that you can use when testing the application A01 MiscDiscreteInput provides a template to map inputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A02 MiscAnalogInput provides a template to map analog inputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A03 MiscDiscreteOutputs provides a template to map outputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A04 MiscAnalogOutput provides a template to map analog inputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram e SolidsTk01 Drive Controls the motor for the Solids Storage Tank Agitator Main routine calls the other routines in this program A01 Drive LDR contains the code to map fault inputs hand mode and resets for the Solids Storage Tank Agitator motor This routine is provided as a Ladder Diagram A02 Drive FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Solids Storage Tank Agitator motor See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e WAS HoldTkValve600 controls the Waste Activated Sludge WAS Valve Main routine calls the other routines in this program A01 Valve LDR contains the cod
79. LECT A RECIPE FROM THE LIST THEN CHOOSE THE APPROPRIATE VFD WHO S PARAMETERS YOU WANT TO SAVE hb 1 00 2 00 3 0 0 4 00 Y NEW ria NAME IS RENAME ACCEPT CANCEL RECIPE NEW NAME HNE W NAME VED VED VED VFD PREV NODE NODE NODE NODE 1 2 3 4 2 From the Save VFD Parameters screen you can Use the UP DOWN buttons to select a database recipe from the list Press RENAME RECIPE to give the selected recipe a descriptive name Press ACCEPT or CANCEL NEW NAME to confirm or discard the naming of the recipe View the new recipe name if a recipe name is being changed Press CLEAR THE SAVED RECIPE to clear the selected database recipe 3 Once the desired recipe is selected from the list press VFD NODE to select the VFD using the parameters you want to save This option is visible only if a PowerFlex VFD is found at the appropriate node To load a recipe 254 Publication IASIMP QS014C EN P February 2013 Chapter 3 1 From the PowerFlex 4 VFD Parameters screen press Load PowerFlex 4 VFD Parameters From Database Into VFD to open the Load VFD Parameters screen OAE x 2 Press UP DOWN to select a database recipe from the list 3 Press VFD NODE to select the VFD into which you wish to load the selected recipe This option is visible only if a PowerFlex VFD is found at the appropriate node Not all of the parameters are loaded into the VFD The Modbus node address comm sp
80. Minutes 3 The operator can access the Control Setpoints by selecting the Setpoints button on the Headworks Primary Treatment Overview screen Setpoints Button Location Publication IASIMP QS014C EN P February 2013 133 Chapter 3 134 Alarms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Process Equipment Process Alarms There are the six types of Process Alarms Channel No 1 Differential Level High Alarm Channel No 2 Differential Level High Alarm e Wet well Level High Alarm e Wet well Level Low Alarm e Wet well Float High High Alarm e Wet well Float High Alarm e Wet well Float Low Alarm Process Alarms Diff Pressure EEEE iS itemm x ws Alarm Delay Time secon High Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 High High M High 4 e Low Low Low Device Fail Publication IASIMP QS014C EN P February 2013 Chapter 3 Equipment Alarms These are the two types of Equipment Alarms Start Stop Faults If the system calls the Mechanical Bar screen and it is not running after 5 seconds he system generates a Start Stop Fail Alarm and displays it at the HMI Start Stop Faults If the system calls the GTD to start and is not running after 5 seconds the system generates a Start Stop Fail Alarm and displays it at the HMI Reporting Equipment Run Times Run times are recoded for the Mechanic
81. PLC will be taken out of Run On the next screen choose option 1 Reuse Device Do not choose option 2 If you choose option 2 Write Only you will only be able to wtite to the memory module one time and will not be able to save any more programs to it Push OK The Run LED flashes on off When loading is complete the Run LED stays off Use the above procedure to put PLC back into Run PanelView component program load On initial power up the PanelView main menu displays 266 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 1 Push File Manager 3 Use the Up Down buttons to scroll to Internal from the To list 4 Push Copy to transfer the application from the USB storage into PanelView The message Operation Succeeded displays 5 Press OK to clear the pop up window File Manoger 6 From the Source list select Internal 7 Once the source is set to Internal push Set As Startup 267 Chapter 3 The application name displays under Startup Application 8 Push Run to launch the application PLC Program Files The PLC code is separated into separate program files Each file contains the logic associated with certain operations The Main file contains all of the jump to subroutine JSR instructions that scans all of the other files 3 20 sequentially J Program Files Svso0 SYS1 Al LAD 2 MAIN LAD 3 APP SETUP LAD 4 IO
82. Power Up Handler Tasks 5 8 MainTask a cm MainProgram lg Program Tags Main c Basin1 Fliushing Control System A Program Tags Main B A001 Fwvi LDR A002 FWV1 FBD Bi An03 Fwv2 LDR AQ04 FWV2 FBD Bi A005 Fwv3 LDR A006 FWV3 FBD Bi A007 Fwv4 LDR A008 FWV4 FBD Bi An09 Fwvs LDR AD10 FWVS FBD Bi A011 Fwv LDR A012 FWV6 FBD Bi A013 Fwv7 LDR A014 FWV7 FBD B EUER Unscheduled Programs Phases J Motion Groups H E Add On Instructions Data Types Trends 5 63 10 Configuration 1756 Backplane 1756 44 fla 3 Emulator Flushing_System Main Program There is no logic in the routine for this example BASIN1_FLUSHING_CONTROL_SYSTEM_ PROGRAM Main This program contains the JSRs to all the routines in this program A001_FWV1_LDR This routine contains all the logic that controls Flushing Water Valvel called FV1 This routine is typical for all the flushing valves that can be in a program for example FV2 FV3 FV7 Here FVx represents any program valve 169 Chapter 3 Rung 0 This rung contains all conditions that would make the valve unavailable for use Bare st icv s Permcnveen Overat YoMsde r rorem Permeve Status Valve 8t Au mtu hook to start Avemaie BasbiFwevi Valve Ste Prog SasniFyryi Pern Ste Permak aive Avatakse mmm Rung 1 This rung opens FVx when the start basin flush HMI PB is pressed This rung is typical for all valves Boom dt PCV Permenv
83. S TO BE ASSIGNED TO LOW LEVEL OR THE PUMP NEEDS TO BE IN OFF SECONDARY BACKUP MEASURING IS SET FOR FLOATS AN INPUT NEEDS TO BE ASSIGNED TO PUMPS STOP AND AN INPUT NEEDS TO BE ASSIGNED TO LEAD START SECONDARY BACKUP MEASURING IS SET FOR FLOATS AT LEAST ONE PUMP NEEDS TO BE SELECTED TO RUN AS BACKUP Publication IASIMP QS014C EN P February 2013 THE HAND OFF AUTO SELECTORS FOR ALL PUMPS IS SET TO OFF Chapter 3 PUMP 1 HAS ITS OVERLOAD TRIPPED VFD FAULT INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OL TRIPPED VFD FAULT OR THE INTERLOCK NEEDS TO BE DISABLED PRESSURE MODE SELECTED AND A STOP PRESSURE SET POINT IS SET LOWER THEN A START PRESSURE SET POINT PUMP 1 HAS ITS OVER TEMP INTERLOCK ENABLED AN INPUT NEEDS TO BE ASSIGNED TO OVER TEMP OR THE INTERLOCK NEEDS TO BE DISABLED PUMP DOWN MODE SELECTED THE PUMP STOP LEVELS NEED TO BE SET PUMP 1 HAS ITS SEAL FAIL INTERLOCK ENABLED LOWERTHENTHE AN INPUT NEEDS TO BE ASSIGNED TO PUMP START LEVELS SEAL FAIL OR THE INTERLOCK NEEDS TO BE DISABLED PUMP UP MODE SELECTED PUMP 2 THE PUMP STOP LEVELS NEED TO BE SET HAS ITS OVERLOAD TRIPPED VFD FAULT HIGHER THEN THE INTERLOCK ENABLED PUMP START LEVELS AN INPUT NEEDS TO BE ASSIGNED TO OL TRIPPED VFD FAULT OR THE INTERLOCK NEEDS TO BE DISABLED PRESSURE MODE SELECTED PUMP 2
84. SH MODE BASIN FLUSHING WATER SOURCE FLUSHING COMPLETE BASIN COMPARTMENT 1 176 Publication IASIMP QS014C EN P February 2013 Chapter 3 Select Flush Mode To operate the system 1 Enter a time in the Flushing Valve On Timer field AAA FushingModeSelect Flushing System 20120910 FLUSHING VALVE MODE PB START BASIN1 FLUSH PB FLUSHING VALVE ON TIMER 1 15 min THE TIME EACH VALVE VMLL OPERATE WHEN TURNED ON 2 Click the Start Basin 1 Flush button see figure below The button will turn yellow indicating that Basin1 Flush is active AAA FushingModeSelect Flushing System 20120910 FLUSHING VALVE MODE PB PAUSE BASIN1 FLUSH PB RESET BASIN1 FLUSH PB FLUSHING VALVE ON TIMER 1 15 min THE TIME EACH VALVE VILL OPERATE WHEN TURNED ON Publication IASIMP QS014C EN P February 2013 177 Chapter 3 178 3 To pause the sequence click the Pause Basin1 Flush PB button Click the button again to resume the sequence 4 To start cycle over from the beginning click Reset Basin1 Flush PB Return all to Auto Button When pressed this will automatically put all the devices not in auto already in auto for you Simulation Mode To operate system in simulation mode 1 Open RSLogix Emulate Version 19 11 2 Insert PLC in slot 3 3 Open copy of Flushing System PLC Version 19 1 go to WHO Active find emulator in slot 3 and download to it 4 When finished
85. SIMP QS014C EN P February 2013 Chapter 4 Notes Publication IASIMP QS014C EN P February 2013 293 Chapter 4 294 Publication IASIMP QS014C EN P February 2013 Chapter 5 Introduction Important Maintenance and Repair Drawings Water and Wastewater Treatment Plant Hardware Drawings Maintenance and Repair This chapter contains valuable resources to help you install and begin to use the Water and Wastewater system Use the following table to locate these resources To Access See Website resources for additional information including Website Resources on page 319 e Rockwell Automation product and knowledge base websites e Water and Wastewater industry websites Related documentation to help you install commission the Documentation Water and Wastewater system This chapter lists the necessary Resources on page 320 user and quick start guides required to install bring your system online Once your Water and Wastewater system is installed it requires periodic planned maintenance and or repair to keep it working properly Refer to these drawings for specific technical electrical system information when your system requires service The Water and Wastewater Treatment Plant Hardware documentation package contains the following system level packages e Lift Station Hardware Drawings Dosing Pump Hardware Drawings Primary Treatment System Hardware Drawings e Headworks Pump Hardware Drawings e
86. START TRIES 122 1 0 BOARD FAIL 38 PHASE U TO GROUND SHORT 260 Publication IASIMP QS014C EN P February 2013 Chapter 3 Alarm Output Configuration Alarm output enabled Alarm output disabled Alarm Output Selections b System Interlock Off High Level Low Level AY From the Alarm Output Configuration screen you can Press UP DOWN to select a process specific alarm from the list Press Add Alarm or Remove Alarm to enable or disable the selected process specific alarm The alarms when enabled combine to turn on PLC output O 0 9 If the alarm is not enabled even though it becomes active it will not turn the PLC output on Press MORE to add pump specific alarms from the Pump Alarm Output Configuration screen s Refer to Pump 1 Alarm Output Configuration on page 261 Pump 1 Alarm Output Configuration current Pump 1 Start Outputs iN Alarm Output Se Pump 1 Failed To Run owarFlex VFO 1 Comm Loss Pump 1 OL Tripr rs Fall ab Fault ump 1 Over Temp Pump 1 Seal Fail es Refer to Alarm Output Configuration on page 261 for screen descriptions and functions Add and or remove alarms for the selected pump Press MORE to Publication IASIMP QS014C EN P February 2013 261 Chapter 3 add or remove alarms on additional pumps if any The alarm output screens for pumps 2 4 are the same as pump 1 PowerFlex 4 series VFD set up must have firmware version 6 0 or higher If Power
87. System Controller organization includes 1 Task Main Task for example 2 Program Pumps for example 3 Routine A01 DiscreteInputs for example The components of this organization correspond to areas of the application The task component is application wide The Program component should be used with the application s functional area and each routine is dedicated to a specific action within this functional area For example the entire Lift Station System is contained within a Task Pump control is contained within a program and functionality within a pump such as pump control versus pump alarming is separated into different routines Lift Station System Application Organization A Program Tags Main E A01 DiscreteInputs E A02 AnalogInputs Bl A03 DiscretOutputs Bj A04 AnalogOutputs Ib Pumps Program Tags Main E A01 Pumpi Alarms Bj A02 Pumpt Control Bl A03 Pump Alarms E A04 Pump2 Control Bi A05 Pump3 Alarms E A06 Pump3 Control Bj A07 Pump4 Alarms E A08 Pump4 Control Bj A09 Pumps Alarms Bj A10 PumpS Control Bj A11 Pumps Alarms Bl A12 Pump6 Control C PumpSystem Program Tags Main Bj A01 StartOrder B A02 Control All programs contain a routine Main which is used to call all the other routines in the task A Job Status Report JSR must be included in the Main routine for every routine in the program For example the following depicts a 84 Publication IASIMP QS014C EN P February 2
88. TD Number 1 Operate the drive in the Local mode by selecting Hand on the Hand Off Auto selector switch located at the MCC The operator uses the buttons located at the tank to start or stop each drive Grit Tank Drive Remote Operator Mode The operator must place the Grit Tank Drive in the Remote Operator mode to use it from the HMI The Grit Tank Drive is placed in the Remote mode by selecting Auto on the Auto Off Hand selector switches located at the MCC for each equipment In the Remote mode the operator may select Auto or Manual mode to control the process from the HMI Equipment Faceplate Operator Mode Manual Once the operator clicks on the GID equipment the system displays a faceplate 207 Chapter 3 208 Single Speed Motor HMI Equipment Faceplate Single Speed Motor argen MB Program al Enabled z amp e e Comm OK The operator uses this faceplate to control the GTD equipment For Manual Operator Control select the Operator mode from the HMI Equipment Faceplate The operator starts stops the GTD equipment remotely from the HMI Equipment Faceplate The available GTD screen commands include Press the Play button to start the GTD screen Press the Stop button to stop the GTD screen Click the Disable button to remove the GTD screen from service Click the Enable button to place the unit back in service Program Mode Auto To place the GTD equipment in Remote Program Mode
89. ToFilterPress_Pump603 Verifying routine 02 Pump FBD of Program SolidsTkO1ToFilterPress_Pump603 Verifying routine Main of Program SolidsTk lToFilterPress Punmp603 Complete 0 error s 0 warning s Publication IASIMP QS014C EN P February 2013 167 Chapter 3 168 Flushing System Application Process Description The Flushing System application contained on the WWWAT CD is a typical example of a flushing system of up to seven valves solenoid or motor type valves used to flush out a basin In the below example seven solenoid valves are used These valves operate in sequence based on an operator selectable Flushing Time input from a pop up window located on the HMI flushing system overview screen The flush system can be started paused or reset from this HMI pop up When the flushing sequence begins the system opens flushing valve 1 FV1 and keeps it open for the duration of the operator selectable flush time Should a flushing valve be out of service for any reason in manual mode or shut down for service for example the program will skip that valve and go to the next available valve in the sequence Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Control Description The controller organization for the Flushing System application is as follows Controller Organizer x Controller Flushing System Controller Tags Controller Fault Handler 3
90. U O ww om f re J sg ue c 7 ROS japa at J ttt Pu sind i DA aS TE WE Description E 120 Network For details see page 14 Diagram 38 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Panel I O Layout Sheets Dosing Pump System Panel 1 0 Layout Sheets Number Title Panel 1 0 Layout Sheet 1 of 3 Panel 0 Layout Sheet 2 of 3 Panel 0 Layout Sheet 3 of 3 Chapter 2 ee SE Description These diagrams show the 1 0 to the controller The format uses three cards per sheet This drawing depicts inputs to the card with the input device to the left of the Input card It also shows output devices to the right of the output card You must add a new sheet for each additional input or output card This drawing package was designed with space reserved for all the Controller Chassis card slots In this example drawing package slot 3 is empty This empty slot is represented on sheet E 131 with an empty area on the sheet and the text Spare If you add a card to slot three you should show it in this spare area If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a pre determined location in the drawing package for all the I O modules Include 1 0 information specific to your application on this dra
91. Water and Wastewater Accelerator Toolkit Allen Bradley Quick Start a a Rockwell Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in th
92. a 271 Important Installation and Commissioning Drawings 271 Water and Wastewater Treatment Plant Hardware Drawings 271 Litt Station Hardware Drawings 1 oct e re enr etre 272 Dosing Pump Hardware Drawings esses 277 Water Treatment Plant Hardware Drawings 0 281 3 Maintenance and Repair Additional Resources Raw Water Intake System Hardware Drawings 281 Pump Controller Station Hardware Drawings 04 286 Chapter 5 THOR toties ares ee vidco Oe vA Ok Wouter E Qe MAC doe 295 Important Maintenance and Repair Drawings isses 295 Water and Wastewater Treatment Plant Hardware Drawings 295 Lift Station Hardware Drawitigs cescs see t eer Re a 296 Dosing Pump Hardware Drawings 0 0 0 0 0000 eee 301 Water Treatment Plant Hardware Drawings 04 305 Raw Water Intake System Hardware Drawings 305 Pump Controller Station Hardware Drawings 044 310 Appendix A Website KESOUECES aca icem int wie acenb bar dee e baies Oed 519 Documentation Resources cedo eeepc EE Ine ere ee E 320 Publication IASIMP QS014C EN P February 2013 Introduction Publication IASIMP QS014C EN P February 2013 Preface The Water and Wastewater Quick Start Guide contains step by step instructions for using the Water and Wastewater Accelerator Toolkit WWWAT This toolkit is a valuable resource for designing installing operating
93. aceplate The faceplate shown is used to control the screening equipment The screening equipment is started and stopped remotely from the HMI Equipment Faceplate The available Bar screen commands include Press the Play button to start the Bar screen Press the Stop button to stop the Bar screen Click the Disable button to remove the Bar screen from service Click the Enable button to place the unit back in service Program Mode Auto To place the Bar screen in Program Mode Auto control perform the following 1 Select Auto on the Auto Off Hand selector switches located at the MCC for each equipment to place the Bar screen in the Remote mode 2 Select Program mode from the HMI Equipment Faceplate When in Remote Program mode the screening will be called to start when the accumulated time is equal to the Cycle Timer pre set or the differential level across the screen reaches setpoint 206 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Bar Screen Cycle Timer On Time Minutes Off Time 120 Minutes The following sequence will occur when the screening system is run in Auto 1 The system commands the Mechanical Bar screen to start 2 The Mechanical Bar screen will run for 2 minutes before being called to stop Grit Removal This section describes the Grit Removal Hand Remote Operator and Program modes Hand Mode Grit Tank Drive G
94. al Bar screen mechanism by the SCADA system Depending on the user s security level the total run time maybe reset by clicking on the Total Reset button next to the appropriate pump e Mechanical Bar Screen Numbers 1 and 2 e Grit Tank Drive Number 1 Single Speed Motor Run Time i GE E Current running time this start 02 hours Maximum continuous running 02 my lime for a given start hours 10 01 Total accumulated running 03 T ems time hours 4 0 07 Total number of motor starts 33 or attempts Publication IASIMP QS014C EN P February 2013 135 Chapter 3 Customization of the Headworks Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the Headworks This section describes customization specific to the Headworks application 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine See the Customization of the Solids Application section for an example of how to add Single Speed Moto
95. ally for a channel of a discrete input card It can be used with any discrete BOOL signal The P Din AOI includes the capability to generate a discrete input alarm such as from a low level switch high vibration switch or flow switch Use This Instruction When e You want to display the state of a process temperature level flow proximity pressure or other switch e You need any of these signal processing or alarming features for a discrete input or any discrete bit value e You require debounce of a Discrete Input signal e You want the system to activate an alarm when the Discrete Input is not in a target state for some period of time e You want the system to enable an alarm when a gating condition is true for some period of time e You want the system to display the switch state with configurable text on an HMI object with operator Faceplate call up e You need Maintenance to be able to provide a substitute value when the device has failed Do Not Use This Instruction When e You need only to show or not show the state of a bit on an HMI display Use basic display objects text multi state indicators with appropriate animation instead e You need only to generate an alarm from some condition you already have in your code Use the P_Alarm AOI or the ALMD built in instruction instead Publication IASIMP QS014C EN P February 2013 61 Chapter 3 Digital Input P_Din Faceplate
96. and design your Water and Wastewater project see Appendix A The Process Library is a collection of RSLogix 5000 and FactoryTalk View SE component Add On Instructions AOIs also known as faceplates Rockwell Automation developed these Faceplates to facilitate the efficient development of flexible and robust process systems This library is included on the WWWAT CD along with the associated documentation refer to the Preface s Introduction section for mote information Selecting the Process Library All systems share common components although the precise functionality of individual process systems varies For example process systems typically include many of these hardware components e Digital Inputs Outputs e Analog Inputs Outputs e Single Speed Motors e Variable Speed Drives Motor and Solenoid Operated Valves 53 Chapter 3 54 You must develop code to manage the interface between the Controller and these devices you must also create several of the following logical constructs to merge this collection of hardware into a cohesive system e Alarms e Interlocks e Permissives Rule Base Inhibits The Process Library includes RSLogix 5000 AOIs for performing each of these tasks In addition the Library includes graphical objects for use in building a Visual Interface to your Controller The combination of code and graphics ensures a visually and functionally consistent system The Process Library enables y
97. and maintaining a Water and Wastewater project The WWWAT resides on a CD containing e Pre configured files e Selection tools Examples of using a Logix Controller to connect to multiple devices PowerFlex AC drives motors and HMI terminals over EtherNet IP and DeviceNet networks e System architecture drawings e CAD drawings e Basic status control and diagnostic logic FactoryTalk View SE faceplates A new stand alone Pump Controller Station Application based on the MicroLogix 1400 and PanelView Component C600 is also now included With these tools and the built in best practices design the system designer is free to focus on their machine control design rather than designing overhead tasks Contact your local Rockwell Automation distributor or sales representative for a copy of the WWWATC CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the appropriate tools Before using this guide and the contents of the WWWAT CD read the Terms and Conditions README pdf on the CD Preface Use this flow chart to determine which chapters in this guide apply to your role in the Water and Wastewater project Each chapter is organized according to the various Water and Wastewater project roles Chapter 1 System Specification Procurement Specifications System Architecture Drawings Website Resources Publications
