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L19 - Rockwell Automation

1. Billing and sub billing charging users of energy the actual usage cost rather than allocating by square footage or other arbitrary methods Power system monitoring and control display and control power flow and energy utilization Demand management monitoring power usage and controlling loads to reduce demand costs Demand response controlling and monitoring usage in response to an energy provider s instruction to reduce demand The PowerMonitor 5000 connects to the user s three phase or single phase AC power system directly or through instrument transformers PTs and CTs It converts instantaneous voltage and current values to digital values and uses the resulting digital values in calculations of voltage current power energy etc Hardware features GS GS x l i O e Era Ee HAN oe Se mei rel B Ti b3 al L 3 o m l Fa a 1 Ethernet port standard RJ 45 jack with LED indicators Ethernet port hardware is included on all models These protocols and functions are supported Ethernet IP HTML web page for configuration and data access Ethernet indicators 39 of 68 e LNK Indicator Solid GREEN IP link established Off No link established e ACT Indicator Flashing YELLOW Data present on Ethernet port Off No data activity present
2. Configuration i EJ Configuration Report ff My User Settings Meters Assigned to Group Contribution factor 56 of 68 Create an Engineering Domain in the Efficient Industries Plant 1 Domain Click on Efficient Industries Plant 1 and Click Add Select Efficient Industries Plant 1 as the Parent Group Check This group is a domain Type in Engineering as the Name Insert 15 for the Default log rate Type Efficient Industries Plant 1 for Report title line 1 Type Engineering for Report title line 2 Click Save http flocalhost FTEnergyMetrix default aspx fh gt BE E h Page Safety Toos FactoryTalk EnergyMetrix ey My Start Page tx ChartsPlus Help Logout System Meters Reports Custom Add Group Layout Save Restore Collapse System Status a E Groups Parent group Efficient Industries Plant 1 7 SEA Efficient Industries Plant 1 IZ This group is a domain a Vi sO Devices Name Engineering Roles and Users Rate Schedules Multi Purpose Report Scripts A Alarm Setup Soo e Unit Setup J Configuration EJ Configuration Report Default log rate 15 My User Settings ita li F Reports title line Eficient industries Plant 1 Q About 1 Reports title g Engineering i tst lt s sisSCS Meters Not Assigned to Group Meters Assigned to Group Contribution factor Contribution factor aaga 5 3 57 of 68
3. CTs by user Q X1 UY 2 CTs may be used only on 3 wire systems O Load Ground 44 of 68 B Configuring PowerMonitor 5000 Hardware Connecting the PowerMonitor 5000 using the Ethernet connection In this lab we will use the ethernet cable to connect to and configure the PowerMonitor 5000 This section is for information only the PM5000 is already configured Connect the Ethernet cable to the PM5000 Double click the Internet Explorer Eth PM 5000 shortcut from the desktop of your station s PC The Internet Explorer shortcut will launch Internet Explorer and open the PowerMonitor 5000 home page The IP Address will display in the address bar as 192 168 1 5 f the home page does not display when Internet Explorer opens type 192 168 1 5 into the address bar and press the Enter key on the keyboard The home page displays general information about the PowerMonitor 5000 unit You can navigate by clicking folders and pages from the tree on the left Powerond of 5O00 Windows Internet Leplorer provided by Rockwell Automation g fle Cd a Fevotes B PowerMondor B00 r A w Page Sefety Took H 4 Allen Bradley MPN Ta ulelaliee aaoo EE sa Mawrase Home s owerMonitor 5 00 Windows Internet Explorer provided by Rockwell Automation hwy je 192 168 169 3 wl X Edt View Favortes Took Heb Continue with the lab to use the web interface to configure the PowerMonitor