98. and outputs to the controller This format uses three cards per sheet Inputs to the card are shown with E 1131 Panel I O Layout the input device to the left of the input card Output Sheet 2 of 2 devices are shown to the right of the output card You must add a new drawing sheet for every additional input or output card This drawing package reserves space for all the slots of a controller s chassis If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a pre determined location in the drawing package for all the 1 0 modules 1 0 specific to an application are shown here and it is expected that these sheets are heavily modified for each application These sheets provide a template for use for many applications even if the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules This provides one example of each type of module that will typically be used in a Raw Water Intake System application Note This drawing depicts 1756 style 1 0 modules If you use different I O modules you must also update these sheets Publication IASIMP QS014C EN P February 2013 309 Chapter 5 Pump Controller Station Hardware Drawings 310 One of the System Architecture sub folders on the WWWAT CD is the Pump Controller Station folder and it contains the following drawings e Titl
99. and selector switches located at the MCC for each equipment In the Remote mode the operator may select Auto or Manual mode to control the process from the HMI Operator Mode Manual Once the operator clicks on the GTD equipment the system displays a Faceplate screen HMI Equipment Faceplate Screen Single Speed Motor hPa co aeg Program gl Enabled j amp e e The operator uses this Faceplate screen to control the GTD equipment For Manual Operator Control select the Operator mode from the HMI equipment Faceplate Publication IASIMP QS014C EN P February 2013 Chapter 3 The operator starts stops the GTD equipment remotely from the HMI screen The available GTD screen commands include Press the Play button to start the GTD screen Press the Stop button to stop the GTD screen Click the Disable button to remove the GTD screen from service Click the Enable button to place the unit back in service Program Mode Auto To place the GTD equipment in Remote Program Mode Auto control perform the following 1 Select Auto on the Auto Off Hand selector switches located at the MCC for each equipment to place the GTD equipment in the Remote mode 2 Select Program mode from the HMI Faceplate template When in Remote Program mode the system calls the GTD equipment to start when the accumulated time is equal to the Cycle Timer pre set Bar Screen Cycle Timer On Time Minutes Off Time 120
100. anel I O Layout Sheets Publication IASIMP QS014C EN P February 2013 Chapter 2 Title Page and Sheet Index Raw Water Intake System Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT RAW WATER INTAKE PS Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication ASIMP QS014C EN P February 2013 41 Chapter 2 Process Flow Diagram Raw Water Intake System Process Flow Diagram E 1110 System The flow diagram assumes a Raw Water Intake System with Process Flow particular I O Any changes to the 1 0 for the Raw Water Diagram Intake System should be reflected on this diagram Network Diagram Raw Water Intake System Network Diagram Network Diagram For details see page 23 42 Publication IASIMP QS014C EN P February 2013 Chapter 2 Panel I O Layout Sheets Raw Water Intake System Panel 1 0 Layout Sheets E m j l THTPUHEHH FP mmn rr Uil je arara 33 Lk EENET ENE E CE Number Title Description E 1130 Panel I O Layout This diagram depicts inputs and outputs to the controller Sheet 1 of 2 This format uses three cards per sheet Inputs to the card are shown with the input device to the left of the input E 1131 Panel I O Layout card Output devices are shown to the right
101. ann 2 Fush intuert Push Flan System Vives Compete Valves Compito Vaives Complete cite Gunia Gaua NaF atena Fisher M Q X u M Rungs 7 and 8 These rungs verify that all valves are either closed or unavailable then all valves are activated This bit must be on for a sequence to be complete These lines of logic may also be modified to add or remove a valve from the sequence Bate P FCV 1 Sewn FI FCV 2 Gaon F1 FCv Bane 8t FCvA Bean FCv 5 1e valve vequested to 19V aive requested io 1 5 v ave requested to 1 Vive requested io Ve Valve requested to Obee and it Cose arei ie Gove an ie Core and Close and conferred Doaa cotrmed Dyred tarred Chet contemed Closed Contrmed Coted Bonn Fwrt_vatve Sts Oored Baer Pew _Vatve Sta COoted Berni Fave Viive Str Coted Basa Frv5_Vieve St_Qoted Vater 4 A vati Vhve Avminbir Basin 41 FCV 6 To vsive requested to 1 Valve requested to Close and is Close and is Ete i Fusneg Conna Ooted Nanm Costi Valves Otea Brini Fwa Valve Stt Come Beater Pwr Valve Ste Cond Berl Varera Geen 81 Fug AB Fuaning vives Valves Coses Closed Basiri VeivesCioned Y ahvesCioneiPes micpow Publication IASIMP QS014C EN P February 2013 175 Chapter 3 HMI Description The following is a brief description of the HMI portion of this project AAA Flashing umpsYatves Flimhing System 201 20930 FLUSHING OVERVIEW L3 ALL to AUTO N cms SELECT FLU
102. ar to that of the Lift Station Specifically the functionality for each program and routine is e Main Program handles general Headworks application and functionality including Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 MiscDiscreteInput includes a template to map inputs that are relevant throughout the Headworks system This routine is provided as a Function Block Diagram A02 MiscAnalogInput includes a template to map analog inputs that are relevant throughout the Headworks system This routine is provided as a Function Block Diagram A03 MiscOutputs includes a template to map outputs that are relevant throughout the Headworks system BarScreen01 controls the motor manages cycle times and Flow Channel Differential levels for the Bar screen 1 system including Main routine calls the other routines in this program A01 BatScreen01 LDR contains the code to monitor and control the Bar Screen 01 motor and reset alarms interlocks and faults associated with the motor This routine is provided as a Ladder Diagram A02 BatrScreen01 FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Bar Screen 01 motor This routine is provided as a Function Block Diagram A03 BarScreenO01 Auto
103. ardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Dosing Pump folder and it contains the following drawings e Title Page and Sheet Index e Process Flow Diagram e Network Diagram e Panel I O Layout Sheets Title Page and Sheet Index Dosing Pump Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT Sheet Index package Modify this sheet as necessary to match the contents of your application s drawing package Publication IASIMP QS014C EN P February 2013 301 Chapter 5 Process Flow Diagram Dosing Pump System Process Flow Diagram Number Title E 110 System Process Flow Diagram Description The Dosing Pump System Process Flow diagram depicts a two pump alum addition process Make any changes to the number of pumps or I O for this process on this drawing For example if you require additional pumps in an application update this sheet with the appropriate pumps and their associated I 0 information The Dosing Pump System Process Flow diagram provides a general overview of the process controlled by the system a quick summary of the controls involved and the process that is being controlled 302 Publication IASIMP QS014C EN P February 2013 Chapter 5 Network Diagram Dosing Pump Network Diagram ao E 120 Network For details see page page 14 Diagram Publication
104. arms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Process Equipment Process Alarms There are the eight types of Process Alarms e Solids Storage Tank High LIT 603 e Solids Storage Tank Low LIT 603 e Solids Storage Tank High High LIT 603 e Solids Storage Tank Low Low LIT 603 162 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 e WAS Tank High e WAS Tank Low e WAS Tank High High e WAS Tank Low Low Process Alarms Solids Tank 1 Level LIT 603 a Fe eleja ui Alarm Delay Time seconds High High High Low Low Low Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 ov High High 4 o High v vo Low vV vf Low Low Device Fail Equipment Alarms These are the two types of Equipment Alarms Start Stop Faults If the Solids Storage Tank Mechanism or Sludge Transfer Pump is called to start and is not running after 5 seconds the system generates a Start Stop Fail alarm at the HMI 163 Chapter 3 Reporting The SCADA system records Process The system will trend common signals and record them for future viewing including WAS Flow Rate WAS Holding Tank Level SST Level Equipment Runtimes Runtimes are recorded for the STP and STD mechanism by the SCADA system Depending on the user s security level the total runtime may be reset by clicking on the Total
105. ary 2013 Chapter 3 Reporting Equipment Run Times Run times are recoded for the Mechanical Bar screen mechanism by the SCADA system Depending on the user s security level the total run time maybe reset by clicking on the Total Reset button next to the appropriate pump Mechanical Bar Screen Number 1 e Grit Tank Drive Number 1 Single Speed Motor Run Time EE E th Current running time this start 02 hours Maximum continuous running 02 time for a given start hours Total accumulated running 03 time hours Total number of motor starts 33 A or attempts LURI Publication IASIMP QS014C EN P February 2013 211 Chapter 3 Customization of the Raw Water Intake Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the Raw Water Intake This section describes customization specific to the Raw Water Intake application 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine
106. ate Pn Cn m PEETI tn vam n rm Coe ate te mrama oun ee asa ROE waini pan oe I Rung 6 This rung indicates remote or local mode to the valve faceplate FVI Perote Varvet Locat FE Publication IASIMP QS014C EN P February 2013 171 Chapter 3 A001 FWV1 FBD These two sheets contain the P perm permissives and the P valveSO add on instructions for FV1 This routine is typical for all valves Sheet 71 All valve permissions are added here Permissives BasiniFwv1 Perm P Perm Lj Permissives FV1 Remote JE t Inp PermQ 0 Sts_PermOK 2 2 A1 1 d inp Permot Sts NBPerrmoK 4 NBPermOk 2841111 1111 1111 1111 Sts Perm 2 2 B2 Signature ID 7SB0ECOO 172 Publication IASIMP QS014C EN P February 2013 Chapter 3 Sheet 2 This sheet contains the P_ValveSO add on instruction for the valve The real opened closed limit switches are attached to the FV_Opened and FV_Closed tags respectively The real world output attaches to the FV1_OUT tag Basin 1 FCV 1 BasiniFwv1_Valve P_ValveSO Solenoid Opersted Valve Signature i A76DEC25 rote The routines for valves 2 through 7 are identical to the above routine for FV1 The only rung in each routine which has to be modified for an additional or a subtracted valve is Rung 5 A017 AUTO LDR This routine contains the information which ties all the valves i
107. ation Title Page and Sheet Index Li 1 s 3 ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT EE ES Description E 150 Title Page and This is the Table of Contents Cover Sheet for the drawing Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 2 Process Flow Diagram Lift Station System Process Flow Diagram Description E 160 System This diagram depicts a Lift Station consisting of two pumps Process How with particular 1 0 Any changes to the number of pumps or Diagram 1 0 for the Lift Station must be reflected on this diagram Network Diagram Lift Station System Network Diagram E 170 Network For details see page 12 Diagram 33 Chapter 2 Panel I O Layout Sheets Lift Station System Panel 1 0 Layout Sheets a u a Number 1e Tee ne GRE eet Title Panel I O Layout Sheet 1 of 2 Panel I O Layout Sheet 2 of 2 mL Description Inputs and outputs to the controller are shown on these diagrams The format uses three cards per sheet Inputs to the card are shown with the input device to the left of the input card Output devi
108. ault Pump 4 Seal Fail Selection 3 of 27 Selection 12 of 27 Selection 21 of 27 Lag Start Pump 4 OL Fault Low Pressure Selection 4 of 27 Selection 13 of 27 Selection 22 of 27 High Level Pump 1 Motor Over Temp High Pressure Selection 5 of 27 Selection 14 of 27 Selection 23 of 27 Publication IASIMP QS014C EN P February 2013 239 Chapter 3 Pump 1 Running Pump 2 Motor Over Temp Power failure Selection 6 of 27 Selection 15 of 27 Selection 24 of 27 Pump 2 Running Pump 3 Motor Over Temp Generator Running Selection 7 of 27 Selection 16 of 27 Selection 25 of 27 Pump 3 Running Pump 4 Motor Over Temp Generator Fault Selection 8 of 27 Selection 17 of 27 Selection 26 of 27 General Fault Selection 27 of 27 Press Next to proceed to the Backup Pump Select screen TIP The Backup Pump Selection screen is visible only if Float is selected as the backup on the Measuring Setup screen If during the measuring device setup floats are selected as secondary backup then these buttons will enable or LEER AE MAU isable the pumps from FLOAT running in backup mode Use floats or some type of contact closure to physically control the On Off points for the pump s i evic 4 Primary Measuring Device gt Floats Analog IN 0 Floats Analog Input IN 1 Usage gt Analog Input IN 1 NOT USED Flow PV in place of IN 0 Press the Delay Betwee
109. ave made in the prior steps Appendix A Reference For System Specification Hardware Selection ControlLogix Selection Guide 1756 SG001 Point 1 0 This document contains the necessary information to specify the components required to build a e ControlLogix based system e ControlLogix Controller Comparison Table It also includes detailed step by step procedures to select ControlLogix System components e Select I O Devices e Select Motion Control and Drives Requirements e Select Communications Modules e Select Controllers e Select Chassis e Select Power Supplies e Select View Products e Select Software System Specification Hardware Selection Publication IASIMP QS014C EN P February 2013 323 Appendix A Notes 324 Publication IASIMP QS014C EN P February 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www tockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation represen
110. ble Faceplate Mode Indicator Requested Mode Indicator Motor Enabled Disabled Indicator Interlock and Permissive Indicators Bypassed Indicator Publication ASIMP QS014C EN P February 2013 Product Tranefer Dump Arigen us taste Pa v gi si in Ovemde Made bypass Intedocks and Permissnes thal can be bypassed Enabled lntetocks and Permissives Enabled Fi Use Run Feedback Chapter 3 Operator Mode Unlock and Lock Command Button Motor Start Stop Command Button Interlock and Permissive Indicators and Navigation Buttons Maintenance Mode Acquire and Release Command Button Motor Enabled Dis abled Command iterock and Permissive Indicators and Navigation Buttons 69 Chapter 3 Motor P_Motor Engineering Tab Process Variable Faceplate Product Transfer Pump Configure Motor Description Label and Tag Motor Provides a Run Feedback Signal Clear Program Commands on receipt AP Perm object is connected to Inp Perm AP Intlk object is connected to Inp Intik AP Reslnh object is connected AP RunTime object is connected Delay to echo back Running Stopped status in Simulation sec 70 Publication IASIMP QS014C EN P February 2013 Permissive P_Perm AOI Permissive P_Perm Permissive P Perm Chapter 3 The following table describes the Permissive P Perm parameter and its usage Description This AOI collects sums up the Permissive condi
111. cation Controller Organization Controller Organizer 3 Controller ChemicalFeedSystem 2 amp 3 Tasks MainTask 5 C8 MainProgram B c Chemcial Tank Levels A Program Tags E A00_Main BOO_Chemical_Tank_1_Level_FBD Bi B00 Chemical Tank 1 Level LDR C00 Chemical Tank 2 Level FBD Bi C00 Chemical Tank 2 Level LDR Bi x00 Auto Control LDR El ca Influent Tank Level A Program Tags Eh A00_Main BOO_Influent_Level_FBD B BOO_Influent_Level_LDR Bi x00 Auto Control LDR 5 3 Influent Flow A Program Tags Eh A00_Main BOO_Influent_Flow_FBD Bi BOO_Influent_Flow_LDR Bi X00_Auto_Control_LDR amp Chemcial_Flow A Program Tags Ea A00_Main BOO_Chemical_Flow_FBD Bi BOO_Chemical_Flow_LDR Bi x00 Auto Control LDR i C8 Chemical Feed System 3 49 Simulation FBD B cC Main Program A Program Tags Main 400_Simulation_FBD 179 Chapter 3 180 Controller Organizer amp amp Tasks a Controller ChemicalFeedSystem 5 8 MainTask E C MainProgram t5 aa Chemcial_Tank_Levels EJ C amp Influent Tank Level 4 C amp Influent_Flow E C amp Chemcial Flow g ca Chemical Feed 5 Ln B B na 4j B EES p 5 on 5 0 55 0 657 0 65 0 65 0 5 LS La m vq A Program Tags Main 4000_CFP_Availabily_LDR 4000_CFP_PIDE_FBD 4000_CFP_PIDE_LDR 4001_Chemical_FeedP1_FBD 4001_Chemical_FeedP1_LDR BO01_Chemical_FeedP2_FBD BO01_Chemical_FeedP2_LDR C001_Chemical_FeedP3_FBD
112. ces are shown to the right of the output card For every additional input or output card new sheets must be added These sheets contain one example of each type of digital and analog I O module typically used in a Lift Station application Note These modules are the input and output points physically located on the L23 controller Different 1 0 modules require changes to these sheets You should modify these sheets to show the 1 0 specific to your application Use these sheets as a template for applications even if the specific I O points vary 34 Publication IASIMP QS014C EN P February 2013 Chapter 2 Device Wiring Schematics Lift Station System Device Wiring Schematics se 88999229294942329054992335322323233410921 8R83 93425832355 17423542234224535121 e Number Title Description E 182 Device Wiring This sheet provides power distribution and manual hand Schematics selector switch wiring information For this application example we recommend you use an Allen Bradley power supply to feed the L23 power Stratix Ethernet switch and the PanelView Plus 600 Modify this sheet to show any additional 24 volt devices required in the design During the project s Hardware Engineering phase this 24 volt power supply must be accurately sized based on the current requirements of the devices connected to it Publication IASIMP QS014C EN P February 2013 35 Chapter 2 36 Dos
113. creen Number 1 e Grit Tank Drive Number 1 Channel Numbers 1 and 2 Differential Level e Channel Number 1 Flow 204 Publication IASIMP QS014C EN P February 2013 Chapter 3 Control Description This section describes the Mechanical Bar screen Number 1 operational mode Hand Mode The Mechanical Bar screen Number 1 is operated locally by selecting the Hand position on the Hand Off Auto selector switch which is located at the MCC The operator uses the Bar screen using buttons located at the equipment In this mode the operator is responsible for operating the conveyor compactor and the Bar screen Mechanical Bar Screen Diff Pressure Motor Control Yo Remote Operator Mode The operator must place the screening equipment in the this mode to use them from the HMI The operator can place the Mechanical Bar screen in the Remote mode by selecting Auto on the Auto Off Hand selector switches located at the MCC for each equipment In the Remote mode the operator may select Auto or Manual mode to control the process from the HMI Operator Mode Manual Click the screening equipment display the Single Speed Motor Faceplate Publication IASIMP QS014C EN P February 2013 205 Chapter 3 Single Speed Motor HMI Equipment Faceplate Template Single Speed Motor argen ele Program gi Enabled ea e e Comm OK For Manual Operator Control select the Operator mode from the Single Speed Motor HMI Equipment F
114. d Monitor 1 0 Modules Configure Redundancy SIL2 Certification Maintain Non volatile Memory Maintain the Battery Status Indicators Hardware Selection Installation and Start up Maintenance ControlLogix 1756 IN101 Controller and Memory Board Installation Instructions ControlLogix Replacing a Suspected Failed Controller Preparing the Chassis Removing the Controller from the Chassis Installing a Memory Board Installing a Compact Flash Card e Connecting a Battery e Installing a Controller into a Chassis e Check the BAT Status Indicator e Check the OK Status Indicator e Updating Controller Firmware e Connecting via a Serial Cable e Interpreting the Status Indicators e Clearing a Major Fault e Clearing a Non recoverable Fault e Choosing the Operating Mode of the Controller e Specifications Hardware Selection Installation and Start up 1769 SG001 L2x Controller Information CompactLogix Selection Guide This document contains the necessary information to specify the exact components required to build a CompactLogix based system including e CompactLogix Controller Comparison Table e What s new in Version 17 e Example Configurations 1X L2X L3X 4X System Specification Hardware Selection Publication IASIMP QS014C EN P February 2013 321 Appendix A Documentation Stored On the WWWAT CD Document Name Publication WWWAT CD Documen
115. d on the WAS valve to put the valve in the Remote mode Select Program mode from the WAS Valve_PV 600 Faceplate Operator Mode Manual Click on the WAS Valve_PV 600 section of the Solids Overview screen The system displays the WAS Valve_PV 600 Faceplate Publication IASIMP QS014C EN P February 2013 Chapter 3 WAS Valve_PV 600 Faceplate WAS Valve PV 600 Aren MG DUEETTEN 05 Enabled eed Did OO Comm OK Por manual Operator Control select the Operator mode on the WAS Valve PV 600 Faceplate The Faceplate shown is used to control the valve s state The operator open closes the valve remotely from the WAS Valve PV 600 Faceplate The available Faceplate commands include Press the Open button to open the valve Press the Close button to close the valve Click the Disable button to remove the valve from service Click the Enable button to place the unit back in service Solid Storage The mechanism is protected from over torque by overload switches set at the factory The ovetload switches sense a buildup of torque as the mechanism revolves A pre set factory overload switch will trip to alarm the SCADA system as torque builds up Further increasing torque will cause a second pre set factory trip switch to trip and stop the mechanism from running When the mechanism stops due to an overload or a power outage the unit must be started manually The storage tank is equipped with a pressure to cur
116. de the screening will be called to start when the accumulated time is equal to the Cycle Timer pre set or the differential level across the screen reaches setpoint Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Bar Screen Cycle Timer On Time Minutes Off Time 120 Minutes The following sequence will occur when the screening system is run in Auto 1 The system commands the Mechanical Bar screen to start 2 The Mechanical Bar screen will run for 2 minutes before being called to stop 3 The operator can access the Control Setpoints by selecting the Setpoints button on the Headworks Primary Treatment Overview screen Setpoints Button Location Headworks HH Float BET co Normal Daily Flow Ez GAL Sy Yesterday Flow GAL Yearly Flow BEECUH MGAL Last Years Flow oa MGAL 4 Grit Removal This section describes the Grit Removal Hand Remote Operator and Program modes Hand Mode Grit Tank Drive GTD No 1 Operate the drive in the Local mode by selecting Hand on the Hand Off Auto selector switch located at the MCC The operator uses the buttons located at the tank to start or stop each drive 131 Chapter 3 132 Grit Tank Drive Remote Operator Mode The operator must place the Grit Tank Drive in the Remote Operator mode to use it from the HMI The Grit Tank Drive is placed in the Remote mode by selecting Auto on the Auto Off H
117. downloading put PLC in run mode 5 Open Factory Talk View SE client and start the HMI application Chemical Feed System Application Process Description The chemical feed pump application is a typical example of a chemical feed system that assumes up to five variable frequency drives VF Ds and transfers chemicals from up to two storage tanks into an influent tank that mixes the chemicals with the incoming influent liquid Three chemical feed mixer units located in the influent tank ensure the chemical is mixed with the influent liquid In this application a PIDE block is used to control the chemical feed flow rate into the influent tank and has manual and calculated set points The five VFD pumps are controlled from the CV Control Variable This application will demonstrate how to use the one CV to control up to five VFDs a very common real world situation This is based on dividing the max CV 0 100 by the number of VFD pumps For this example 0 20 CV will Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 equal 0 100 speed for Pump 1 Pump 2 will use a CV of 21 40 to control 0 100 of its speed and so on This is explained in more detail in the Chemical Feed System Program section Control Description Refer to the Chemical Feed Application Controller Organization illustration to view the application s organization within the Controller Chemical Feed Appli
118. e Fail Equipment Alarms These are the two types of Equipment Alarms Start Stop Faults If the PLC commands the Flocculation Mixer to start and it is not running after 5 seconds it generates a Start Stop Fail alarm at the HMI Start Stop Faults If the PLC commands the SCM to start and it is not running after 5 seconds it generates a Start Stop Fail alarm at the HMI SCM Fault this is a contact from the SCM and once opened the PLC generates a SCM Fault alarm at the HMI Publication ASIMP QS014C EN P February 2013 221 Chapter 3 Reporting The SCADA system records Process The system will trend common signals and record them for future viewing including Sedimentation Basin Level LIT 1204 Equipment Runtimes The SCADA system records run times for the blower and SCST Drive Mechanism Depending on the user s security level the total runtime may be reset by clicking on the Total Reset button next to the appropriate pump Flocculation Mixer SCM Single Speed Motor Run Time Run Time for Single Speed Motor i EE Current running time this start 2 hours 0 2 Maximum continuous running 02 Ig time for a given start hours 10 0 Total accumulated running 03 I S time hours 070 Total number of motor starts or attempts Customization of the Separation Application General customization notes are included in the Lift Station Application section page 102