4. Demand Interval is usually fixed interval but may be a sliding window Demand Interval is typically 15 minutes long but may be 30 or 60 minutes Single highest interval Demand occurring in the billing period is the Peak Demand Units of measure same as Power kW Demand dictates the minimum capacity of the electrical system Power Quality The absence of malfunctions or failures caused by power anomalies Sags voltage dips gt 10 Swells voltage rises gt 10 Interruptions Noise harmonics unbalance 38 of 68 PowerMonitor 5000 features and functions The PowerMonitor 5000 is the next generation of high end electric metering products from Rockwell Automation This new family of meters provides advanced technology new functionality faster response and superior accuracy The M5 model is the base version and provides an extensive range of metering functionality The PowerMonitor 5000 communicates power and energy parameters to controllers HMI software and applications such as FactoryTalk EnergyMetrix over Ethernet or other optional networks The PowerMonitor 5000 works with controllers or software applications to address key customer applications including Load profiling logging power parameters such as real power apparent power and demand for analysis of power usage by loads over time Cost allocation reporting actual energy cost by department or process to integrate energy information into management decisions
5. The Command Status and other values are shown on page 55 in the PM5000 User Manual A Zero value is a Command Active or Test Passed In this example of the three Power Factor Ranges two passed ail Wiring_Diagnostics Command_Status 0 Voltage_Input_Missing 0 Current_Input_Missing 0 1 0 0 0 Range1_L97_C89_Status 0 Range1_Voltage_Input_Inverted 0 Range1_Current_Input_Inverted 7 Range1_Voltage_Rotation 123 P Range1_Current_Rotation 5 E Range2_L85_C98_Status 0 Range2_Voltage_Input_Inverted 4 Range2_Current_Input_Inverted L Range2_V _Rotation 123 Range2_Current_Rotation 123 Range3_L52_L95_Status Range3_Voltage_Input_Inverted o Range3_Current_Input_Inverted Range3_Voltage_Rotation 123 Range3_Current_Rotation 123 51 of 68 Wiring Correction The PowerMonitor 5000 features virtual wiring correction We will be able to demonstrate wiring diagnostics in the lab as we have the power monitor wired with three phase power From Command gt Wiring _ Correction gt Wiring Correction Command select Correct wiring using manual input parameters Change Input 11 Mapping to I1 inverted Click Apply changes System_Registers 4 Wiring_Corrections Wiring_Corrections Wiring_Correction_Commands Correct wiring using manual input parameters Input_V1_Mapping Input_V2_Mapping Input_V3_Mapping Input_Ii_Mapping Input_I2_Mapping Input_I3_Mapping I3 Apply Changes Verify the virtual wiring co
6. This group also includes a utilities subgroup tor nonprocuction cost allocation analysis and utility shadow billing 1 Open Internet Explorer The FactoryTalk EnergyMetrix login page is set up as the home page lt http localhost FT EnergyMetrix gt Log in with user name labadmin and password rockwell This login gives you administrator access to the Efficient Industries Plant 1 domain X Login Windows Internet Explorer fm x GOE le http localhost FTEnergyMetrix malalla S Bing pi w Favorites 3 Suggested Sites g Web Slice Gallery 7 fy gt A Page Safety Tools FactoryTalk EnergyMetrix Help User name labadmin Password eoeccees l Remember my user name on this computer Version 2 00 00 Build 15 Rockwell Allen Bradley Rockwell Software Automation Once you log in there are four tabs on the navigation pane Each tab is described below System Meters Reports Custom System Allows Configuration for Groups Domain tree structure Devices Roles and Users Rache Schedules Custom Reports Multi Purpose Reports My Start Page and other setups i e Units User settings Alarm sub scriptions Meters Allows to Configure Meters and meter tags and to view Meter data in tabular Trend and Calendar Trend Reports Allows to Configure Reports automatic report jobs and to generate view reports on demand Custom Allows to Configure custom page with URL Link for