119. e Page and Sheet Index e Communications Diagram e Panel Layout Diagram e Power Layout Sheets e Panel I O Layout Sheets Title Page and Sheet Index Pump Controller Station Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT ine TH olii Tt Y nn H Pi Hs Ha M OCT aah C EUH Number Description Index Title Page and This is the Table of Contents Cover Sheet for the drawing Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Chapter 5 Communications Diagram Pump Controller Station Communications Diagram E 12 Pump Control Refer to Pump Controller Station Architecture Drawing on Communications page 28 for details Diagram Publication IASIMP QS014C EN P February 2013 311 Chapter 5 312 Panel Layout Diagram Pump Controller Station Panel Layout Diagram Number 13 E amim mri mi auLt Fi uo I ill iil Th oss Title Pump Description Controller requirements Station Panel Layout Diagram You can modify this as needed for your application Publication IASIMP QS014C EN P February 2013 Chapter 5 Power Layout Sheets Pump Controller Station Power Layout Sheets Publication IASIMP QS014C EN P
120. e Speed Drive Permissives and Interlock AOIs that monitor and control the RAS Pump See the Using Add On Instructions section above for more information This routine is provided as a Function Block Diagram A04_PumpDischargeFlow contains the Analog Input AOI and U_FlowTot AOI that totalizes the RAS pump discharge flow This routine is provided as a Function Block Diagram AerationTk01_Mixer01 Controls the motor and manages cycle times and flow channel differential levels for the Aeration Tank 1 Mixer 1 system including Main routine calls the other routines in this program A01 Mixer LDR contains the code to monitor and control the Aeration Tank 1 Mixer 1 Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram A02 Mixer FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Aeration Tank 1 Mixer 1 motor See the Using Add On Instructions section above for more information This routine is provided as a Function Block Diagram AerationTk01 Mixer02 Controls the motor for the Aeration Tank 1 Mixer 2 system as described for the Aeration Tank 1 Mixer 1 system AerationTk02_ Mixer01 Controls the motor for the Aeration Tank 2 Mixer 1 system as described for the Aeration Tank 1 Mixer 1 system AerationTk02_Mixer02 Controls the motor for the Aeration Tank 2 Mixer 2 system as described for the Aeration Tank 1 Mixer 1 s
121. e This Instruction When e To use a motor operated valve or other valve that requires separate open and close outputs This valve may use limit switch feedback for the ends of travel The valve may also require an output to trigger a valve stop function such as breaking a seal in circuit on the valve operator to stop travel or switch the direction of travel Do Not Use This Instruction When You need to operate a single solenoid spring return valve fail closed or fail open Use the P_ValveSO Solenoid Operated Valve AOI instead You need to operate a multi solenoid valve such as a Mix Proof Valve that has positions such as CIP other than opened and closed You will need specific Mix Proof Valve logic A Mix Proof Valve Add On Instruction may be added in the future You need to monitor a valve that is primarily operated by hand The valve could support a trip output to drive it to a safe position Use the P ValveHO Hand Operated Valve Add On Instruction instead 76 Publication IASIMP QS014C EN P February 2013 Chapter 3 Motor Operated Valve P ValveMO Operator Tab Process Variable Faceplate Motor Operated Inlet Exit Valve AA Ree 8 5 Mode Indicator Operator Mode fo Operator ei al Unlock and Lock I Y Command Buttons Valve Disabled Indicator Valve Open Close and Stop Command Buttons win sonacan 94 m A Transit Stall Open and close ermissive Indicators A and Navigati
122. e consistency between projects by reusing commonly used control algorithms For algorithms that will be used multiple times in the same project or across multiple projects it may make sense to incorporate that code inside an AOI to make it modular and easier to reuse Provide an Easier to Understand Interface AOIs enable you to design a mote user friendly interface by Placing complicated algorithms inside of an AOI and marking the essential Parameters as visible or required Reduce documentation development time through automatically generated instruction help Publication IASIMP QS014C EN P February 2013 55 Chapter 3 56 Intellectual Property Protection An AOI enables you to insert Proprietary code inside it using source protection to prevent unauthorized users from viewing or changing your code You can use AOIs across multiple projects You can define the instructions the instructions can be provided by someone else or they can be copied from another project Once defined in a project AOIs behave similarly to the built in instructions already available in the RSLogix 5000 software They appear on the instruction tool bar and in the instruction browser for easy access just like built in RSLogix 5000 software instructions This is an example of AOIs in the instruction tool bar AOI Instruction Tool bar 4 Hf tot avortes Add On Alarms imer Counter ompare Publication IASIMP QS014C EN P Februa
123. e sequence will run The above illustration is showing only two pumps The sample code in the Controller provides routines for up to six pumps There is a development screen provided that can be used as a starter for additional pumps It can be opened on the HMI by selecting the Test 6 Pumps button from the overview screen Wet Well pumps are not interlocked with the main plant well If the main well is in an alarm state the Lift Station pumps will start in Auto Run Pumps Manually Use the following steps to run the pumps manually from the HMI 1 While in Maintenance or Operator mode navigate to the Lift Station screen 2 Click on the desired pump and then click on the Play button 99 Chapter 3 3 Click on the Stop button to stop the pump from the Control screen In manual mode the pump will continue to run regardless of a low Wet Well level Run Pumps Manually RA Beo ug ae BS al Play push button Enabled Rumning e a Stop push button e e Comm OK Place Pumps in Remote Program Place the pumps in Remote Program control 1 Select Remote on the MCC for pumps 1 and 2 2 Verify that the circuit breakers and disconnects are turned on 3 Make sure on the Lift Station Pump N ox Faceplate for pump numbers 1 and 2 are in the unlocked Operator mode 4 Verify that the pump status is in service on the Lift Station Pump N ox Faceplate screen with no faults 5 Verify that the correct pump rotat
124. e the following priority also shown in the illustration above 1 Hand highest 2 Maintenance 3 Override 4 Operator and Program lowest The AOI still processes and retains the lesser priority mode requests but the resultant mode is that of the highest priority request 66 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Selecting Modes Chapter 3 This table shows how to request verify and release a mode It also shows the trigger input cycle Mode Request Input Acquired Output Release Input Hand Inp_Hand 1 level Sts_Hand 1 Inp_Hand 0 level Maintenance MCmd_Acq 1 edge Sts_Maint 1 MCmdRel 1 edge Override Inp_Ovrd 1 level Sts_Ovrd 1 Inp_Ovrd 0 level Operator OCmd_AcqLock 1 Sts_Oper 1 OCmd_UnLock 1 Program See Program Mode See Program Mode See Program Mode Program Mode The Program Command functionality depends on the configuration for clearing Program Commands Cfg_PCmdClear Mode Program Option Cfg_PCmdClear 1 PCm PCm PCm PCm Command d Acg 1 edge d Rel 1 edge d Lock 1 edge d_Unlock 1 edge Description Request Program Mode Release Program Mode Lock Program Mode Unlock Program Mode Cfg_PCmdClear 0 PCm PCm PCm PCm d_Acqg 1 level d Acq 0 level d_Lock 1 level d Lock 0 level Request Program Mode Release Program Mode Lock Program Mode Unlock Progra
125. e to map fault inputs hand mode and resets for the Waste Activated Sludge WAS valve This routine is provided as a Ladder Diagram A02 Valve FBD contains the Motor Operated Valve and Permissives AOIs that monitor and control the Waste Activated Sludge WAS valve See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e WAS StotageTk ToSolidsTk01 Pump600 controls the motor for the WAS Storage Tank to Solids Storage Tank pump Main routine calls the other routines in this program Publication IASIMP QS014C EN P February 2013 153 Chapter 3 A01_Pump_LDR contains the code to map fault inputs hand mode and resets for the WAS Storage Tank to Solids Storage Tank pump This routine is provided as a Ladder Diagram A02 Pump FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the WAS Storage Tank to Solids Storage Tank pump See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e PrimTkToSolidsTk01 Pump601 Controls the motor for the Primary Tank to Solids Tank pump Main routine calls the other routines in this program A01 Pump LDR contains the code to map fault inputs hand mode and resets for the Primary Tank to Solids Tank pump This routine is provided as a Ladder Diagram A02 Pump FBD contains the Single Speed Motor Perm
126. eed and comm formate will not overwrite what is already set in the VFD This way the VFD parameters from node 1 can be written into the VFD at node 2 TIP If the system has a combination of different PowerFlex 4 VFD s such as one PowerFlex 4 and one PowerFlex 40 Care needs to be taken to ensure that the parameters of a PF 4 VFD do not get loaded into a PF 40 VFD TIP After the parameters are loaded into the VFD The VFD needs to have the power cycled in order for the new parameters to take effect Publication IASIMP QS014C EN P February 2013 255 Chapter 3 256 Warning Screen From the Warning screen you can View the current warning message Press Push to Acknowledge Warning to scroll through each active warning if multiple warnings exist TIP Although some of the warnings can be alarms they are typically settings or setup issues that have conflicts List of available warnings NO WARNINGS EXIST PRIMARY MEASURING IS SET FOR FLOATS AND THE MODE IS SET FOR EMPTY PUMP DOWN A PUMP IS ASSIGNED TO LAG2 AN INPUT NEEDS TO BE ASSIGNED TO HIGH LEVEL OR THE PUMP NEEDS TO BE IN OFF PRIMARY MEASURING IS SET FOR FLOATS AN INPUT NEEDS TO BE ASSIGNED TO PUMPS STOP AND AN INPUT NEEDS TO BE ASSIGNED TO LEAD START PRIMARY MEASURING IS SET FOR FLOATS AND THE MODE IS SET FOR FILL PUMP UP A PUMP IS ASSIGNED TO LAG2 AN INPUT NEED
127. elated documentation to help you install commission the Documentation Water and Wastewater system This chapter lists the necessary Resources on page 320 user and quick start guides required to install bring your system online Refer to the system architectural drawings for I O check out and system troubleshooting during installation and commissioning These drawings reside on the Water and Wastewater Accelerator Toolkit CD See the Introduction section in the Preface for more information The Water and Wastewater Treatment Plant WWTP Hardware documentation package contains the following system level drawing packages e Lift Station System e Dosing Pump Station System e Primary Treatment System e Headworks System e Secondary Treatment System e Solids Handling System Chemical Feed System e Flushing System The Lift Station and Dosing Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings Publication IASIMP QS014C EN P February 2013 271 Chapter 4 Lift Station Hardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Lift Station folder and it contains the following drawings e Title Page and Sheet Index Process Flow Diagram e Net
128. er The operator starts and stops the blower remotely from the BLR 400 Blower Faceplate selecting the BLR 400 icon on the Secondary Overview Screen The available Faceplate commands include Press the Play button to start the blower Press the Stop button to stop the blower Click the Disable button to remove the blower from service Click the Enable button to place the unit back in service RAS Pump The RAS pumps ate Variable Frequency Drive controlled VFD which allows their speed to be throttled The flow of the RAS is controlled by varying the speed of these pumps There will be one pump for each secondary Clarifier Tank Hand Mode Select Hand on the Hand Off Auto selector switch located at the VFD to operate the pump locally The operator uses the buttons located at the VFD to operate the pump Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the VED to put the RAS Pump in the Remote mode 145 Chapter 3 Operator Mode Manual Click on the RAS Pump section of the Secondary Overview screen Selecting the RAS Pump on the Secondary Overview Screen RAS P 401 EET The system displays the Blower RAS P 401 Faceplate RAS Pump P 401 Faceplate a a g relel uic alia Enabled Drive OK Stopped gt E S7 e e Requested 20 00 Operator 20 00 20 00 20 00 Operator 20 00 Comm OK For manual Operator Control se
129. et Overat Yee r rorem Pernceve Status Verve Pt Adeo mtu woo start Avrete BashiFwyi Vee Sta prog Serif wr Perm Ste Famok Vabve Avadeiin EA Rung 2 and 3 These rungs take the flush time entered from the HMI and place it in a timer specific to the applicable valve If a basin flush is active the flush sequence is not complete and the valve is opened the timer is started for FVx These rungs are typical for all valves Grete Dest Tari PRE 30000 Expeessew Flush Secfamer 50001 Selected med Opened Basrifas eecwi Mateni Besifwvi Vive Ste Opened 3E yt JE Tene On Delay EN 170 Publication IASIMP QS014C EN P February 2013 Chapter 3 Rung 4 This rung indicates that the valve flush time has expired Once expired the next available valve is activated Plush System Compe Bandi Fath Done Viive 1 Flush Dore Timer De FiushEnai Baun FhushOone Vahi Flush Done E M Valve 1 Pan Done Vaai Fiunt Done RESET FLUSH SEQ re pe Rung 5 This rung causes the valve to close when the next valve in the sequence is open and available To customize this rung for an additional valve the valve s ladder and FBD routines are inserted and the next valve s tags are inserted in sequence in this rung For a valve following FV7 for example valve FV8 tags would be added to the last 2 rungs DELI d ITI iaa Comi ae e y Vas vate Tmewaad ba bee iri pone D Samira v
130. ew Controller scoped tag Alias Device Definition Screen Name t Alias For WWTP FeedP3 C Device Alm WWTP_FeedP3_OverLoad C Device_Alm0_Input FeedP2 OverLoad C Device Alm Input IOFaut 1 FeedP2 OverLoad IOFauh C 5 Configure and alias for all I O for the new pump The Required Pump I O illustration depicts the subset of the I O required Required Pump 1 0 FeedP3 Fault WWTP CLX RACKO2 Slot00 CNB I Slot 1 Data 6 FeedP3 Fault IOFault WWTP CLX RACKO2 Slot00 CNB I Slot 1 Fault 6 FeedP3 In amp uto WWTP CUX RACKO2 Slot00 CNB I Slot 1 Data 4 FeedP3 In amp uto IOFault WWTP CUX RACKO2 Slot00 CNB I Slot 1 Fault 4 FeedP3 OverLoad WWTP CUX RACKO2 Slor 0 CNB I Slot 1 Data 7 FeedP3 OverLoad IOFaut WNWTP CUX RACKO2 Slot00 CNB I Slot 1 Fault 7 FeedP3 RunFdbk WWTP CL RACKO2 Slot00 CNB I Slot 1 Data 5 FeedP3 RunFdbk IOFauit WNWTP CU RACKO2 Slot00 CNB I Slot 1 Fault 5 FeedP3 SpeedFdbk WWTP_CLX_RACK02_Slot00_CNB 4 1 Ch3Data _FeedP3_SpeedF dbk_lOF ault WWTP_CLX_RACK02_Slot00_CNB 4 1 Ch3F ault Publication IASIMP QS014C EN P February 2013 121 Chapter 3 Be sure to alias all the I O to the new points for the additional pump Be certain that all inputs and outputs are aliased to the correct location 6 Verify the new routines verify and ensure that they contain no errors The most commonly overlooked issues will be reconciling all the tags used in the routine The ladder diagram itsel
131. extremely low e High High Level the Alum storage tank is extremely High Using the Analog Signal faceplate all four process alarms can be configured for changing condition Users with the correct security level can also inhibit all alarms Equipment Alarms These are the two types of Equipment Alarms Alum Fault Check the Feed Pump control panel for system or over current faults e Start Stop Pump Failure Check the local disconnect and pump status Fae we oo Process Alarms Alarm Delay Time secon High High 5 000 High 5 000 Low 5 000 Low Low 5 000 Device Fail 0 000 Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 High High 4 o High Yet Y Low yer Y Low Low TA pece Device Fail s i 119 Chapter 3 Customization of the Dosing Pumps Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the Dosing Pumps This section describes customization specific to the Dosing Pumps application 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput rungs 0 4 e MainProgram A02 AnalogInput rung 0 e MainProgram A03 Outputs as needed this routine is not used in the example e FeedPumpl1 A01 Alarms rungs 0 4 FeedPumpl A02 Control rungs 3 5 e
132. f the pumps Main routine calls the other routines in this program A01_Control contains the code for the pump decisions and metering Feed Pump 1 and Pump 2 handle only pump control Start and Stop commands are issued to these programs and they handle unit level control of the pump motors Main routine calls the other routines in this program A01 Alarms handles inputs and alarms relating to a specific pump A02 Control handles pump control permissives and interlocks for the motor as well as the motor control itself are handled here Add On Instructions are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P_ in their name The other AOIs have a prefix of U as shown in the AOI illustration 114 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 AOls amp Add On Instructions AJ P_Aln AJ P Alarm GJ P DIn GI P_intik GJ P Mode P Motor a P_Perm AJ P Reset AJ P ResInh iz P RunTime z AIJ U FlowPacing AJ U FlowTot U Heartbeat GJ U Module RJ U WallClock Control Description Phosphorus concentrations in the final effluent are limited by the National Pollutant Discharge Elimination System NPDES Permit meaning
133. f will likely verify since this is a duplicate of another function routine Pump 1 0 Verification Screen Verifying program Verifying routine 01 Alarms of Program FeedP3 Verifying routine 02 Control of Program FeedP3 Verifying routine Main of Program FeedP3 Complete 0 error s 0 warning s FeedP3 Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Additional Flow Pacing To include additional flow pacing for other pumps add rungs to routine A01 Control in program FeedPSys Each pump with flow pacing requires a U FlowPacing AOI on its own rung Add additional rungs below the existing Flow Pacing rungs as shown in the Adding Rungs To The FeedPSys Program AO1 Control illustration Adding Rungs to the FeedPSys Program A01 Control fu fare p Prt r et Pares petiit ma Pun gm va Aroste mre va Pci tt C foe hae tS gee eee ve fot fat Pn demum va Orem cm hasten Woe vm Omm mt ho sce fee Perg w Img Ferren Poe Pere Ch festure J ne poe an and Pe dll mm onm c U fief F2 t wor Aim g gt P PF em otar e emos ome 5 AMI pmo e ew P2 ete m tm COND Se eters C_ fuod et ue OO um T tem me on e moe vom t Dem e Ot New pnt cdm Mie om Pare oat mo Oe Pune nm EIL va Pane oem dtt ose ve Feci un tt C see wu ponner uote 17 oreo vat Seem eom Mie el O
134. ft Station Inputs and outputs to the controller are shown on these diagrams The format uses three cards per sheet Inputs to the card are shown with the input device to the left of the input card Output devices are shown to the right of the output card For every additional input or output card new sheets must be added Refer to these sheets during the Commissioning process 275 Chapter 4 Device Wiring Schematics Device Wiring Schematics 8R 3 993783232 5153349535342234223 2521 8949949539929842 94220842323353222332429951 Schematics selector switch wiring information Refer to these sheets during the Commissioning process 216 Publication IASIMP QS014C EN P February 2013 Chapter 4 Dosing Pump Hardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Dosing Pump folder and it contains the following drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e Panel I O Layout Sheets Title Page and Sheet Index Dosing Pump Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT Sheet Index package Modify this sheet as necessary to match the contents of your application s drawing package Publication IASIMP QS014C EN P February 2013 277 Chapter 4 278 Process Flow Diagram Dosing Pump System Process Flow Diagram Number Title E 110 System Process Flow
135. function blocks for the high and low flow faults of the P AIn block Again the ALMD blocks are used if the user wants to populate the alarm summaty page with alarm messages For a detailed explanation of how to set up your alarms please refer to the Factorylalk Alarms and Events System Configuration Guide Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Typical P_Aln instruction used for Influent Flow Influent Flow INP Pv D Influent Flow IO FAULT cjInp P Bad INCOMING INFLUENT FLO Influent Flow P amp ln P Aln Analog Input Val InpPV D Val HiHiLim Val HiLim Val LoLim D Val LoLoLim D 1 50000000e 038 1 50000000e 038 1 50000000e 038 1 50000000e 038 Sts Err r a HiHi Alm HiHi 3 2 C1 Alm Hi E Hi Alm Lo ui 2 C2 Alm LoLo m L4 amp Lo 2 C3 Let Lolo Signature ID 792E8730 A L Fal 2 C4 Sheet 2 contains the ALMD function blocks for the high and low flow faults of the P_AIn block Again the ALMD blocks are used if the user wants to populate the alarm summary page with alarm messages For a detailed explanation of how to set up your alarms please refer to the FactoryTalk Alarms and Events System Configuration Guide 185 Chapter 3 ALMD blocks used to display alarm messages on the alarm summary page if used THESE ALARMS WILL PRODUCE MESSAGES THAT WILL SHOW UP IN THE ALARM SUMMARY PAGE
136. g Pump Panel 1 0 Layout Sheet contains one example of each type of module that will typically be used in a lift station application Note that these modules are 1756 style 1 0 modules Different I O modules will require changes to these sheets Publication IASIMP QS014C EN P February 2013 Water Treatment Plant Hardware Drawings Publication IASIMP QS014C EN P February 2013 Chapter 5 The Water Treatment Plant Hardware documentation package contains the following system level packages e Raw Water Intake System Hardware Drawings e Separation Station System Hardware Drawings e High Service Pump Station System Hardware Drawings The Raw Water Intake System Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings Raw Water Intake System Hardware Drawings The System Architecture folder on the WWWAT CD contains the Raw Water Intake System sub folder Select this sub folder to view the following Raw Water Intake System drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram Panel I O Layout Sheets 305 Chapter 5 306 Title Page and Sheet Index Raw Water Intake System Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER
137. ge the speed value in the Speed Setpoint box 7 To remove the Feed Pump from service click Disable and to place the unit back in service click Enable Remote Program Mode Use the following steps to place the Feed Pumps in Remote Program Control mode 1 Select Remote mode on the Drive Speed selector switch at the Feed Pump control panel Publication IASIMP QS014C EN P February 2013 117 Chapter 3 118 2 Select Remote mode on the Pump Start selector switch at the Feed Pump Control Panel 3 Select the Program mode from the HMI The pump runs and the output feed rate is controlled by the flow pacing signal and the dosage adjustable at the HMI from 0 X ppm entered by the operator Transfer between the Controller operator and Program modes is smooth The pump output in gallons per hour feed rate and stroke speed setpoint is calculated The Program Logic Controller PLC will output the speed signal to the pump based on the appropriate flow pacing signal Alum Control Setpoints Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Alarms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Process Equipment Process Alarms There are the four types of Process Alarms Low Level the Alum storage tank is low e High Level the Alum storage tank is high e Low Low Level the Alum storage tank is
138. ges to the 1 0 for the Raw Water Intake System should be reflected on this diagram For example if additional pumps are required in an application you should update this sheet with those pumps and their associated 1 0 A diagram like the one on this sheet shows a general overview of the process controlled by the system in this drawing set It provides a quick summary of the controls involved and of the process that is being controlled 283 Chapter 4 284 Network Diagram Raw Water Intake System Network Diagram E 1120 Network For details see page 23 Diagram Publication IASIMP QS014C EN P February 2013 Chapter 4 Panel I O Layout Sheets Raw Water Intake System Panel 1 0 Layout Sheets Number Title Description E 1130 Panel I O Layout The Run Water Intake System Panel 1 0 Layout Sheets Sheet 1 of 2 depict inputs and outputs to the controller This format Panel I O Layout uses three cards per sheet Inputs to the card are shown E 1131 Sheet 2 of 2 with the input device to the left of the input card Output devices are shown to the right of the output card You must add a new drawing sheet for every additional input or output card This drawing package reserves space for all the slots of a controller s chassis If an additional chassis is required use this same format with space reserved in the drawings for any empty slots of the chassis This provides a
139. gned to Lag1 as Secondary will start in this case all of them Ifa pump was set to Lag2 as the Secondary selection it will start 60 sec after the Lag1 pump s start If all of the pumps are set to Lag2 as Secondary then no pumps will start during the first 60 sec Lag1 time The sequence is lead pump delay lag pump s delay lag2 pump s Once a pump starts it will continue to run until the Pumps Stop float clears Example 2 Same setup as above except the Secondary selections are now as shown Let s say that pump 2 is the lead pump Lead Start float is activated Pump 2 starts 60 sec time delay pump 1 lag1 starts 60 sec time delay pump 3 lag2 starts Because pump 4 is set to Not Used it does not run 241 Chapter 3 242 Example 3 The setup is as shown however now the Lag1 pump is not allowed to run in backup Again let s say that pump 2 is the lead pump Lead Start float is activated Pump 2 starts 60 sec time delay and although pumps 1 and 3 are both set for lag1 they do no run because the lag1 pumps are not allowed to run due to the selection on the Backup Pump Selection screen 60 sec time delay pump 4 lag2 starts Configuring Analog Inputs Now that the application has been set up you can continue through the rest of the configuration 1 From the Main screen press Analog Inputs Config to display the configuration screen This b
140. he screening cycle and moves the screenings to the Screenings Compactor which empties into the grit and screen hopper for subsequent disposal HMI Description The operator controls and monitors these processes as follows 1 Go to the Overview screen 2 Click the Headworks button or the Headworks icon to display the Headworks Application screen Selecting the Headworks Button T Influent Chamber amp Bar Screen Grit Chamber Tank 127 Chapter 3 Headworks Primary Treatment Overview Screen ovre I c vocis Ic ves ER Lost Years Flow ERE c The status information on the Headworks Primary Treatment Overview screen includes Mechanical Bar screen Numbers 1 and 2 e Grit Tank Drive No 1 Channel Numbers 1 and 2 Differential Level e Channel Number 1 Flow 128 Publication IASIMP QS014C EN P February 2013 Chapter 3 Control Description Mechanical Bar Screen Numbers 1 and 2 This section describes the Mechanical Bar screen modes Hand Mode The Mechanical Bar screens Number 1 and Number 2 are operated locally by selecting the Hand position on the Hand Off Auto selector switch which is located at the MCC The operator uses the BAR screen buttons located at the equipment In this mode the operator is responsible for operating the conveyor compactor and the Bar screen Mechanical Bar Screen Diff Pressure Motor Control Lo Remote Operator Mode The operator must place the screening
141. hen troubleshooting an object you can immediately see the state of the I O associated with it and check that the correct I O is mapped to the correct location e It provides a simple understanding of which I O applies to a particular object Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication IASIMP QS014C EN P February 2013 The following example depicts the P Motor object All I O associated with this motor is mapped on the rung with the motor object P Motor Object DEVICE MOTOR This rung sotually monitors and controls the Oewioe motor Mapping inputs Mun F eedbace Hand Mode celeotion Litt Station 4 Pump 3 Input Signal RUN Pump 1 Running dback from motor Device Ruck dbl Device Motorinp Ruck dbk Looal 1 Data 137 L Y1 Ft Motoring uon dbk Litt Station 4 Pump 1 ImSelect Hand rump wi Khardevite d Control In Auto Atrateay Device InZuto D evice1 Motor inp Hand koonl 1T1 Data 1 7 LST IP 41 Motor np Hand gt ON Litt Station 1 Pump Overall Litt Station 1 Pump Pemizzive Statux 1 1er armizxiver COR 19 OF to start motor oan start Device Term Stz lernoc Device t Motor inp Memnok LST1 FP Ferm Ste_Penmor LSTI P1 Motor Inp Peimios Lam Station amp 1 Pump 1 Hon Eypascable Pemmusive Status 7 Left Station 1 Pump norm bypagrable 1 t Non Dyp amabis
142. ical Feed set point and pump sequence selection AAA ChemicalFeed LeadLag PIDSPs Chemical F CHEMICAL FEED SYSTEM CONTROL CURRENT CHEM FEED SP 250 00 GPM CHEMICAL FEED SETPOINTS MANUAL FLOW SELECT CALCULATED SETPOINT GPM LEAD LAG SEQUENCE VALUES PUMP SEQUENCE 1 2 3 4 5 PUMP SEQUENCE 2 3 4 5 1 P 2 LEAD PB PUMP SEQUENCE 3 4 5 1 2 P 3 LEAD PB PUMP SEQUENCE 4 5 1 2 3 P 4 LEAD PB PUMP SEQUENCE 5 1 2 3 4 P 5 LEAD PB To operate system perform the following tasks 1 In above pop up choose Manual Flow Set Point and enter a flow value or select Calculated Set Point When Select Calculated Set Point is chosen you must insert a value in the Influent Flow faceplate see fig 24 since the calculated set point value is derived from influent flow 2 Select a pump sequence 3 Press the Start Cycle button Simulation Mode 198 Publication IASIMP QS014C EN P February 2013 Chapter 3 To operate the system in simulation mode perform the following 1 Open RSLogix Emulate Version 19 11 Insert PLC in slot 3 2 Open a copy of Chemical Feed System PLC Version 19 1 go to WHO Active find the emulator in slot 3 and download to it 3 When you are finished downloading put PLC in run mode 4 Open the FactoryTalk View SE client and start the HMI application Water Treatment Plant The Water Treatment Plant WTP documentation package contains the Applications following application
143. ing Pump Hardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Dosing Pump folder and it contains the following drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e Panel I O Layout Sheets Title Page and Sheet Index Dosing Pump Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT m Description E 100 Title Page and This is the Table of Contents Cover Sheet for the drawing Sheet Index package Modify this sheet as necessary to match the contents of your application s drawing package Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 2 Process Flow Diagram Dosing Pump System Process Flow Diagram Number Title Description E 110 System The Dosing Pump System Process Flow diagram depicts a Process Flow two pump alum addition process You make any changes to Diagram the number of pumps or I O for this process on this drawing For example if you require additional pumps in an application update this sheet with the appropriate pumps and their associated 1 0 information The Dosing Pump System Process Flow diagram is very helpful for a quick summary of the controls and the process being controlled 37 Chapter 2 Network Diagram Dosing Pump System Network Diagram eee z T GRR EE Mme E MU BSEIMUOMEMMQ
144. ing table describes the key design points of the Raw Water Intake Pump Station System Architecture Drawing Hardware ControlLogix Processor Description Controls the Raw Water Intake Pump Station System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the pumps EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the plant network Publication IASIMP QS014C EN P February 2013 23 Chapter 1 24 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e Each specific site must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Run Water Intake Pump Station System Add more drives as needed e The Ethernet Switch has a limited number of ports Select the appropriate Stratix switch as required for the number of EtherNet IP devices in the system P addresses and node numbers are unique to your application and you must include them on this drawing Publication IASIMP QS014C EN P February 2013 Chapter 1 Separation Station System Architecture Drawing This is a typical Separation Sta
145. ion for that specific reason Itis assumed the processor will be running other systems of the plant Publication IASIMP QS014C EN P February 2013 137 Chapter 3 The organization of this application is similar to that of the Lift Station Specifically the functionality for each program and routine is e Main Program handles general Secondary application and functionality including Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 MiscDiscreteInput includes a template to map inputs that are relevant throughout the Secondary system This routine is provided as a Punction Block Diagram A02 MiscAnalogInput includes a template to map analog inputs that are relevant throughout the Secondary system This routine is provided as a Function Block Diagram A03 MiscOutputs includes a template to map outputs that are relevant throughout the Secondary system This routine is provided as a Punction Block Diagram e SecTank01 Drive Controls the motor for the Secondary Clarifier Tank 1 system including Main routine calls the other routines in this program A01 Drive LDR contains the code to monitor and control the Secondary Tank 01 motor and Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram
146. ion sequence has been selected and the start stop pump set points are set to the correct level 100 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Alarms The Lift Station generates these two types of alarms Process Alarms e Equipment Alarms Process Alarms These are the six different types of Process Alarms Low Level the wet well is low e High Level the wet well is high e Low Low Level the wet well is extremely low e High High Level the wet well is extremely high or is overflowing e High Level Float e Low Level Float Equipment Alarms These are the four different types of Equipment Alarms Pump Permissive Inhibit Restart Pump Interlock Motor Overload Motor High Temperature or Low Water Cutoff Start Stop Pump Failure Check the MCC selector switch and local disconnect e I O Fault Use the Lift Station Level Faceplate to configure the analog Process Alarms changing condition Users with the correct security level can also inhibit both alarms 101 Chapter 3 102 Lift Station Level Faceplate Lift Station Level HA ae gv e Alarm Delay Time secon High High High Low Low Low Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 vf High High 4 o High v Low rA Vf Low Low Device Fail Customization The example programs included on the WWWAT CD provide you with a start to the application developmen
147. ipment Run Times oor en eere edes 135 Customization of the Headworks Application 136 Secondary Application acci saw ee TORRE Oo I OPAC 8 137 Process Descrip 124a yoia tiine vete rcs Ped 140 HMIDesctpti nzs sexe nen bene RESO e FEY RS 142 Control Description Blower BLR 400 004 144 AIDS risotto uPTEMOSEVU Co tee Nett A anat vts 148 BSDOEBE E nck saint ete ay er ee ad on dos a ACE 150 Customization of the Secondary Application 151 Solids xpplicatofirc ennor hin oic e p E EERO 152 Process Descriptio is siei ie eden t Rari ito rra neues 155 Publication IASIMP QS014C EN P February 2013 Installation and Commissioning Publication IASIMP QS014C EN P February 2013 HMI Desert ilotb s pouce eio aw way od NEW HF were noe T OETR 156 Control IDDesetipidonis us ees se PR eae da Ced eoa 158 IB s eic AO sc aM ELI oL SS a 162 Bepoting notet ecce oie iut Tail bebe M abri tS eee 164 Customization of the Solids Application 0 0 165 Flushing System Application d co ev s MAS A HEROS eR AA 168 HMI D scHptlona 13 eren RP Ra ee Etro e a 176 Select Flush Mode 45e v pru Ko Ce ae vM erbe ra x eT PUES 177 Return all to Auto Button sv 5eoot iet bo vet vL KE eds 178 Simtlation Mode ses dd Quee exo i Ue Me ouod ee 178 Chemical Peed System Application v 000 E vate ee 178 Process D sciiption ierre 8 tek in a SS ES dte d par etu 178 Control DIGS CHLOE e ors Lotes dg uita pond tae te dr 179 Che
148. is manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss IMPORTANT Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ELM A ES A A A Allen Bradley Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Table of Contents Preface System Specification Hardware Design Application Engineering Publication IASIMP QS014C EN P February 2013 Table
149. is sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Chapter 4 Communications Diagram Pump Controller Station Communications Diagram E 12 Pump Control Refer to Pump Controller Station Architecture Drawing on Communications page 28 for details Diagram Publication IASIMP QS014C EN P February 2013 287 Chapter 4 288 Panel Layout Diagram Pump Controller Station Panel Layout Diagram Number 13 E amim mri mi auLt Fi uo I ill iil Th oss Title Pump Description Controller requirements Station Panel Layout Diagram You can modify this as needed for your application Publication IASIMP QS014C EN P February 2013 Chapter 4 Power Layout Sheets Pump Controller Station Power Layout Sheets Publication IASIMP QS014C EN P February 2013 289 Chapter 4 290 1 3and5 Power Layout Sheets Description Pump Control Power Distribution 480VAC Power and 24VDC Power Drawings Publication IASIMP QS014C EN P February 2013 Chapter 4 Panel I O Layout Sheets Pump Controller Station Panel 1 0 Layout Sheets Publication IASIMP QS014C EN P February 2013 291 Chapter 4 T MGR 8 11 1 0 Layout Pump Control Drive and PLC 1 0 Drawings Sheets 292 Publication IA
150. iscDiscreteOutputs B A04 MiscAnalogOutputs C3 HighServicePumpP1300 3j Program Tags En Main B A01 Pump LDR 3 A02 Pump FBD c HighServicePumpP1301 A Program Tags Main B A01 Pump LDR B A02 Pump FBD This task should reside in a Controller in the main facility of the plant where the High Service Pump Station application is present and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other systems of the plant Publication IASIMP QS014C EN P February 2013 Chapter 3 The organization of this application is similar to that of the other applications in this toolkit Specifically the functionality for each program and routine is e Main Program handles general High Service Pump Station application and functionality including Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 MiscDiscreteInput includes a template to map inputs that are relevant throughout the High Service Pump Station system This routine is provided as a Function Block Diagram A02 MiscAnalogInput includes a template to map analog inputs that are relevant throughout the High Service Pump Station system This routine is provided as a Functi
151. issives and Interlock AOIs that monitor and control the Primary Tank to Solids Tank pump See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e Solids TkO1ToFilterPress Pump602 controls the motor for the Solids Tank to Belt Filter Press pump ar Screen 1 system Main routine calls the other routines in this program A01 Pump _LDR contains the code to monitor and control the Bar Screen 01 motor and Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram A02 Pump FBD contains the Single Speed Motor Permissives and Intetlock AOIs that monitor and control the Bar Screen 01 motor See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram Add On Instructions are used extensively in this application There is a collection of Process Libraty AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P in their name The other AOIs have a prefix of U_ as shown in the AOI illustration 154 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 AOls E S Add On Instructions P_Aln P_Alarm P_DIn P Intlk w AJ P Mode P Motor P Perm 4 P_Reset z P ResInh P_RunTime Hs U_CommFail ff U_FlowTot H
152. it 101 Pump 1 INP_RUNNING LIM 7 Limit Test CIRC Lowe Limit 20 01 Pump1 Lagi PT Compute m Dest Chemical_FeedP1_P_VSD PSet_SpeedRef 100 0 Expression 80 100 ChemicalFeedP PIDE CV 5 Test ChemicalFeedP PIDE CV 99 98525 High Limit 100 rM Pumpi Lag2 EO M SI s H Limit Test CIRC E 9 4 Compute Low Limit 40 01 Dest Chemical FeedP1 P VSD PSet SpeedRef 100 0 Test ChemicalFeedP PIDE CV Expression 50 100 ChemicalFeedP PIDE CV 5 99 98525 High Limit 100 LIM Pump1 Lag3 CPT 4 Limit Test CIRC E Compute Low Limit 60 01 Dest Chemical_FeedP1_P_VSD PSet_SpeedRet 100 0 Test ChemicalFeedP PIDE Cv Expression 40 100 ChemicalFeedP_PIDE CV 5 99 98525 High Limit 100 M Pump1_Lag4 PT Limit Test CIRC E Compute r Low Limit 80 01 Dest Chemical FeedP1 P VSD PSet SpeedRef 100 0 4 Test ChemicalFeedP_PIDE CV Expression 20 100 ChemicalFeedP PIDE CV 5 99 98525 High Limit 100 RUNG 5 and 6 Max speed calculation the speed at which when the pump reaches it the next pump in the sequence is started In this case at a value of 90 the next pump in line will start Max speed calculation CFP1 at Max Speed Chemical FeedP1 P VSD Sts Running GRT TON Greater Than 4 gt B Timer On Delay Source A ZU Ms ae bk Timer Timer CFP1Max Preset 3000 Source B Accum 3000
153. king device to remove debris from the raw wastewater The Mechanical Bar screens cycle periodically to rake debris from the bar rack and deposit the screenings on a belt conveyor This conveyor runs during the screening cycle and moves the screenings to the Screenings Compactor which empties into the grit and screen hopper for subsequent disposal HMI Description The operator controls and monitor these processes as follows 1 Click the WTP button to go Water Treatment Plant WTP Overview screen 2 Click the appropriate Raw Water Intake amp Pump Station icon to display the Raw Water Intake amp Pump Station Overview screen The Raw Water Intake amp Pump Station icons are enclosed in the large red box on the WTP Overview screen If you want to return to the WWTP Overview screen click the Overview button Selecting the Raw Water Intake WTP Overview Screen L RAW WATER INFLUENT CHAMBER GRIT CHAMBER TANK RAPID MIX FLOCCULATION SEDIMENTATION INTAKE amp PUMP amp BAR SCREEN STATION MEMBRANE EQUIPMENT CLEARWELL AND HIGH SERVICE PUMP STATION n GAC EQUIPMENT DISTRIBUTION SYSTEM RESERVOIR menu Em D ceciay WIP Overview 203 Chapter 3 Raw Water Intake Overview Screen D Ci conection 0 apen rejected Eror 2040101 an route Compact ogr n sit 0 of the castes at 10 16 3232 The status information on the Raw Water Intake amp Pump Station Overview screen includes Mechanical Bar s
154. l CAD files from the Rockwell Automation Configuration and Selection Tools Website at http www tockwellautomation com en e tools How to Access Additional CAD Figures from the Website Use these steps to access the additional CAD figures from the Rockwell Automation website 1 Go to http www tockwellautomation com en e tools 2 On the Product Selection tab type the catalog number of the part you want click on the product directory for additional information or use the Product Configuration Assistant To assist you in the hardware design phase of your water or wastewater project the WWWAT CD contains links to numerous websites where you can find useful and up to date information For more information on websites and documentation that will help you plan and design your Water and Wastewater project see Appendix A 51 Chapter 2 Notes 52 Publication IASIMP QS014C EN P February 2013 Chapter 3 Additional Resources Process Library Module Publication IASIMP QS014C EN P February 2013 Application Engineering To assist you in the hardware design phase of your Water and Wastewater project refer to the Water and Wastewater Accelerator Toolkit WWWAT This toolkit resides on a CD and contains links to numerous websites that contain useful and up to date information Refer to the Preface for more information about the WWWAT For more information on websites and documentation that will help you plan
155. lect the Operator mode on the RAS P 401 Pump Faceplate The Faceplate shown is used to control the RAS pump The operator starts and stops the pump remotely from the RAS P 401 Pump Faceplate selecting RAS P 401 on the Secondary Overview screen The available Faceplate commands include Press the Play button to start the pump Press the Stop button to stop the pump Click the Disable button to remove the pump from service Click the Enable button to place the unit back in service 146 Publication IASIMP QS014C EN P February 2013 Chapter 3 Secondary Clarifier Tank Plant operators manually control the Secondary Clarifier Tank SCT The SCT center drive runs continuously and is protected from over torque by overload switches set at the factory The overload switches sense a build up of torque as the mechanism rotates A factory pre set overload switch will trip the Final Tank Mechanism Overload common alarm as the torque builds up Purther increasing torque will cause a second factory pre set switch to trip and stop the mechanism from running When the mechanism stops due to an overload or a power outage the operator must restart the unit manually Hand Mode Select Hand on the Hand Off Auto selector switch located at the MCC to operate the SCT locally The operator uses the buttons located at the MCC to operate the SCT Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located
156. level Controller Settings Delete Selected Controleris Name v Ascending g MicroLogir 1400 192 168 1 100 PLC Micro 1400 series A 1766 L32BXB 1 Analog I O module 1762 IF2OF2 2 chnl Input 2 chnl Output Publication IASIMP QS014C EN P February 2013 263 Chapter 3 264 2 Channel settings Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 MicroLogix Memory Module The Multifunction Pump Control PLC program comes stored on a 1766 MM1 memory module To load the program from the memory module into the PLC 265 Chapter 3 Use the up down buttons on the directional keypad to scroll to the Advanced Set option on the LCD display and push OK Directional keypad 2 Scroll down to Comms EEPROM and push OK Scroll to Load from MM and push OK 4 The Run LED will flash on off When loading is complete the Run LED will stay off Push OK To place the PLC into Run push the ESC button several times until the display no longer changes This will bring you out to the main menu Sctoll down to Mode Switch and push OK 6 Scroll down to Run and push OK The PLC Run LED will turn on To save the program from the PLC into the memory module 1 Use the up down keypad to scroll to the Advanced Set option on the LCD display and push OK Scroll down to Comms EEPROM and push OK Scroll to Store to MM and push OK The
157. level architectural drawings e Lift Station System e Dosing Pump Station System Primary Treatment System Headworks System e Secondary Treatment System e Solids Handling System Lift Station System Architecture Drawing The following is an example of a typical Lift Station System Architecture Drawing Lift Station System Architecture Drawing 12 Publication IASIMP QS014C EN P February 2013 Chapter 1 The following table describes the key design points of the Lift Station System Architecture Drawing Hardware Description L23 Processor Controls the Lift Station EtherNet IP Enables the HMI hard drive and system controller to communicate with each other PanelView Plus Human Machine Interface HMI PowerFlex 70 Drives the pumps DeviceNet Controls 1 0 and other devices Esteem Wireless Modem Connects the Lift Station to the Supervisory System The WWW AT CD contains architecture drawings that are only intended to be the basis for your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e The HMI shown in the Lift Station Architecture Drawing is a PanelView Plus 600 with a keyboard Do you have another size screen preference Do you prefer display only with no keypad e The pumps in this application are controlled via contactors Optionally sh
158. lk View Studio 9701 VWSBxxxAENE 5 0 or later PanelView Plus Site Edition Applications FactoryTalk Services RSLinx Enterprises RSLinx Classic xxx number of screens required for the application Preface Notes 8 Publication IASIMP QS014C EN P February 2013 Chapter 1 Introduction Procurement Specifications Publication IASIMP QS014C EN P February 2013 System Specification Use this chapter to learn about the Water and Wastewater product portfolio The Water and Wastewater Accelerator Toolkit WWWAT CD contains procurement documents to help you develop the appropriate Request for Proposals RFPs We suggest that you copy and then paste these documents directly into your bid documentation package Our objective is to save you time when writing these specifications Most of the hardware referenced on the CD has an associated procurement specification This hardware includes ControlLogix controllers e 2x Compactions controllers PanelView Plus HMIs e PowerFlex 70 variable frequency drives Development Software Go to the product information section on the WWWAT CD to access the appropriate procurement documents WWWAT CD Product Information Menu WWWAT Common Tools Quick Start Process Objix Product Information 12x Controller Information PanelView Plus Information Lift Station Dosing Pumps Supervisory System vitly v Help Se p i
159. ll Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication IASIMP QS014C EN P February 2013 Supersedes Publication IASIMP QS014B EN P October 2009 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A
160. m Gener te Report AA Routine Print gt C Bring Type Print Options Trend LLST1 CMLX 20090301 Kevin MPC ACD 2 LST1 CMLX 20090301 Kevin ACD 3 CAMy Documents MACHINE 1 ACD 4LST1 CMLX 20090301 ACD SLSTI CMLX 20090301 Emulate ACD WWTP CLX 20090301 ACD Z CAMy Documents M Machine2 ACD 8 Add On Instructions Samples ACD Ext Once you import an AOI the system lists it in the Controller Organizer s AOI folder The Process Library Module code may be viewed but not edited User Modules The applications in this toolkit also contain user modules These modules can be identified by the prefix U_ and have been written exclusively for the WWwWAT and its associated applications Use these AOIs as written or customize them as required Publication ASIMP QS014C EN P February 2013 89 Chapter 3 Water and Wastewater The Water and Wastewater Treatment Plant WWTP documentation package Treatment Plant contains the following applications Applications e Lift Station System e Dosing Pump Station System e Headworks System e Secondary Treatment System e Solids Handling System Lift Station System Application The WWWAT CD contains a Lift Station system application This application is written assuming up to six pumps transfer the Lift Station building well contents to the Raw Sewage wet well at the Wastewater Treatment Plant You can also modify the application use in a pumping application
161. m Select a Visualization Product Choose one of the following visualization products for your application e PanelView PanelView Plus terminals e Industrial Computers e InView Message Displays Once you have decided on a Visualization product choose the specific product and software for your application This section includes the necessary system specification and part number information required to select the correct visualization solution E3 and E3 Plus 193 SG008 E3 Overload Information required to specify part numbers for E3 and System Solid State Information E3 Plus Solid State Overload Relays Specification Overload Relays Hardware Selection Selection Guide 322 Publication IASIMP QS014C EN P February 2013 Documentation Stored On the WWWAT CD Document Name Point 1 0 Selection Guide Publication Number 1734 SG001 WWWAT CD Folder Point 1 0 Document Contents A step by step guide for selecting Point I O Hardware including e Select the Communications Interface e Identify part numbers for specific I 0 Modules You can choose between analog digital and specialty modules Module specifications and part numbers are listed e Select a Terminal Base Assembly e Select a Power Supply Unit e Select Point 1 0 Accessories e Determine mounting requirements This section provides information on the spacing requirements for your Point I O This information will vary based on the selections you h
162. m Mode 67 Chapter 3 Motor P_Motor AOI Motor P_Motor Motor P_Motor The following table describes the Motor P_Motor parameter and its usage Description The P_Motor single speed motor object controls a non reversing single speed motor in a variety of modes and monitors for fault conditions Use This Instruction When e You want to control a single speed running or stopped motor The motor can use a full voltage starter FVNR a soft starter or other motor protective equipment However it might provide run feedback The P Motor AOI provides Faceplates and graphic symbols for the operator display control and appropriate modes alarms Do Not Use This Instruction When e You want to control a two speed fast slow stopped motor Use the P_Motor2Spd two speed motor AOI instead e You want to control a reversing forward stopped reverse motor Use the P MotorRev Reverse Motor AOI instead e You want to control a motor with continuously varying speed Use the P VSD Variable Speed Drive AOI instead e You want to control a motor that is part of a valve actuator Use the P ValveMO Motor Operated Valve AOI instead 68 Publication IASIMP QS014C EN P February 2013 Motor P_Motor Operator Tab Process Variable Faceplate Mode Indicator Motor Enabled Dis abled Motor Status Indicator Communication Status Indicator Motor P_Motor Maintenance Tab Process Varia
163. m level This is a standard Process Library Faceplate To obtain pump status and control click either pump icon Clicking a pump opens the Process Library Faceplate for VFDs The variable speed Alum Feed Pumps may be operated in either Hand or Remote mode as selected by a Remote Off Hand selector switch at the associated control panel Hand Mode Use the following steps to place the Feed Pumps in Hand Control mode 1 Select Hand mode on the Drive Speed selector switch at the Feed Pump control panel 2 Select Hand mode on the Pump Start selector switch at the Feed Pump control panel In Hand position the operator starts and stops the pump using the appropriate button station located on the control panel To adjust chemical dosing use the Motor Speed potentiometer at the Feed Pump Control Panel Remote Operator Mode Use the following steps to place the Feed Pumps in Remote Operator control mode 1 Select Remote mode on the Drive Speed selector switch at the Feed Pump control panel 2 Select Remote mode on the Pump Start selector switch at the Feed Pump control panel 3 Select Operator mode from the HMI 4 The pump is started and stopped remotely from the HMI screen A faceplate is displayed by clicking on the Feed Pump icon 5 To start the pump press Play and to stop the pump press Stop 6 To modulate the Feed Pump rate either click in the Operator Setpoint box and type in a value between 0 and 100 percent to chan
164. mO6 Inp_PermO Signature ID 79B0ECO0 Chemical FeedP1 P Intlk Pntik intkok Chemical FeedP TkLvl Interlock OK lt inp IntlkOO Sts IntlkOK 4 2 B2 Influent_Tank_Level_OK f h mko Sts _NBIntIkOK H amp i NBIntkOK E Inp Intlk02 Rdy Reset 3 2 B2 amp Inp_IntkkO3 E Inp IntlkO4 Inp Intlk05 E Inp IntlkO6 E Inp IntlkO7 amp Inp Reset Signature ID amp 183CEE3 Customization To add a pump the programmer would copy the above FBD routine paste it into a new routine and then change the tag names Notice the Pump 1 tag is a UDT that just has to be copied and pasted with a new tag name Then it can be used as desired in the program and routine Publication IASIMP QS014C EN P February 2013 191 Chapter 3 Typical VSD block for Pump 1 Chemical_FeedP1_P_VSD PUMP RUNNING o USED FOR SIMULATION P VSD IN THIS CASE 0 0 Pump 1 INP SPEEDFDBK D d Inp_SpeedFdbk Out SpeedRef D g Pump_1 0UT_SPEEDREF 1 Pump_1 INP_RUNNING Er 0 amp Inp Running Out Datalink D 0 Pump 1 INP ALARM a 2 Inp_Alarm Out Run Fo E ca Pump_1 OUT_RUN i Pump_1 INP_FAULT d4 Inp Faulted Val SpeedRef wm amp Inp AtSpeed Val SpeedFdbk 3 bn PermOK F amp jInp FwdPermOK Val InpDatalink D t p 00 1 E1 NBPermOK ee 4 SS amp Inp FwdNBPermOK Val OutDatalink Po
165. maps outputs that are relevant throughout the Lift Station e Pump System determines how many pumps to run and which pumps to statt This is a supetvisor of the pumps Main routine calls the other routines in this program A01 StartOrder determines the order in which to start the pumps Publication IASIMP QSO014C EN P February 2013 91 Chapter 3 A02_Control calculates the pump demand the number of pumps to start e Pumps handle only pump control Start and Stop commands are issued to these programs and they handle unit level control of the pump motors Main routine calls the other routines in this program A0x Pumpn Alarms handles inputs and alarms relating to a specific pump A0x Pumpn Control handles pump control permissives and interlocks for the motor as well as the control of the motor itself are handled here 92 Publication IASIMP QS014C EN P February 2013 Chapter 3 Control Description Normally the wet well pumps transfer the Lift Station well contents when the well level rises above the programmed high water level in the well Alternatively floats in the wet well control the pumps in case of a Programmable Logic Controller PLC fault or level transmitter malfunction This allows the pumps to turn on via a hard wired circuit if the water level is too high Hand Mode Place the pumps in Hand control 1 Select Hand mode on the Drive Speed selector switch at the Feed Pump contr
166. mical Feed Mixers unuu en Shp eRe EN RAP RC RR 196 HMI D scipton etr e ios qot too to o a Ce apace een rae AOR 197 Water Treatment Plant Applications ican yaa e ex vete 199 Raw Water Intake Applicatiom s 4 code ee ee 199 Process DeserHoDu eet Vua de Vea RR SR a Se Vasa Re RS 202 HMI Deseo d uso E RR E CO phe 203 Control Des tiptionn oA pa atid sagen dde e 1A 205 ABTS otn Eau a ert tud nt Adie esee aee d ters 209 Reporting Equipment Run Times enceck tene mee hes 211 Customization of the Raw Water Intake Application 212 Separation Application i Loved tore aA Rte RO 213 Process D escHpHOD S es EET PR RS A E Dhow Oo ERES 215 HMI Desert bora esa Coe ted eed EL ox Pe eda e 216 Control Descpplotls sv e este op UN AY ewe 218 AJartns Soo cag S PORC ES aye ha aU Tea eis ant a 220 RepoOFU HE eee sat detrei yard Peeled ae iod ot aware dtl 222 Customization of the Separation Application 222 High Service Pump Station Application 000 224 Pro ess Desenpiobuss Ser VIA P Ue T REEVUEE EV aui rg 226 HMI Descriptions sooo vbt ep ET RN ERES 227 Control D scipliotlors S etsy pote OU Sa e be Meine A a 229 ABMS Se icicle a sis dein du Sed cy Sabi qai dene dtd t 231 Reporti 4 G5 neansy ne see etat vert a nd e ce eres 233 Customization of the High Service Pump Station Application 234 Pump Controller Staion were garg fos oracio E RAT Eee UPON Ea 234 GChapter 4 Installation and Commissioning vss eere ae a t
167. n ie P Alarm G3 P DIn w A P Intlk ig P Mode t iz P Motor m iz P Perm H iz P Reset w P ResInh P RunTime Ls U CommFail i iz U_FlowTot w 5 U Heartbeat H A U RepeatCycTmr i i u wallClock Process Description The High Service Pump Station process consists of a Clear Well High Service Pumps and Elevated Tank Clear Well Clear Well Storage CWS should be sized in conjunction with distribution system storage to relieve the filters from having to follow fluctuations in water use High Service Pumps The High Service Pumps HSPs deliver water to the Distribution System DS The DS is the elements of the municipal waterworks between the treatment facility and the consumer The function of the DS is to deliver water under reasonable pressure in volumes adequate to meet peak consumer demands in the service area The PLC controls the High Service Pump Station process Clear Well High Service Pumps and Elevated Tank and it is located in the Operations Building Publication IASIMP QS014C EN P February 2013 Chapter 3 HMI Description The operator controls and monitors these processes as follows 1 Click the WTP button to go Water Treatment Plant WTP Overview screen 2 Click the appropriate High Service Pump Station icon to display the High Service Pump Station Overview screen The High Service Pump Station icons are enclosed in the large red box on the WTP Overview screen
168. n IASIMP QS014C EN P February 2013 Chapter 3 e Control of VFD sthrough Modbus communication which reduces the control wiring to the drives PowerFlex 4 40 400 VFD s only e Pump control can be done with starters PowerFlex 4 series VFD s or with another manufactures VFD Pump sequencing control User selectable alarms with the ability to choose which ones can be used to initiate an alarm dialer user supplied Pump statistics The ability to save and load VFD parameters from the HMI PF4 vfd s only e Sclectable pump interlocks Main Screen Flashes when a Warning exists Flashes when an Alarm exists Common header KS Not visible until an application has been selected Application Config visionis Maintenance Contig Analog Only visible if analog device is being used gt Inputs Wamings C ontig Analog Alarm Outputs Output Config Contig Legend depends on if Pressure Follower Pressure p mode is selected or Level mode is selectd Set Points Pressure Overview Level Set Points Pump Down Uvervwiew Legend depends on if Pressure Follower Pump Up Level Pump Down or Level Pump Up mode isselected Overview Publication IASIMP QS014C EN P February 2013 235 Chapter 3 236 The main screen displays configuration monitoring and maintenance controls Some control label content displays based on the current configuration Several of the buttons on the
169. n Pump Starts Seconds to enter the delay before the next one starts when more than one backup pump is enabled TIP 240 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 If on the Measuring Setup screen above the Secondary backup Measuring Device is set to NOT USED then no pumps will run in backup TIP If on the Measuring Setup screen above the Secondary backup Measuring Device is set to Floats then backup pumps will start when the Lead Start float is activated and continue until the Pumps Stop float is activated A lead start and a pumps stop selection must be assigned to an input on one of the Digital Input Assign screens Because this is a backup operation likely due to a failure the pumps do not alternate Setup Examples Example 1 In a pump down application Floats are being used as backup On the Pump Sequence Setup screen the Primary selection for all pumps is set to Alternate and the Secondary selections are set to Lag1 And on the Backup Pump Selection screen lead lag and lag2 pumps are all allowed to run as backup As the level rises and activates the Lead Start float The lead pump because all ate set for alternate it could be any of the four pumps starts Let s say that the Delay Between Pump Starts see graphic above is set for 60 sec If the Pumps Stop float does not clear in this time all of the pumps assi
170. n amp ulo P603 Inhuto C Locat31 Data TTC T Equip In amp uto IOFaul PB03 In amp uto IOFaul C Locat3 Faul 11 C E Equi Ini PB03 Ini C P603 INKE Equip_lOFault k E Equip Motor P603 Motori C P803 MoloiC Equip_Out_Run O_P603_Out_Run C Locat 0 Data4 C Equip RunFdbk P503 RunFdbk C Local 31Dala 1 ac Equip RunFdbk IOFault P503 RunFdbk IDFaul C iLocal 3 Faul12 C 4 Configure and alias all I O for the new pump The Configuring and Aliasing New Pump I O table depicts the subset of the I O required Be sure to alias all the I O to the new points for the additional pump Be certain that all inputs and outputs are aliased to the correct location Configuring and Aliasing New Pump 1 0 P503 Faull Local 3 l Data 10 P503 Faul IOFaull Local 3 Fault 10 P603 In uto Locat31 Data 11 P603 In amp uto IOFault _Locat3 1 Fault 11 P603 RunFdbk Locat31 Data 12 P503 RunFdbk IOF ault Local 31 Fault 12 D P603 Dut Run Local 4 0 Dala 4 166 Publication IASIMP QS014C EN P February 2013 Chapter 3 5 Confirm that the new routines verify and contain no errors The most commonly overlooked issues are reconciling all the tags used in the routine The ladder and Function Block Diagrams themselves typically verify since they are duplicates of the original routines Routine Verification Verifying program SolidsTk01ToFilterPress Pumpb03 Verifying routine AQ1 Pump LDR of Program SolidsTk01
171. n your application together Rung 0 This rung examines the HMI start PB When the button is pressed the StartBasin1 Flush bit is turned on This bit is used throughout the application to indicate that a flush sequence has been started Stat Basn s fah Sop Bat 1 Fhan PO From HA Bees 1 fou Oho PO From Ha Stet Bata Et Pht Batri Push State BeinifuiD ne BasniFiush SuePe Starten Plush JE c Stot Basn 1 Phash ny tBu ng Tie On Dey EN Tee Tier frevet 1000 HON Accu Q Publication IASIMP QS014C EN P February 2013 173 Chapter 3 Rungs 1 and 2 These rungs ensure that a new sequence will not begin unless all valves are either closed or otherwise unavailable prior to the sequence start Sri Bown fl Stop Pu Bart hve Stag Rungs 3 and 4 These rungs ensure that all valves in the sequence have either completed their flushing or were unavailable at the time the sequence began These lines of logic may also be modified to add or remove a valve from the sequence Vaha 1 Fush Done Vietve F6 Fun Dore Vaes Flush Done Vatre 56 A vnde Vavel _Avsdatie Teer 12 PS From HM Been t Puan Done Temeri 2 00 Bape Flush Shete Basen FhustOore Basin 1 Flush Done Brant FishDenm 174 Publication IASIMP QS014C EN P February 2013 Chapter 3 Rung 6 This rung tells the system that the entire flush sequence is complete Additional flush sequences may also be added here Sensi Push B
172. nalog In 0 is the only option for the primary measuring device Select a secondary measuring device TIP If the primary measuring device is an analog device you can assign a float to be used as backup not available if primary measuring is floats Use the second analog input IN 1 to measure flow rate from an analog transmitter or as the process variable if the default analog input IN 0 fails When analog input IN 1 I 1 1 is set for Flow the flow is totalized using a calculation in the PLC A more accurate way to totalize would be to use digital input I 0 0 as a totalized pulse Publication IASIMP QS014C EN P February 2013 237 Chapter 3 3 Press Next to proceed to the Motor Control Setup screen In the example shown four pumps have been configured the screen will only display as many pumps as you set up in the initial configuration screen Starter Starter Powerex 4 Series VFD Powerhex 4 Seres VFD Other VFD Other VFD Starter Starter Powerex 4 Series VFD Powerflex 4 Senes VFD Other VFD Other VFD aT From the Motor Control Setup screen you can use the Up Down buttons to select the pump control device The Starter and Other VFD selections use physical outputs from the PLC to control the start stop operation of the motors while the PowerFlex 4 option uses Modbus communication to control the VFD 4 Press Next to proceed to the first Digital Inputs Assign screen There are four Digital Inputs
173. nder each pump and for pump sequence control indicating lead and lag Below are examples of all the components that should be duplicated for this application Note that the descriptions change for each For example Pump 1 to Pump 3 and the backing tags must be updated to the appropriate tag in the Controller Some of these animations are on the main Lift Station overview screen and some ate on the Pump Setpoints screen Lift Station Duplicated Component Examples Pump 1 Lead 20 Fr s Publication IASIMP QS014C EN P February 2013 111 Chapter 3 A basic test screen for 6 pumps is provided to give you a start on creating additional pumps This can be accessed via the Test 6 Pumps button on the Lift Station screen This Test 6 Pumps button is not intended to remain in a working application and should be removed once it is determined how many pumps the application will have The Lift Station Test 6 Pumps Example illustration depicts a test screen with six pumps This serves only as a start from which to customize your application Lift Station Test 6 Pumps Example 112 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Dosing Pumps Application The Dosing Pumps application is provided on the WWWAT CD This is the Dosing Pump application s organization within the Controller Dosing Pumps System Application Controller Organization y Tasks amp
174. ng Setup screen under the Analog Input In 1 Usage selection TIP Note In order for the analog output to transmit a VFD speed reference the corresponding pump needs to have either PowerFlex 4 series VFD or Other VFD selected from the Motor Control Setup screen Setting the Process Configuration 1 From the Main screen press Process Config to display the setup screen The number of pumps shown may vary depending on how many pumps are in use 1 22 2013 Pump 3 Hand Hand Auto gt Auto Suto Alternate Alternate Lead Lag 1 Lag 2 Not Used Not Used THE SECONDARY SELECTION IS USED ONLY WHEN THE PRIMARY SELECTION IS SET FOR ALTERNATE AND A SECOND PUMP IS NEEDED TO RUN interlocks Setpoints PSetpoints Ly Backup Pump HUE essure Level E y Pump Selection 2 From the setup screen you can Use the UP DOWN buttons to select between Hand Off and Auto for each configured pump Set a Primary selection for each pump Select from Alternate Lead Lag 1 and Lag 2 Set a Secondary selection for each pump Select from Lag 1 Lag 2 and Not Used 244 Publication IASIMP QS014C EN P February 2013 Chapter 3 The secondary selections only come into use when the primary selection is set as Alternate and a second pump is required to run The following are three examples of sequencing 1 Pumping sequence example 1 All pumps have Alternate selected as primary and are in Auto When a p
175. ns that prevent starting equipment but which are ignored once the equipment is running Those are permissive not interlock conditions Use the P Perm AOI instead You have only one interlock condition for the equipment Connect the condition directly to the interlock input on the device Publication IASIMP QS014C EN P February 2013 63 Chapter 3 Interlock P Intlk Faceplate Status Indicator Condition Met Condition Bypassed Input Good Condition Bypassed Input Bad Condition Not Met First Interlock to Fail Operator Tab 64 Interlocks for Product Tramfer Purnp Group Intedock Group Critical lotik Motor High Current Motor Power Failure Motor Overload Trip Pump Case High Tomp Flow Switch Miun atch Engineering Tab Bypass Indicator Reset Button Merlocks for Product Tranefer Pump Mae uer Meter Power F aire Bssssseteeceeve Wesddosutaaroroeieoiaoaon Pumo Case High le Res ianeaeantordesorit nodae Flow Switch Memateh ee eonen Vibration cr Maie ereaeenee ettam tens emn Rssvavevoyueeeeee oeeoe 1 Reersoossao rue rre et ierit omomod peeeonaevoereeoeeeeettetsoeenvn Passessssoorerertorisssrssssari Clear Program Cormmands o recent Publication IASIMP QS014C EN P February 2013 Mode P Mode AOI Mode P_Mode Mode P_Mode Chapter 3 The following table describes the Mode P_Mode parameter and its usage De
176. nt network Publication IASIMP QS014C EN P February 2013 19 Chapter 1 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e Each specific site must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Secondary Treatment System Add more drives as needed e The Ethernet Switch has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP devices in the system IP addresses and node numbers are unique to your application and you must include them on this drawing 20 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 1 Solids Handling System Architecture Drawing This is a typical Solids Handling System Architecture Drawing Solids Handling System Architecture Drawing The following table describes the key design points of the Solids Handling System Architecture Drawing Hardware ControlLogix Processor Description Controls the Solids Handling System 1756 Series Controls 1 0 PowerView Plus HMI EtherNet IP Establishes a c
177. o ww Omena iter LLLI pve mete ITI 123 Chapter 3 Headworks Application The Headworks application is provided on the WWWAT CD Refer to the Headworks System Application Controller Organization illustration to view the application s organization within the Controller Headworks System Application Controller Organization 3 Tasks amp amp MainTask E amp MainProgram 3 Program Tags Main By A01_MiscDiscreteInputs 4 A02 MiscAnalogInputs y A03 MiscDiscreteOutputs 4 A04 MiscAnalogOutputs a BarScreen01 Program Tags Main B A01_BarScreen01_LOR 4 A02_BarScreen01_FBD B A03_BarScreen01_Auto By A04 DiffLevel H E BarScreen 2 Ir Program Tags Main B A01 BarScreeno2 LOR Ey A02 BarScreen 2 FBD B A03 BarScreenO2 Auto B A04 DiffLevel C3 GritTanko1 3 Program Tags Main B A01 GritTankDrive LDR 3 A02 GritTankDrive FBD B 03 GritTankDrive Auto B A04 GritTankFlow 2 23 wetwell A Program Tags Eh Main g A01 Wetwell This task should reside in a Controller in the main facility of the plant where the Headworks application is present and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other systems of the plant 124 Publication IASIMP QS014C EN P February 2013 Chapter 3 The organization of this application is simil
178. ogram and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01_MiscDiscreteInput provides a template to map inputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A02 MiscAnalogInput provides a template to map analog inputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A03 MiscDiscreteOutputs provides a template to map outputs that are relevant throughout the secondary This routine is provided as a Function Block Diagram A04 MiscAnalogOutput provides a template to map analog inputs that are relevant throughout the secondary This routine is provided as a Punction Block Diagram e SedBasin01 Drive controls the Sedimentation Basin s Sludge Collection Drive motot Main routine calls the other routines in this program A01 Drive LDR contains the code to map fault inputs hand mode and resets for the Sedimentation Basin s Sludge Collection Drive motor This routine is provided as a Ladder Diagram A02_Drive_FBD contains the Single Speed Motor Permissives and Interlock AOIs that monitor and control the Sedimentation Basin s Sludge Collection Drive motor See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e FlocBsn01_M1202 controls
179. ol panel 2 Select Hand mode on the Pump Start selector switch at the Feed Pump control panel 3 In Hand position press the button station located on the control panel to start stop a pump Remote Operator Mode Place the pumps in Remote Operator control 1 Select Remote on the MCC for pumps 1 and 2 Verify that circuit breakers and disconnects are turned on 2 Select Operator mode on the Lift Station Pump No x Faceplate screen for each of the pumps 1 and 2 3 Verify that the pump status is in service on the Lift Station Pump No x Faceplate screen with no faults Human Machine Interface HMI Control Go to the Lift Station screen from the HMI screen 1 Click the Lift Station 1 button The system displays the Lift Station screen Publication IASIMP QS014C EN P February 2013 93 Chapter 3 Selecting the Lift Station 1 Button on the HMI Screen Yemen Tare a ae on el 2 Click the Wet Well Level Faceplate The system displays the Process Library Faceplate fot the analog module that is monitoring the Wet Well Level Lift Station Screen Provides you with the alam condition and current level of the wet well For more information about the Pump Setpoint button see page 69 91 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Lift Station Level Faceplate Lit Station Lewel This analog faceplate provides detailed information about
180. ommunication path between the ControlLogix Processor Control Panels and the plant network 21 Chapter 1 22 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e Each specific site must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Solids Handling System Add more drives as needed e The Ethernet Switch has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP devices in the system P addresses and node numbers are unique to your application and you must include them on this drawing Publication IASIMP QS014C EN P February 2013 Chapter 1 Water Treatment Plant The Water Treatment Plant documentation package contains the following Drawings system level architectural drawings e Raw Water Intake Pump Station System e Separation Station System High Service Pump Station System Raw Water Intake Pump Station System Architecture Drawing This is a typical Run Water Intake Pump System Architecture Drawing Run Water Intake System Architecture Drawing The follow
181. on Block Diagram A03 MiscOutputs includes a template to map outputs that are relevant throughout the High Service Application This routine is provided as a Function Block Diagram A04 MiscAnalogOutput provides a template to map analog inputs that are relevant throughout the High Service Application This routine is provided as a Function Block Diagram HighServicePumpP1300 controls the High Service Pump 1300 A01 Pump _LDR contains the code to configure the source of the speed reference for the VFD for the High Service Pump 1300 and reset alarms interlocks and faults associated with the pump This routine is provided as a Ladder Diagram A02 Pump FBD contains the Variable Speed Drive Permissives and Interlock AOIs that monitor and control the High Service Pump 1300 See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram e HighServicePumpP1301 Controls the High Service Pump 1301 as described for the High Service Pump 1300 AOIs are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P in their name The other AOIs have a prefix of U_ as shown in the AOI illustration Publication IASIMP QS014C EN P February 2013 225 Chapter 3 226 AOls amp J Add On Instructions EJ P AI
182. onds to enter the time delay in seconds between Lag pump starts If system pressure falls below the start set point the Lag pump starting is delayed by this value Press Off Pressure to set the system pressure point at which all of the pumps shut off Press More to see the second Pressure Setpoints screen SET POINT ADJUSTMENTS S Unde ermal pean te sed e VFD conte by Pm The speed Press VFD Manual Speed Hz to set the speed at which the drive will run when placed into Manual Press Enter The Alternation Time In Minutes to set the time between pump alternations This is only used if the Primary selection is set to Alternation on the Process Configuration screen TIP Lead pump alternation will only occur if the lead pump is the only pump running If the alternation time has elapsed during high demand when more pumps are running the alternation will happen only when all pumps other than the lead pump have turn off Press High Setpoint to set the high pressure alarm threshold TIP 248 Publication IASIMP QS014C EN P February 2013 Chapter 3 The High Pressure alarm set point is not the same as the All Pumps Off set point on the Pressure Set point 1 screen The All Pumps Off set point is meant to turn the pumps off before it goes into High Pressure alarm Press Low Setpoint to set the low pressure alarm threshold Pressure Overview Screen From the Pressure Overview scteen you can
183. or HMI features for an Wiese preis The Analog Input Instruction m put arany Analog avert P_VSD UT p Um e You want Linear scaling from Raw to You only need to display a number on a ees Engineering Units a screen and do not need any of the value from am input units to MD scaling or alarming features Just engineering output units e You need High Low High High use a numeric display field and entry of a Substitute Low Low and Out of Range alarms ER Process Variable provides with dead band and delay per alarm Mei UU such Se a i DR You use an indicator graphic object example orifice flow meters with label and engineering units rate of change alarming or limiting To keep the Instruction memory You use a faceplate with mode or alarming for deviation from a and execution footprint small selection alarm limit entry and reference value Use the P AlnAdv certain capabilities used less maintenance capability for substitute Advanced Analog Input Instruction frequently are reserved for the PV instead Advanced Analog Input AOI e You have the dual sensors for one process variable such as dual pH meters and need to select one or the other sensor or their average Use the P AlnDual Dual Analog Input Instruction instead 58 Publication IASIMP QS014C EN P February 2013 Chapter 3 Analog Input P_Aln Process Variable Faceplate Product Transier Flow Rate m x vx ala Mode Indica
184. osed Limit Switch signal Jf Valve provides an Open Limit Switch signal Fault when both limit switches are ON OFF Delay to echo back Open Closed status in Simulation sec Publication ASIMP QS014C EN P February 2013 79 Chapter 3 Variable Speed Drive P_VSD The following table describes the Variable Speed Drive P_VSD parameter and its usage Variable Speed Drive P_VSD AOI Description Use This Instruction When Do Not Use This Instruction When Variable Speed This AOI is used to operate one e You need to operate a motor e You need to operate a single speed Drive P_VSD variable speed motor using a connected to a variable speed drive motor running stopped only Use Drive AC variable frequency or The drive can be an AC variable the P_Motor Instruction instead DC in a variety of Modes frequency or DC drive and can be e You need to operate a two speed monitoring for fault conditions connected via an 1 0 or control motor fast slow stopped only network intelligent drive Oya Use the P_Motor2Spd Instruction hardwired analog and discrete I O instead This instruction is designed to work You need to operate a simple with all currently available and many reversing motor forward reverse legacy Allen Bradley drives including stopped only Use the P_MotorRev Bulletin 1336 Bulletin 1395 Instruction instead PowerFlex 4 40 70 700 7000 e You need to operate a motor with and PowerFlex
185. ou to e Speed up development time and focus your energies on the custom aspects of your application Increase quality by reusing well tested code to reduce the likelihood of code bugs Aids in producing well structured code in addition the standard graphics increases the consistency of your HMI thus reducing the need for operator training e Leverage scalability build ever larger systems using the same reusable modules Publication IASIMP QS014C EN P February 2013 Chapter 3 Using the Process Library Module The Process Library is a collection of components that provide a large amount of flexibility You can choose to use any number of the modules and it does not require you to code within a rigid structure You also retain the flexibility of a Logix System while saving yourself the trouble of writing and maintaining standard functionality The Process Library makes extensive use of AOIs which are custom instructions that a user designs and creates Using AOIs you can create new commonly used logic instruction sets provide a common interface to this logic and provide instruction documentation AOIs are intended to be used to encapsulate commonly used functions or device control They are not intended to be a high level hierarchical design tool Programs with routines are better suited to contain code for the area or unit levels of your application These are some benefits to using an AOI Reuse Code AOIs promot
186. own are a PowerFlex 70 Drives to run the pumps and higher horsepower drives may require a different PowerFlex series drive e I O on this sheet is optionally shown as both Point I O and Compact Block I O Select an I O style based on your requirements e The number of PanelView could change based on the operating procedures at your facility Simply add more PanelView stations as needed e The number of contactors or PowerFlex 70 Drives could change based on the number of pumps in the Lift Station Add more contactors or PowerFlex Drives as needed e The Ethernet Switch shown has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP devices in the system IP addresses and node numbers should be included on this drawing They are specific to your application Publication IASIMP QS014C EN P February 2013 13 Chapter 1 Dosing Pump System Architecture Drawing The following is an example of a typical Dosing Pump System Architecture Drawing Dosing Pump System Architecture Drawing The following table describes the key design points of the Dosing Pump System Architecture Drawing Hardware Description ControlLogix Processor Controls the Dosing Pumps 1756 Series Controls 1 0 Remote 1756 Chassis with Analog Communicates with the Dosing Pumps and Discrete 1 0 Devices ControlNet Communicates with the Dosing Pump System
187. p Station 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine See the Solids application s Customization of the Solids Application section for an example of how to add Single Speed Motor AOIs in a FBD routine WWWAT CD Select Pump Controller Station from the WWWAT CD Main Menu to locate this application Introduction The multifunction pump controller station package is designed to be a stand alone versatile control system that allows the user the ability to choose between a pump down lift station pump up water tank or a pressure follower water distribution control process with just a few simple screen selections The control combines the power and functionality of a MicroLogix 1400 PLC and the versatility of a PanelView component HMI Engineering cost is kept low because the user only needs to configure parameters instead of developing control programs Functionality includes Control of up to 4 pumps User assignable inputs Use of floats analog or a combination of both to control the process Publicatio
188. p has its own routines in the Pumps program The routines are numbered sequentially A01 A02 etc For I O mapping go to the following rungs e Pumps AOx Pumpn Alarms rungs 0 4 e Pumps AOx Pumpn Control rungs 3 5 Where x sequential routine number n pump number This is not intended to be a complete list of the I O assignments necessary It is only intended to point out some required rungs that must be customized for a particular application As an important step in the software development process care should be taken to properly assign I O to all the necessary places in the software Many I O points for a specific application may not be anticipated by this example application In these situations additional software must be developed to account for these points Motor Permissives and Interlocks The sample Lift Station application provides places for additional permissives and interlocks to be added to the program Keep the following points in mind e Permissives allow or prevent a motor from starting If a permissive is not true the motor will not start when it receives a start command But once the motor is started it will continue to run on a loss of a permissive e Interlocks allow or prevent a motor from continuously running If an interlock is not true the motor will not run when it receives a start command Once the motor is started it will stop on a loss of an interlock e To include additional permissive
189. p2 Max Speed Pump To Max Speed Pump3 Lag Pump3 Max Speed Pump4 Lag4 Pump4 Max Speed Pump To Max Speed Pump5 Lag4 Pump5 Max Speed 188 Pump Lag4 Ma gt A000_CFP_PIDE_FBD This routine contains the PIDE function block PIDE is only available in function block format Publication IASIMP QS014C EN P February 2013 Chapter 3 PIDE function block that controls how many pumps are needed to achieve the GPM set point 1 PUMP_CYCLE_RUNNING g ChemicalFeedP_PIDE PIDE Enhanced PID Enableln ProgProgReq e ProgOperReq ProgCasRatReq Prog amp utoReq ProgManualReq ProgOverrideRed e ProgHandReq AutotuneTag PYHHAlarm PYHAlarm P LAlarm PVLLAIarm PVROCPosAlarm PYROCNegAlarm DevHHAlarm DevHAlarm DevLAlarm DevLL Alarm ProgOper CasRat Auto Manual Override Hand ChemFeedAutotune 45 508377 D A000 CFP PIDE LDR In this routine the Chemical Feed Flow set point is copied from the HMI input and placed in the PIDE set point Also the PV process variable is copied into the PIDE PV The last part of this routine contains a small example of starting and stopping the automatic cycle of this system The purpose is to stop the PIDE from executing and zeroing out the CV current set point and PV This enables the operator to be able to stop the system quickly and start it again with a different set point It is a simple method to be able to s
190. pre determined location in the drawing package for all the 1 0 modules 1 0 specific to an application are shown here and it is expected that these sheets are heavily modified for each application These sheets function as a template for many applications even if the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules This provides one example of each type of module that will typically be used in a Raw Water Intake System application Note This drawing depicts 1756 style 1 0 modules If you use different I O modules you must also update these sheets Refer to these sheets during the Commissioning process Publication IASIMP QS014C EN P February 2013 285 Chapter 4 Pump Controller Station Hardware Drawings 286 One of the System Architecture sub folders on the WWWAT CD is the Pump Controller Station folder and it contains the following drawings e Title Page and Sheet Index e Communications Diagram e Panel Layout Diagram e Power Layout Sheets e Panel I O Layout Sheets Title Page and Sheet Index Pump Controller Station Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT ine TH olii Tt Y nn H Pi Hs Ha M OCT aah C EUH Number Description Index Title Page and This is the Table of Contents Cover Sheet for the drawing Sheet Index package Modify th
191. r The Separation application process consists of e Rapid Mix e Flocculation e Sedimentation Rapid Mix The Rapid Mix process destabilizes the particle s charges Before the raw water enters the Rapid Mix area coagulants are added to the water to neutralize the negative charges on suspended solids Once the charge is neutralized the small suspended particles stick together The high energy Rapid Mix process disperses the coagulant and promotes particle collisions which is needed to achieve good coagulation Flocculation Directly downstream of the rapid mix process is the Flocculation process Flocculation is a gentle mixing of the raw water to increase the particle size from submicroscopic to visible suspended particles 215 Chapter 3 216 Sedimentation Sedimentation basins are used to settle out the floc before going to the filters The inlet to the basin is designed to distribute water evenly at uniform velocities The sludge collection drive removes the sludge from the bottom of the basin and allows pumps to transfer the sludge to holding tanks The Separation process Flocculation and Sedimentation is controlled by the PLC located in the Chemical Building HMI Description The operator controls and monitors these processes as follows 1 Click the WTP button to go Water Treatment Plant WTP Overview screen 2 Click the appropriate Separation icon to display the Separation Overview screen The Separation
192. r AOIs in a FBD routine 136 Publication IASIMP QS014C EN P February 2013 Chapter 3 Secondary Application The WWWAT CD contains the Secondary application Refer to the Secondary System Application Controller Organization illustration to view the application s organization within the Controller Secondary System Application Controller Organization E53 Tasks amp amp MainTask a Eg MainProgram a Program Tags Main B A01 MiscDiscreteInputs A02 MiscAnalogInputs A03 MiscDiscreteOutputs BY A04 MiscAnalogOutputs E E SecTankD1 Drive iB Program Tags Main Bl A01 Drive LOR A02 Drive FB0 2B SecTank02 Drive 2 Program Tags Main AQ Drive LOR A02 Drive FED E E AerationBlower 9 Program Tags Main B A01 Blower LDR E A02 Blower FBD 2 SecTank1 RAS Pump ID Program Tags Main Bj A01 Pump LDR B A02 Pump FED BY A04 PumpDischargeFlow E 8 AerationTkO1 MexerO1 Program Tags Main B A01 Mixer LDR BQ A02 Mixer FBD E EB AerationTkO1 Mixer 2 Program Tags Main B A01 Mixer LDR B A02 Mixer F amp D 2 AerationTkO2 Moxer 1 Program Tags Main B A01 Mixer LDR BY A02 Mxer F amp D E AerationTk02 Mexer02 g Program Tags Main B A01 Mixer LDR E A02 Mixer FED This task resides in a Controller in the main facility of the plant where the Secondary application is present and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this applicat
193. r Single Speed Motor Current running time this start 02 hours Maximum continuous running 02 c lime for a given start hours 10 0 Total accumulated running 03 Kc time hours J 1070 Total number of motor starts 33 el or attempts 0 U 150 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Customization of the Secondary Application General customization notes are included in the Lift Station Application section page 102 of this chapter Refer to this section before customizing any application including the Secondary This section describes customization specific to the Secondary application 1 0 Assignment As in the Lift Station I O is mapped into this application This is done in the following project locations e MainProgram A01 DiscreteInput as needed this routine is provided as a template e MainProgram A02 AnalogInput as needed this routine is provided as a template e MainProgram A03 Outputs as needed this routine is provided as a template Additional Pumps Motors Single Speed Motor AOls in a FBD Routine See the Customization of the Solids Application section for an example of how to add Single Speed Motor AOIs in a FBD routine 151 Chapter 3 Solids Application The WWWAT CD contains the Solids application Refer to the Solids System Application Controller Organization illustration to view the application s organi
194. rates alarms including Main routine calls the other routines in this program A01 Wellwell contains the code to monitor Wet Well level and generates alarms utilizing the Analog P AIn and Discrete P Din Input AOIs This routine is provided as a Function Block Diagram AOIs are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P in their name The other AOIs have a prefix of U as shown in the AOI illustration AOls J Add On Instructions w EJ P AIn w P Alarm Gj P DIn w P Intlk w AJ P Mode H E P Motor mz P Perm ig P Reset w P ResInh 4 US P RunTime U_CommFail U_FlowTot H GJ U Heartbeat U RepeatCycTmr 1 z U WallClock Process Description The Headwotks treatment consists of Screening Influent Flow Measurement and Grit Removal From the inlet well the wastewater enters one or two preliminary treatment flow channels Each flow channel consists of an 126 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Inclined Bar screen with a mechanical raking device to remove debris from the raw wastewater The Mechanical Bar screens cycle periodically to rake debris from the bar rack and deposit the screenings on a belt conveyor This conveyor runs during t
195. rd Text Reverse Text Speed Feedback Scaling Minimum 0 Ly 82 Publication IASIMP QS014C EN P February 2013 WWWAT CD Applications Publication IASIMP QS014C EN P February 2013 Chapter 3 The WWWAT CD contains sample applications that you can use to begin your Water and Wastewater project There are three major application groupings on the WWWAT CD Water Treatment Development Tools Wastewater Treatment Development Tools and Pump Controller Station Refer to Pump Controller Station on page 234 Water Wastewater Development Tools Press the Water or Wastewater Development Tools to locate these applications LISTEN THINK SOLVE Introduction to Accelerator Toolkits Install WWWAT on your computer Terms and Conditions WWWAT Version Changes and Updates Water Treatment Development Tools L Wastewater Treatment Development Tools Water Wastewater Treatment Application Framework All Water Wastewater Treatment applications on the WWWAT CD share a common framework This section examines that framework The WWWAT CD Phase 4 contains the following Water Wastewater Treatment applications e Lift Station System e Dosing Pump Station System e Headwotks System e Secondary Treatment System e Solids Handling System Chemical Feed System e Flushing System e Raw Water Intake Pump Station System e Separation Station System e High Service Pump Station System 83 Chapter 3 The
196. rent P T transmitter located near the bottom of the tank The transmitter transmits a 420 mA signal to the Programmable Logic Controller PLC The signal is converted to indicate the tank levels on local indicators Publication IASIMP QS014C EN P February 2013 159 Chapter 3 Solids Storage Tank on the Solids WTP Overview screen Solids Storage Tank Hand Mode Select Hand on the Hand Off Auto selector switch located at the MCC to operate the SST locally The operator uses the buttons located at the MCC to operate the tank Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches located at the MCC to put the SST drive in the Remote mode Operator Mode Manual Click the SST Drive section of the Solids Overview screen The system displays the Solids Tank 1 Drive Faceplate Solids Tank 1 Drive Faceplate Solids Tank 1 Drive Argen Be a c Enabled Stopped gt B Je ele Comm OK 160 Publication IASIMP QS014C EN P February 2013 Chapter 3 For manual Operator Control select the Operator mode on the Solids Tank 1 Drive Faceplate The Faceplate shown is used to control the Storage Tank Drive STD The operator starts and stops the STD remotely from the Solids Tank 1 Drive Faceplate The available Faceplate commands include Press the Play button to start the STD Press the Stop button to stop the STD Click the Disable button to remove the STD from service
197. rom the blower starter control panel and once opened the HMI generates a Blower Fault alarm 148 Publication IASIMP QS014C EN P February 2013 Chapter 3 SCT Center Drive Fault This is a contact from the center drive mechanism and once opened the HMI generates a SCT 1 Center Drive Mechanism Fault Alarm RAS Pump VED Fault This is a messaged fault from the VFD drive unit Once the PLC receives the fault message the HMI generates a VED alarm RAS P 401 Alarms mFS we co BO o Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 vf Fail To Start v Fail To Stop VO Fault Interlock Trip vw Drive Fault Single Speed Motor Run Time E 63 th Current running time this start 02 hours j Maximum continuous running 02 tirne for a given start hours Total accumulated running 03 time hours d Total number of motor starts or attempts 33 Publication IASIMP QS014C EN P February 2013 149 Chapter 3 Reporting The SCADA system records Process The system will trend common signals and record them for future viewing including RAS Pump P 401 Output Frequency Command Frequency Equipment Run Times Runtimes are recorded for the blower SCT center drive mechanism and RAS Pump P 401 Depending on the user s security level the total run time may be reset by clicking on the Total Reset button next to the appropriate pump Single Speed Motor Run Time Run Time fo
198. rts pumping when the well level goes above 1 0 feet The pump stops when the level drops below 0 5 feet This results in a dead band of 0 5 feet The lag pump operates similarly except that it starts at 2 0 feet and stops at 1 5 feet You can easily adjust all of these values on this single screen 3 Adjust the Lead and Lag pumps using the Operator Settings switches in the lower right side of this screen 98 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 a Click the appropriate radio button to assign a pump as Lead or Lag The screen contains Lead and Lag radio buttons for Pump 1 and Pump 2 For example in the illustration below pump 1 is assigned as the lag pump and pump Z is assigned as the lead pump Pump 2 will start when the water level reaches the start level for the lead pump and stop when the water level drops to the stop level You can change these assignments at any time Lift Station Pump Setpoint Screen Alternate Sequence Operator Rotation Operator Settings Pump 1 Pump 2 Lead Lead Lag Lag Pump 1 Pump 2 Next Lead Lag Current Lag Lead The sequence of pumps is shown below these switches The sequence displayed will reflect the sequence currently active in the Controller If any pump fails to start the next pump in the sequence will start For example if the lead pump s disconnect is pulled and does not start the next pump in th
199. ry 2013 Using Add On Instructions Alarm P_Alarm AOl Alarm P_Alarm Chapter 3 This section lists the modules that exist in the Process Library and provides a brief functional description for each of them Refer to each module s documentation for more detailed information The Process Library section of the WWWAT CD contains separate documentation files for each of the modules Refer to the Preface for more information about the WWWAT Alarm P_ Alarm The following table describes the Alarm P_Alarm parameter and its usage Description This instruction monitors an input condition and when it has been true for a specified time initiates an alarm It also monitors Alarm Acknowledgement Alarm Reset Alarm Inhibiting Disabling and Alarm Suppression for FactoryTalk Alarm and Events Use This Instruction When e You want to develop your own AOls and have it generate alarms that are compatible with the alarm setup for the Process AOls Use the P Alarm instruction embedded within your AOl You have a condition in your logic outside of any AOI that you need to generate an Alarm Use the P_Alarm instruction stand alone within your program logic Do Not Use This Instruction When e You have a discrete input signal from a flow switch pressure switch level switch or other device and want to display the device state generate alarms or condition the alarm based on time or gating signals Use the
200. s HMI Description The operator controls and monitor these processes as follows 1 Go to the Wastewater Treatment Plant WWTP Overview screen 2 Click the Solids button or one of the Solids icons to display the Solids Overview screen Selecting the Solids Overview Screen 156 Publication IASIMP QS014C EN P February 2013 Chapter 3 Solids Overview Screen O Evert Time Alam Name Condition Message A s 7 28 200875412AM Solids Tank Dive FaledtoStat TRIP Alem tad cleared Alam eget quality c good Supervisor LJ CIP connection 0 open rejected Error 2040101 on route CompactLogix in slot O of the chassis at 10 16 3 232 The status information on the Solids Overview screen includes e WAS Valve PV 600 e WAS Flow Rate FIT 600 e WAS Tank Level e Solids Storage Tanks Mixing Drive e Solids Transfer Pump e Solids Storage Tank Level LIT 603 Publication IASIMP QS014C EN P February 2013 157 Chapter 3 158 Control Description Was Valve Once the RAS process has been started the operator starts the WAS wasting process Hand Mode Select Hand on the Hand Off Auto selector switch located on the WAS valve to operate the WAS valve locally The operator uses the buttons located on the valve to open close it Selecting the WAS Valve PV 600 on the Solids Overview Screen WAS Valve PY 600 Remote Operator Mode Select the Auto position on the Auto Off Hand selector switches locate
201. s e Raw Water Intake Pump Station System Separation Station System e High Service Pump Station System Raw Water Intake Application The Raw Water Intake application is provided on the WWWAT CD Refer to the Raw Water Intake System Application Controller Organization illustration to view the application s organization within the Controller Publication IASIMP QS014C EN P February 2013 199 Chapter 3 200 Raw Water Intake System Application Controller Organization 3 Tasks amp MainTask g amp MainProgram 9 Program Tags Main By A01_MiscDiscreteInputs 4 A02 MiscAnalogInputs y A03 MiscDiscreteOutputs E A04 MiscAnalogOutputs 8 BarScreend1 Program Tags Main B A01 BarScreeno1 LR 4 A02 BarScreen01 FBD B A03 BarScreenO1 Auto E A04 DiffLevel 2 3 Barscreen 2 g Program Tags Main B A01 BarScreenO2 LOR Ey A02 BarScreen02 FBD B A03 BarScreen02 Auto B A04 DiffLevel C3 GritTanko1 3 Program Tags En Main B A01 GritTankDrive LDR 3 A02 GritTankDrive FBD B A03 GritTankDrive Auto 4 A04 GritTankFlow 2 23 Wetwell A Program Tags Main R A01_Wetwell This task should reside in a Controller in the main facility of the plant where the Raw Water Intake application is present and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other sy
202. s http rockwellautomation com components connected Technical information about component level products from Rockwell Automation http rockwellautomation com components connected Literature Rockwell Automation manuals and publications http www rockwellautomation com literature Selection Configuration and Support Information An interactive product selection tool that assists you in catalog generation http www ab com e tools An interactive product selection tool that assists you in choosing the correct Rockwell Automation product for your application http www rockwellautomation com en e tools configuration html CAD drawings of Rockwell Automation products http www rockwellautomation com en e tools drawings html Answers to technical questions and solutions to problems http support rockwellautomation com General technical support http support rockwellautomation com Product Information Allen Bradley product information http www ab com CompactLogix product information http www ab com programmablecontrol pac compactlogix index ht ml PanelView product information http www ab com eoi graphicterminals PowerFlex drives product information http www ab com drives Power supply information Publication IASIMP QS014C EN P February 2013 http www ab com industrialcon
203. s Backup Pump Selection to open the Backup Pump Selection screen Visible only if Float is selected as backup on the Measuring Setup screen Refer to page 240 Press Pressure Setpoints to open the Pressure Setpoints screen Visible only if Pressure follower mode is selected Refer to Pressure Setpoints on page 247 Press Level Setpoints to open the Level Setpoints screen Visible only if an analog device is being used for measuring level Refer to Level Setpoints on page 247 Publication IASIMP QS014C EN P February 2013 245 Chapter 3 Pump Interlocks You can use the Pump Interlocks screen to select from a list of faults that will inhibit the pump from running PUMP INTERLOCKS Select the desired pump motor then choose the interlocks from the selection list that you want to prohibit the pump from running push ADD or REMOVE Interlock Selection A Current Interlo gt Low Level Pressure F e Low Level Pressure High Level Pressure QJ High Level Pressure OL Tripped Fault J Motor OL Fault Pump Over Temp nter Motor Over Temp Pump Seal Fail Pump Seal Fail x 1 Select and perform the following steps for each pump individually 2 Select the interlock from the list and then use the Add Interlock button to add it to the Current Interlocks or use the Remove Interlock button to remove it from the Current Interlocks For example If Pump Seal Fail is in an alarm state press Remove Interlock to allo
204. s consists of a system overview and the basic electrical drawings for wiring the I O The Lift Station package also includes device level wiring information These examples can be used in the actual wiring of the field devices for the project Each Water and Wastewater project is unique These hardware drawings provide you with a starting point for the hardware engineering You must customize your project to meet your site requirements The Water and Wastewater Treatment Plant Hardware documentation package contains the following system level drawing packages e Lift Station System Dosing Pump Station System Primary Treatment System e Headworks System e Secondary Treatment System e Solids Handling System Chemical Feed System e Flushing System The Lift Station and Dosing Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings 31 Chapter 2 32 Lift Station Hardware Drawings One of the System Architecture sub folders on the WWWAT CD is the Lift Station folder and it contains the following drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e Panel I O Layout Sheets Device Wiring Schematics Title Page and Sheet Index Lift St
205. s for a pump motor to start add contacts to rung 3 of A02 Control in Pump 1 or Pump 2 Each permissive input is mapped on a branch in this rung All these permissives are inputs to the Process Library AOI that is located on the last branch of the rung All permissives must be true to allow the pump to start If there is an input that is normally closed use an XIO instruction on the branch of the rung to properly map it into this AOI 103 Chapter 3 Motor Permissives and Interlocks a tem m Ramee nrbe Berne tame wm s agp mo rtm te u Httitir UE EEEE EE ETTETITIT Resets Fault and Alarm resets in the application are accomplished through a P_Reset block from the Process Library This reset object distributes the Reset command to all the Process Library AOIs that may require a reset Care must be taken in deciding how to distribute the reset commands This must be planned before the customizations that follow can be completed Considerations include questions such as e What devices will reset when a particular button is pressed How are devices to be grouped they are reset at the same time with the same reset button e Do some devices overlap into more than one Reset group For example in the Lift Station application provided in the WW WAT the reset is distributed to all the pumps Rung 2 of each Pump Control routine has a 104 Publication IASIMP QS014C EN P February 2013 Chapter 3
206. s in a FBD routine To add additional Solid Transfer pumps to the Solids application add additional pump programs as required these will be duplicates of Solids TkO1ToFilterPress Pump602 To add additional Solid Transfer pumps 1 Copy and paste the existing Solids TkO1ToFilterPress Pump602 and rename it the name Solids TkO01ToFilterPress Pump6093 is used here Selecting Additional Pumps C SolidsTkO1ToFilterPress Purnp602 3j Program Tags Main B A01 Pump LDR 4 A02 Pump FBD E SolidsTkO1ToFiterPress_Pump603 Program Tags Eh Main B A01 Pump LDR 4 A02 Pump FED 2 Create new controller scoped tags for the new pump Publication IASIMP QS014C EN P February 2013 165 Chapter 3 Creating New Controller Scoped Tags P602_Fault i P_DIn cH P602_Intk P Int P602_Motor P_Motor i P602_Perm P Perm P602 Reset IP Reset P602_Resinh IP Reslnh P602_RunTime P Runtime H PRO3 Faut P Dn P603 Intk P Intlk F P603_Motor P_Motor LE P603 Pem P Perm PB03 Reset P Reset P03 Reeslnh IP Reslnh 3 In the program scoped tags for the new pump program define the Alias for Device and the other associated tags as this new controller scoped tag Defining Device Aliases Equip Fault J P803 Faul C Local 3 Data 10 C Equi Fault OF aut P503 Faul IOFaul C Locat3 Faut 10 C Equip GroupReset PLC Device ReselPB C PPLC Device ReselPB C Equip I
207. scription This AOI provides selection of the Mode owner of an instruction or control strategy The Mode instruction is usually embedded within other instructions to extend their functionality It is possible to use a stand alone Mode instruction to enhance a program where modes are wanted Use This Instruction When e Creating an AOI for a device which e Requires separate acquisition by an operator and Program logic e Supports Override or Hand capabilities e Needs a separate Maintenance Mode Embed the P Mode instruction within your AOI Creating a Control Strategy and you want standard arbitration between operator and Program modes and perhaps Override Maintenance or Hand modes Use the P Mode instruction stand alone within your strategy and condition Commands and Actions in the strategy on the P Mode AOI mode Status bits Do Not Use This Instruction When e Creating an AOI which does not do anything differently for e operators versus Program logic e Override or Hand conditions e Maintenance users You do not need Modes or the P Mode instruction Creating a complex strategy for shared equipment Shared Use Common Resource which has complex rules for arbitration and allocation of the equipment You need rule based sharing logic beyond the capabilities of the P Mode instruction Publication IASIMP QS014C EN P February 2013 65 Chapter 3 Mode Explanation Diagram The modes hav
208. sh due to lack of oxygen in which case adequate treatment will not be provided Return Activated Sludge RAS Pump A RAS pump is located near the Secondary Clarifier Settling Tank SCST The RAS pumps remove the aerated sludge that accumulates on the bottom of the SCST The pumps discharge into the Aeration Tank s Anoxic Zone where RAS is mixed with primary effluent Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Secondary Clarifier Settling Tank The mixed liquor flows from the Aeration Tanks effluent channel to the SCST In the SCST many of the solids are settled out while the effluent exits over weirs and flows to the Secondary Effluent Pumping Station in the Tertiary Filter Building The purpose of the SCST is primarily to produce a clarified effluent with a secondary objective of removing and returning sludge to the system The SCST is part of a discrete process train including a Primary Clarifier Aeration Tank and a SCST Flow from a Primary Clarifier flows into a corresponding Aeration Tank and then into the corresponding SCST 141 Chapter 3 HMI Description The operator controls and monitors these processes as follows 1 Go to the Wastewater Treatment Plant WWTP Overview screen 2 Click the Secondary button or the Secondary icon to display the Secondary Overview screen Selecting the Secondary Overview Screen E e 142 Publication I
209. ss How with particular I O It provides a general overview of the Diagram process controlled by the system a quick summary of the controls involved and the process that is being controlled 297 Chapter 5 298 Network Diagram Network Diagram E 170 Network Diagram For details see page 12 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Panel I O Layout Sheets Lift Station Panel 1 0 Layout Sheets Chapter 5 1e GENES Am LOXLSECTL T J J Number Title E 180 Panel I O Layout Sheet 1 of 2 E 181 Panel I O Layout Sheet 2 of 2 Description Inputs and outputs to the controller are shown on these diagrams The format uses three cards per sheet Inputs to the card are shown with the input device to the left of the input card Output devices are shown to the right of the output card For every additional input or output card new sheets must be added 299 Chapter 5 Device Wiring Schematics Device Wiring Schematics 8R 3 993783232 5153349535342234223 2521 8949949539929842 94220842323353222332429951 Schematics selector switch wiring information Refer to these sheets during the Commissioning process 300 Publication IASIMP QS014C EN P February 2013 Chapter 5 Dosing Pump H
210. start may damage the equipment e he state model of the P Reslnh instruction is appropriate for limiting the restarts of the equipment Three Starts rule hot cold model etc e You don t have the sensors or equipment for more advanced motor monitoring or modeling Do Not Use This Instruction When e You have more advanced motor monitoring equipment or motor heating models available Use the advanced equipment to provide a start permissive instead e You have a small motor that can repeatedly start and stop without damage or a simple thermal cutout provided with the motor is sufficient to protect it Publication IASIMP QS014C EN P February 2013 73 Chapter 3 Run Time P_RunTime The following table describes the Run Time P_RunTime parameter and its usage Run Time P_RunTime AOI Description Use This Instruction When Do Not Use This Instruction When Runtime This AOI is used to accumulate e You want the functionality ofa run e You have advanced software for P_RunTime the total run time and count of time meter or start counter monitoring equipment run time that starts for a motor or other without having to add hardware only needs the equipment running equipment It is a software devices for these functions to your status as Its input implementation of the Motor Control Center mechanical hour meter that is e vou need the total run time often mounted in the door of a current
211. stems of the plant Publication IASIMP QS014C EN P February 2013 Chapter 3 The organization of this application is similar to the other applications in this toolkit Specifically the functionality for each program and routine is e Main Program handles general Raw Water Intake application and functionality including Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump Inputs simulation bit that you can use when testing the application A01 MiscDiscreteInput includes a template to map inputs that are relevant throughout the Raw Water Intake system This routine is provided as a Function Block Diagram A02 MiscAnalogInput includes a template to map analog inputs that are relevant throughout the Raw Water Intake system This routine is provided as a Function Block Diagram A03 MiscOutputs includes a template to map outputs that are relevant throughout the Raw Water Intake system This routine is provided as a Function Block Diagram BarScreen01 controls the motor manages cycle times and Flow Channel Differential levels for the Bar Screen 1 system including Main routine calls the other routines in this program A01 BarScreen01 LDR contains the code to monitor and control the Bar Screen 01 Motor and Reset Alarms Interlocks and Faults associated with the motor This routine is provided as a Ladder Diagram
212. t Typically many customizations and adjustments have to be made to the application to make it operational for a particular project Customization is a vital part of the software development This section outlines some of the basic tasks that must be done for this customization and other steps may be necessaty The important point to remember is that these example applications only serve as a start It is the responsibility of the application engineer to assess the requirements of the project take ownership of the application and drive it to completion Some general customization concepts will be discussed in this section Though you may not be interested in the Lift Station application it is an important section to read because the customization information contained in this section applies to other areas as well 1 0 Assignment As mentioned earlier in this document I O is mapped at one place in the application for each I O point As part of customizing the example Lift Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 3 Station application be sure to check all the locations for I O that is mapped including the following e MainProgram A01 DiscreteInput rungs 0 4 e MainProgram A02 AnalogInput rungs 0 3 e MainProgram A03 DiscreteOutputs as needed e MainProgram A04 AnalogOutputs as needed this routine is not used in the example For Pump I O each pum
213. t Contents Reference For Number Folder 1769 CompactLogix IASIMP 0S010 PowerFlex 70 This document contains information on how to deploy a Packaged Controller Information CompactLogix Packaged Controller This step by step guide includes the following e How to Assemble the Hardware e Hardware Setups for Communicating between your PC and the Controller e Installing RSLogix 5000 and RSLinx software e Software Configuration for Serial and Ethernet Communications From Your PC to the Controller e Software Setups for Communicating between your PC and the Controller e Loading Controller Firmware e Creating an RSLogix 5000 project e Downloading to the Controller e Adding Point I O to the Project e Including a PowerFlex 40 in your application and establishing communications e Creating a simple PanelView Plus Application and Establishing Communications with your CompactLogix packaged controller e Interfacing your CompactLogix packaged controller with a DeviceNet Network e 1769 CompactLogix Packaged Controller User Manual Visualization VIEW SGO01 PanelView Plus This document contains the necessary information to System Platforms Selection Information specify the visualization components required for your Specification Guide application Hardware Selection Select a Visualization Platform Determine platform style you want to use e Dedicated platform optimized for machine level interface e Open platform a device with a preloaded operating syste
214. take Pump Station System Separation Station System e High Service Pump Station System The Raw Water Intake System Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication IASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings Raw Water Intake System Hardware Drawings The System Architecture folder on the WWWAT CD contains the Raw Water Intake System sub folder Select this sub folder to view the following Raw Water Intake System drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e Panel I O Layout Sheets 281 Chapter 4 282 Title Page and Sheet Index Raw Water Intake System Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT RAW WATER INTAKE PS Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Process Flow Diagram Chapter 4 Raw Water Intake System Process Flow Diagram Number E 1110 Title System Process Flow Diagram Description The Run Water Intake System Flow diagram depicts a Raw Water Intake System with particular 1 0 Any chan
215. tart from a clean slate Publication IASIMP QSO014C EN P February 2013 189 Chapter 3 Set point process variable and simple start stop cycle logic 0 PUMP CYCLE RUNNING Move Source Chemical Feed Setpoint 250 0 Dest ChemicalFeedP PIDE SPProg 250 0 Move Source Chemical Flow P Aln val 113 59337 Dest ChemicalFeedP PIDE P 113 72094 Any Pump Sequence Selected START PUMP CYCLE HMI PB Pump Sequence Selected STOP PUMP CYCLE HMI PB PUMP CYCLE RUNNING F PUMP CYCLE RUNNING ChemicalFeedP PIDE Enableln PUMP CYCLE RUNNING lo Move Source uU Dest ChemicalFeedP PIDE SP 260 0 Move Source 0 Dest ChemicalFeedP_PIDE PY 113 72094 Move Source 0 Dest ChemicalFeedP_PIDE CY 45 508377 A001 Chemical FeedP1 FBD This routine contains the permissive interlocks VSD and alarm blocks for chemical feed Pump 1 190 Publication IASIMP QS014C EN P February 2013 Chapter 3 Typical permissive and interlock function blocks for Pump 1 Chemical_FeedP1_P_Perm e SOPermOK 1 tJinp_Permoo Sts Permok p 2 A2 1 tjInp Perm 1 XSts NBPermOK 3 vu X p ec NBPermOK amp Inp Perm02 2 A2 Inp_Perm03 Pump 1 REMOTE Pump 1 NP FA amp LILT a Pump_1 4LM_FTSTART Pump 1 amp LM FTTSTOP Inp_Perm04 Inp_Perm05 E Inp_Per
216. tative or visit http www tockwellautomation com support Installation Assistance If you expetience an anomoly within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone en html Canada or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility Howevet if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwe
217. the output of the higher level P Reset instruction to the Inp Reset input of the lower level P Reset instruction Do Not Use This Instruction When e You want to reset a single piece of equipment valve motor Use the Operator or Program Reset Command directly on the equipment 72 Publication IASIMP QS014C EN P February 2013 Chapter 3 Reset Inhibit P_Resetinh The following table describes the Reset Inhibit P_ResetInh parameter and its usage Reset Inhibit P_Resetinh AOI Reset Inhibit P_Resetlnh Description This AOI prevents damage to a large motor through repeated starts The high starting current for a large motor causes considerable heating Because the thermal mass of a large motor is much smaller relative to its horsepower and starting current compared to smaller motors repeated starts or start attempts over a short time will overheat the motor windings potentially damaging the motor permanently The Restart Inhibit AOI provides a rule based state model for restarts and is NOT intended to model or monitor the motor heating It cannot replace sensor based motor monitoring systems It can however be a simple solution to avoid overstressing a motor without the cost money or Controller resources of more extensive modeling and monitoring Use This Instruction When e You have a large motor or other piece of equipment where repeated start stop cycles or failures to
218. the Flocculation Mixer motor Main routine calls the other routines in this program A01 Pump LDR contains the code to configure the source of the speed reference for the VFD for the Flocculation Mixer and reset alarms interlocks and faults associated with the mixer This routine is provided as a Ladder Diagram A02 Pump FBD contains the Variable Speed Drive Permissives and Interlock AOIs that monitor and control the Flocculation Mixer motor See the Using Add On Instructions section for more information This routine is provided as a Function Block Diagram Add On Instructions are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P_ in their name The other AOIs have a prefix of U_ as shown in the AOI illustration 214 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 AOls E S Add On Instructions mig P AIn P_Alarm P_DIn P_Intlk P_Mode P Motor P Perm P Reset 9 3 P ResInh P_RunTime U_CommFail U_FlowTot U_Heartbeat U RepeatCycTmr EJ U_WallClock Process Description Raw water especially river water contains both dissolved and suspended particles Coagulation and flocculation processes are used to enlarge and sepatate the suspended solids portion from the wate
219. the VSD to operate the pumps locally The operator uses the buttons located at the VSD to operate it High Service Pump Lit 1302 Level 1 LIT 1302 BEEET F Stopped HS Pump 1 oo EI Remote Operator Mode The operator must place the pumps in this mode to use them from the HMI The operator can place the pumps in the Remote mode by selecting Auto on the Auto Off Hand selector switches located at the VSD for each equipment In Remote mode the operator selects Program mode to control the process from the HMI Operator Mode Manual Click the High Service Pump icon to display the High Service Pump 1 M 1300 Faceplate Publication IASIMP QS014C EN P February 2013 229 Chapter 3 230 High Service Pump 1 M 1300 Faceplate HMI Template High Service Pump 1 M 1300 A PER REUS Program a al Enabled Drive OK Stopped At Speed gt a 218 elle s EE Requested 30 00 Operator 30 00 0 00 0 00 Operator 20 00 Comm OK For Manual Operator Control select the Operator mode from the High Service Pump 1 M 1300 Faceplate Operators use this faceplate to control the pump equipment remotely The available commands include Press the Play button to start the pump Press the Stop button to stop the pump e Click the Disable button to remove the pump from service Click the Enable button to place the unit back in service Publication IASIMP QS014C EN P February 2013 Publication
220. the wet well level The Lift Station screen depicts the Wet Well Level with a water animation Lift Station Wet Well Level Animation This animation shows a low wet well level of 150 feet 95 Chapter 3 Lift Station Wet Well Level Animation This animation shows a high wet well level of 12 feet Pump Faceplates For each pump in the Lift Station there are a Pump Motor and Digital Input Faceplate Lift Station Pump Faceplate Motor Faceplate Digital Input Faceplate Digital Input Faceplate 96 Publication IASIMP QS014C EN P February 2013 Chapter 3 Lift Station Motor Faceplate Lift Statio no Pump A3 PERR Da 2 Enabled Sope b M e ej Lift Station Digital Input Faceplate Lift Station lt 1 Purng 1 Overload Trip APEPRE Publication IASIMP QS014C EN P February 2013 97 Chapter 3 Pump Setpoints The Pump Setpoint screen provides you with information about when each pump should start and stop 1 Click the Pump Setpoints button that appears on the Lift Station screen The system displays the Pump Setpoint screen Lift Station Pump Setpoint Screen Adjustthese setpoints forwhen you want each pump to start and stop Manual Setting switches 2 Use the Start or Stop fields to adjust the setpoint for when each pump starts and stops The setpoints are based on the Wet Well Level For example in the illustration above the lead pump sta
221. tion System Architecture Drawing Separation System Architecture Drawing The following table describes the key design points of the Separation Station System Architecture Drawing Hardware Description ControlLogix Processor Controls the Separation Station System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the pumps EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the plant network Publication IASIMP QS014C EN P February 2013 25 Chapter 1 26 The WWWAT CD also contains System Architecture Drawings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application Each specific site manager must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Separation Station System Add more drives as needed e The Ethernet Switch has a limited number of ports Select the approptiate Stratix switch as required for the number of EtherNet IP devices in the system P addresses and node numbers are unique to your application and you must include them on this drawing Publication IASIMP QS014C EN P February 2013 Chapter 1
222. tions which allow a piece of equipment to start run energize open etc Permissive conditions generally must only be true to start the equipment Once the equipment is running Permissives are ignored Use the P_Intlk Interlocks AOI for collecting conditions which stop running equipment as well as prevent it from starting Use This Instruction When e You have multiple or cascaded Permissive conditions which prevent some equipment motor valve and drive from starting but which are ignored once the equipment is running Link the P_Perm Status bits to the Inp_PermOK and Inp_NBPermOK inputs of the motor valve or drive e You want configurable text descriptions of the Permissive conditions and other features of the P_Perm Faceplates Do Not Use This Instruction When e You have conditions that shut down running equipment as well as prevent it from starting These are interlock not Permissive conditions Use the P_Intlk Instruction instead e You have only one Permissive condition for the equipment connect the condition directly to the permissive input on the device Publication IASIMP QS014C EN P February 2013 n Chapter 3 Reset P_Reset AOI Reset P_Reset Reset P_Reset The following table describes the Reset P_Reset parameter and its usage Description This AOI provides a central point at which to reset equipment faults and latched alarms for a control strateg
223. to put the SCM drive in the Remote mode Operator Mode Manual Click the SCM section of the Solids Overview screen The system displays the Sedimentation Basin 1 Drive Faceplate Sedimentation Basin 1 Drive Faceplate Sed Bain 1 Drive a agla ala OO 005 Enabled Tn gt mj z amp e el For manual Operator Control select the Operator mode on the Sedimentation Basin 1 Drive Faceplate The Operator uses this faceplate to control the SCM The operator starts and stops the SCM remotely from the faceplate The available faceplate commands include Press the Play button to start the SCM Press the Stop button to stop the SCM e Click the Disable button to remove the SCM from service e ClicktheEnablebuttontoplacetheunitbackinservice Alarms The Supervisory Control and Data Acquisition SCADA system generates these two types of alarms Publication IASIMP QS014C EN P February 2013 Chapter 3 e Process Equipment Process Alarms There are the four types of Process Alarms e Sedimentation Basin LIT 1204 High Level Alarm e Sedimentation Basin LIT 1204 Low Level Alarm e Sedimentation Basin LIT 1204 High High Level Alarm e Sedimentation Basin LIT 1204 Low Low Level Alarm Process Alarms Solids Tank 1 Level LIT 603 i pg xo um Alarm Delay Time seconds High High High Low Low Low Ack Reset Severity Alarm Reqd Reqd 1 2 3 4 vf High High J o High TA v Low v vf Low Low J Devic
224. tor Operator Mode Unlock and Lock Requested Mode Command Button Indicator High and Hign High Limits Current Process Variable Graph Current Process Variable Low and Low Low Limits _ Buttons to select Input PV or substitute PV 1 0 Status Indicator Operator Tab Maintenance Mode Acquire and Release Mode Indicator Requested Mode Command Indicator Button Threshold Deadband High High Alarm 90 00 1 00 level Alam High Alarm 80 00 1 00 Thresholds and Deadbands Low Alarm 20 00 1 00 Low Low Alarm 10 00 1 00 Out of Range High 110 00 TT Out of Range Low 10 00 Maintenance Tab J Bumpless Program Operator Transition Publication IASIMP QS014C EN P February 2013 59 Chapter 3 Analog Input P_Aln Engineering Tab Faceplate Product Transfer Flow Rale akal Label Tag Raw Input Scaling Input Maximum 100 00 Configure Input and Scaled Ranges Minimum 0 00 Configure Device Description Label and Tag Disallow selection of Substitute PV Clear Program Commands on receipt PV Filter Time Constant sec 0 0 unfiltered 60 Publication IASIMP QS014C EN P February 2013 Digital Input Instruction P_DIn Chapter 3 The following table describes the Digital Input Instruction P Dln parameter and its usage Digital Input Instruction P_DIn AOI Digital Input P DIn Description This AOI receives and processes a single discrete condition bit or PV typic
225. trols products power supplies 319 Appendix A Documentation Resources The WWWAT CD contains Rockwell Automation user manuals and installation instructions that you can refer to while designing your application This table lists each document s publication number folder location and describes its content so you can quickly locate the required information The publications can be found on the CD in the folder WWWAT Common Tools gt Product Information Documentation Stored On the WWWAT CD Document Name CompactLogix Packaged Controller Installation Instructions Publication Number 1769 IN082 WWWAT CD Folder L2X Controller Information Document Contents Installation Checklist Controller Dimensions How to Install the Battery How to Connect Expansion Modules Minimum Spacing Requirements How to Panel Mount How to DIN Rail Mount Grounding Considerations Wiring Power to the System Wire the 1 0 Removable Terminal Blocks Expansion Module Wiring Selecting Operating Mode Status Indicators Reference For Hardware Selection Installation and Start up PanelView Plus Installation Manual 2711P IN002 PanelView Plus Information Environmental Information Mounting Clearances Cutout Dimensions Panel Mounting Instructions Product Dimensions Removing and Installing the Power Terminal Block DC Power Connections AC Power Connections Troubleshooting Battery Removal System Specifications
226. ump is required to run pump 1 starts and runs until the level is satisfied The next time a pump is required to run pump 2 starts however the level gets to a point where one pump cannot keep up and a second pump is required At that point all of the pumps with Lag 1 selected as secondary will start All pumps will continue to run until the level is satisfied 2 Pumping sequence example 2 Same scenario as example 1 except pump 2 is Off After pump 1 runs and then turns off Pump 3 will run on the next cycle Because even though pump 2 has alternate selected it is turned Off and is therefore taken out of the alternation sequence 3 Pumping sequence example 3 Pump 2 is set for Lead pump 1 is set for Lag 1 and pump 3 is set for Lag2 When the level requires a pump to run pump 2 comes on and runs until the level is satisfied If the level continues to change and requires another pump to run pump 1 will start If the level still continues to change and requires another pump pump 3 will start The pumps will continue to run until the stop level is satisfied With all pumps now off when the level requires a pump to come on the sequence repeats itself there is no alternation 4 Access other setup screens as needed from the navigation at the bottom of the Process Config screen Press Pump Interlocks to open the Pump Interlocks screen Refer to Pump Interlocks on page 246 Pres
227. unlatched as the style of mode selection this is the maintained style of mode control If you wish to change this type of control to the Edge style an understanding of the method of mode selection within the Process Library is required These paragraphs have touched on this topic but more information can be found within the Process Library documentation Refer to the manual for the Mode object for more detailed information 108 Publication IASIMP QS014C EN P February 2013 Chapter 3 Publication ASIMP QS014C EN P February 2013 Adding or Removing Pumps The Controller application provides routines for up to six pumps The HMI application is written for two pumps although a test screen is provided to serve as a start or seed for adding additional pumps to the HMI Both applications can be adjusted to suit your process but this requites an understanding of the software and careful customization This section describes some of the details that must be tended to as pumps are added or removed To adjust the number of pumps in the Controller first add or delete routines as necessary to have one alarm and one control routine for each pump Note that these routines are numbered sequentially with AOx where x is the sequential You may number the pumps or name them as required for your application You may choose to name a pump PumpWest instead of Pump1 for example Lift Station Pump Controller Routines amp Pumps 8 Program Tags
228. utton is not visible unless an analog device is being used Measurement Setup screen Analog input IN 0 pressure or level measuring device Calibration and Scalina Analog Input Raw Value Analog Input m Value 0 00 mA Apply a 4mA Signal Apply To Analog In 0 LES Then Push To Calibrate Card Defaults Enter 4m ter 20m Enter Scaled Value Se value Engineering Unit Analog Input Scaled Value 00 0 Analog E E IN 1 The screen includes displays showing the raw data coming from the analog input card and mA value of the input from the calibrated zero and span set card 2 Select one of the two following calibration methods Publication IASIMP QS014C EN P February 2013 Chapter 3 Apply a 4mA signal to the cards input I 1 0 then push Apply a 4mA Signal To Analog In 0 to make the zero adjustment After making the zero adjustment choose Apply a 20mA Signal To Analog In 0 to make the span adjustment if a signal is available Select No 4 20m4A Signal Available to calibrate the analog input using the card s default values if no current calibrator is available IMPORTANT You must use one of these calibration methods to ensure proper operation 3 Enter a scaled value in the Enter 4mA Signal Value field For example 0 Ft 4 Enter a scaled value in the Enter 20mA Signal Value field For example 10 Ft 5 Enter a measurement unit type in the Enter Engineering Unit field For example Ft Inch PSI
229. ve Run Firme 2 pude dod eO EUREN o cu o e wh 74 Motor Operated Valve P_ValveMO oL E ee Rte 76 Variable Speed Drive POV SD i eed tt ace pee ERR 80 WWWAT CD Applications eoi dete tede LA o SR at ate oe A 83 Water Wastewater Treatment Application Framework 83 T puts arid Outs aese else sted rege eaaa Pa bti RA oid 86 PON Servite vara Elva date du sa ees cor bu DL S REL t 88 Using the Process Moddles 451 et EU e Dr ea 89 Uset ModuleSs sator ta ne ras T CPC OS vala PROMO 89 Water and Wastewater Treatment Plant Applications 90 Lift Station System Application can Lt LE Medos ap ee RAD 90 Control DesctlptoB c oie eC Boia tet h rene an ar b toa os 93 AETS Qu da teo iius rinde uad 4r beso isst toad aA 101 Qustotzattot v cea oet eU RERO OS Eb tea 24 102 RESETS Los Cape od pa aa e ed p sm orate up ute 104 Adding OF REMOVING PUMPS casi ou nace mated vate ar PES 109 Dosing Pumps Applications 2o oed eats soa ts decree 113 Control Desctptidti cu ea telly or UG AC AT ERE x 115 Arms i6 odes eee PEE auci oper aa Docs bea 119 Customization of the Dosing Pumps Application 120 Additional Flow PACH yet tae eine e ton Mite OT oe tee iy 123 Headwotks Application tL RE x EHE Reo 124 Process DescHDHODuo me np vete tablas etis DUE PN I IAS EROR 126 HMI DeschipiOn i oicccE sr hera edi we c Ov SE s 127 Control Description Mechanical Bar Screen Numbers 1 and 2 129 AIAS oes da pee tud tae eda a bae deti 134 Reporting Equ
230. vices in the system P addresses and node numbers are unique to your application and you must include them on this drawing This is a typical Pump Controller Station Architecture Drawing Pump Controller Station Architecture Drawing p p p ET The following table describes the key design points of the Pump Controller Station Architecture Drawing Hardware Description MicroLogix 1400 Controls the Pump Station PanelView HMI Component C600 PowerFlex 4 Drives the Pumps Publication IASIMP QS014C EN P February 2013 Additional Resources Publication IASIMP QS014C EN P February 2013 Chapter 1 The WWWAT CD contains links to numerous websites where you can find more information on the System Specification and Procurement phases of your Water and Wastewater project For more information on websites and documentation that will help you plan and design your Water and Wastewater project see Appendix A 29 Chapter 1 30 Publication IASIMP QS014C EN P February 2013 Chapter 2 Introduction Hardware Drawings Water and Wastewater Treatment Plant Hardware Drawings Publication ASIMP 0S014C EN P February 2013 Hardware Design This chapter contains valuable resources to help you design the necessary Water and Wastewater hardware for your project The WWWAT CD contains a System Architecture folder which contains a drawing package for each application Each of these drawing package
231. w the pump to continue running in that alarm state A white X in a red circle indicates an interlock that has been removed while a blue check mark in a gray box indicates an interlock that has been added Current Interlocks 246 Publication IASIMP QS014C EN P February 2013 Publication ASIMP QS014C EN P February 2013 Chapter 3 Level Setpoints 20mA Scaled value Current level scaled value 4mA Scaled value From the Level Setpoints screen you can Press On Setpoint to enter the level at which you want the selected pump to turn on Press Off Setpoint to enter the level at which you want the selected pump to turn off Press VFD Speed Hz to enter the desired VFD speed in Hz when running in Level mode The VFD Speed Hz button is not visible if Starters were selected on the Motor Control Setup screen Press the High and Low Alarm Setpoints to enter the threshold values for triggering the related alarms Pressure Setpoints From the first Pressure Setpoints screen you can 247 Chapter 3 Press Pressure Setpoint to enter the desired system pressure Press Start Pressure to set the pressure combined with the time delay at which the Lag 1 and Lag 2 pumps will come on if the desired pressure is unable to be maintained View the current pressure reading analog input must have been set up previously Press Once Below Start Pressure The Next Pump Will Start in Sec
232. wing We expect you to modify these sheets to fit your application You use these sheets as a template for use with many applications even though the specific 1 0 points vary These sheets include digital input and output modules as well as analog input and output modules The Dosing Pump Panel I O Layout Sheet contains one example of each type of module that will typically be used in a lift station application Note that these modules are 1756 style 1 0 modules Different I O modules will require changes to these sheets 39 Chapter 2 Water Treatment Plant Hardware Drawings 40 The Water Treatment Plant WTP Hardware documentation package contains the following system level drawing packages e Raw Water Intake Pump Station System e Separation Station System High Service Pump Station System The Raw Water Intake System Pump Station drawings are included in this section for reference These are typical of the others all can be found on the WWWAT CD Publication LASIMP SP012 You can also go to the Rockwell Automation Integrated Architecture Tools Website http www ab com go iatools and download the drawings Raw Water Intake Pump Station System Hardware Drawings The System Architecture folder on the WWWAT CD contains the Raw Water Intake System sub folder Select this sub folder to view the following Raw Water Intake System drawings e Title Page and Sheet Index Process Flow Diagram e Network Diagram e P
233. wings that are intended only to support your application Hardware modifications may be required to fulfill your application needs Consider these points when designing the hardware for your application e Each specific site must determine the 1756 Chassis I O card configuration based on the specific needs of the I O devices adjacent to that chassis e The number of PowerFlex 700 Drives may change based on the number of pumps in the Primary Treatment System Add more drives as needed The Ethernet Switch has a limited number of ports Select the appropriate Stratix switch as required for the number of EtherNet IP devices in the system P addresses and node numbets are unique to the application and you must include them on this drawing Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Chapter 1 Headworks System Architecture Drawing The following is an example of a typical Headworks System Architecture Drawing Headworks System Architecture Drawing The following table describes the key design points of the Headworks System Architecture Drawing Hardware ControlLogix Processor Description Controls the Headworks System 1756 Series Controls 1 0 PowerFlex 700 Drive Drives the motors EtherNet IP Establishes a communication path between the ControlLogix Processor PowerFlex 700 Drive and the plant network 17
234. work Diagram Panel I O Sheets e Device Wiring Schematics Title Page and Sheet Index Lift Station Title Page and Sheet Index ROCKWELL AUTOMATION WATER WASTEWATER ACCELERATOR TOOL KIT aT artes BE ak ee UT Te F mu TUS nee Sheet Index package Modify this sheet as necessary to match the contents of the drawing package for your application 272 Publication IASIMP QS014C EN P February 2013 Chapter 4 Process Flow Diagram Lift Station System Process Flow Diagram Number Title Description E 160 System The Lift Station Process Flow diagram depicts a Lift Station Process Flow consisting of two pumps with particular I O It provides a Diagram general overview of the process controlled by the system a quick summary of the controls involved and the process that is being controlled Publication IASIMP QS014C EN P February 2013 273 Chapter 4 Network Diagram Lift Station Network Diagram E 170 Network For details see page 12 Diagram 274 Publication IASIMP QS014C EN P February 2013 Publication IASIMP QS014C EN P February 2013 Panel I O Sheets Lift Station Panel 1 0 Sheets Chapter 4 Number 1e GENES ee ke e T J J Title Panel I O Layout Sheet 1 of 2 Panel I O Layout Sheet 2 of 2 Description The Li
235. y The P_Reset accepts an Operator Reset Command a Program Reset Command and a Reset Input These commands are initiated from a button input higher level P_Reset AOI from a containing control strategy say a Unit Reset sent to a P_Reset at Equipment Module scope or from any other source The Reset AOI also includes a Reset Required input for collecting the Ready to Reset outputs of the various instructions it resets and providing a ready to reset reset required status which can illuminate a button or make an HMI reset button visible The Reset AOI includes a timer function which causes its output to be held on for at least a minimum time This allows the reset signal to be sent via physical output cards to field devices that may required it e g motor drives and gives time for the cleared status from the device to propagate back to an Interlock or Permissive inputs to the system Use This Instruction When e You want a common reset point Master Reset for alarms and fault conditions for a control strategy process unit process cell or equipment group process area or plant section or even a small site Tie the output of the P Reset instruction to the Inp Reset input of the equipment to be reset e You want a cascading reset strategy where there is a P Reset instruction for a small equipment scope such as a strategy which incorporates resets from wider scope unit cell area site resets Tie
236. ystem Add On Instructions are used extensively in this application There is a collection of Process Library AOIs and a collection of other AOIs developed specifically for this application Process Library AOIs can be identified by a prefix P in their name The other AOIs have a prefix of U_ as shown in the AOI illustration 139 Chapter 3 140 AOls E E Add On Instructions w RJ P AIn P_Alarm amp P DIn w P Intlk ig P Mode iz P Motor P_Perm Es P Reset f3 P ResInh P_RunTime U Commf ail l J Uu FlowTot m U Heartbeat U_RepeatCycTmr rz U WallClock Process Description The Secondary application consists of an aeration tank blower RAS pump and a Secondary Clarifier tank Aeration Tank Effluent from the Primary Settling Tanks primary effluent contains soluble and colloidal impurities which were not removed in the preliminary and primary treatment processes Secondary treatment employing the activated sludge process with biological phosphorus removal removes most of these impurities before the wastewater is filtered disinfected and discharged Blower In the activated sludge treatment process oxygen is required to maintain aerobic conditions for the treatment process If an adequate air supply is not maintained such that the available dissolved oxygen DO satisfies the biochemical oxygen demand BOD the organisms will fail to reproduce effectively and may peri
237. zation within the Controller Solids System Application Controller Organization amp y Tasks E A MainTask e Program Tags Main By A01 MiscDiscreteInputs R A02 MiscAnalogInputs dy A03 MiscDiscreteOutputs ER A04 MiscAnalogOutputs E SolidsTkO1 Drive A Program Tags Main B A01_Drive_LOR 4 A02_Drive_FBD 8 was_HoldTkvalvesoo Program Tags Main B A01 valve LDR I A02 Valve FBD E WAS_StorageTk_ToSolidsTkO1_Pump600 8 Program Tags Eh Main B A01 Pump LDR 4 A02 Pump FBD Ei 8 PrimTkToSolidsTkO1_Pump601 A Program Tags Ea Main B A01 Pump LDR Ey A02 Pump FBD i 8 SolidsTkO1ToFilterPress_Pump602 A Program Tags Ef Main B A01 Pump LDR 4 A02 Pump FBD This task resides in a Controller in the main facility of the plant where the Solids application is present and it is not intended to be the only application in the Controller A ControlLogix processor is specified for this application for that specific reason It is assumed the processor will be running other systems of the plant 152 Publication IASIMP QS014C EN P February 2013 Chapter 3 The organization of this application is similar to that of the Lift Station Specifically the functionality for each program and routine is e Main Program handles general Solids application and functionality Main routine calls the other routines in this program and includes a Wall Clock AOI that calculates the day of the week It also includes a Pump

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