7. d T http localhost FTEnergyMe b Suggested Sites g Web Slice Gallery 7 FactoryTalk EnergyMetrix am ry i e n A reenPrint User name admin Password IY Remember my username on this computer i Login Help Version 2 10 00 Build 43 Rockwel Aven Bradley Rockwell Software Automation r Mia Basle Ai Pana Ine All Ah Daa aet Once you log in there are four tabs on the navigation pane Each tab is described below System Meters Reports Custom System Allows Configuration for Groups Domain tree structure Devices Roles and Users Rate Schedules Custom Reports Multi Purpose Reports My Start Page and other setups i e Units User settings Alarm sub scriptions Meters Allows to Configure Meters and meter tags and to view Meter data in tabular Trend and Calendar Trend Reports Allows to Configure Reports automatic report jobs and to generate view reports on demand Custom Allows to Configure custom page with URL Link for Files i e user can upload a scanned copy of Utility Energy Bill to Custom page Note The right View Pane is updated only after a sub category is selected of any given tab Tree Item 6 of 68 gt http locathost FTEnergyMetrix default aspx Windows Intern P GJ Base Server 2008 R2 Standard x64 me p gt fx al 2 z Favorites EA E j Suggested Stes 7 E j Web Sce Galery http Aocalhost FTEnergyMetrix defauit aspx Logged in as FactoryT
8. device Devices may be directly connected to the server over a network if the FactoryTalk EnergyMetrix server is also on the network through an appropriate network interface and you have configured the appropriate RSLinx Classic device drivers Devices routed through a ControlLogix gateway or RSLinx Classic gateway are also considered directly connected devices Factory Talk EnergyMetrix uses device classes to determine how to interact with a particular device The device class includes the device family communication type and specifies whether the device has a clock that can be synchronized Examples of supported device classes in FactoryTalk EnergyMetrix are listed below PowerMonitor 5000 and OPC Server on Ethernet devices will be demonstrated in the next lab steps PowerMonitor 5000 device _PowerMonitor 1000 device PowerMonitor 500 device PowerMonitor wireless W250 device PowerMonitor 3000 device ControlLogix or CompactLogix controller FactoryTalk Live Data Server on Ethernet NEW with FactoryTalk EnergyMetrix OPC Server on Ethernet Meters in a FactoryTalk EnergyMetrix project are the tag addresses and datatypes in the Devices 1 Add PowerMonitor 5000 to Efficient Industries Plant 1 gt Engineering gt Electricity Group 59 of 68 In the System tab click Devices then Efficient Industries Plant then Engineering and exapnd the tree and click on Electricity vM gt Logged in
9. 2 Optional communications port future 3 USB host port USB standard A receptacle Not used in this model 4 USB device port The USB device port is a USB Mini B receptacle that accepts standard USB Mini B plugs for connection to a host device such as a notebook computer 5 Configuration Lock switch When enabled this switch prevents changes in configuration that would affect revenue accuracy 6 Power Device and Network status indicators e Power status OFF No control power GREEN Control power is present e Device status OFF No control power Flashing GREEN RED Power monitor is booting up Flashing GREEN Power monitor has not been configured GREEN Power monitor is running Flashing RED Power monitor has detected a recoverable minor fault RED Power monitor has detected a non recoverable major fault e Network status OFF No control power Flashing GREEN RED Power monitor is booting up Flashing GREEN seems to blink green no matter what 7 Status input KYZ output and control relay wiring terminals e Four internally powered status inputs e 2 may be used for demand period synchronization e KYZDPDT solid state relay for signaling use e Three DPDT control relays 8 Control power and ground wiring terminals e 120 240 VAC 50 60 Hz e 24VDC 9 Voltage sensing wiring terminals e Direct connect to up to 690 VAC 3 phase line to line e Maximum nominal line to ground voltage 398 e Use potential transformers PTs
10. Cereal Production Real Energy Net AWA Efficient Industries Plant 1 Electricity Cereal Production Friendly O Production Line Real Energy Net Eee ee ee ee S E E S eS ee ee ee ee 0 1290 lt lt i 3 1 2014 3 8 2014 3 15 2014 4 18 2014 11 of 68 From the above trends notice the reduction in aggregate electricity consumption level in the second billing cycle compared to the first billing cycle This is primarily due to the implemented energy efficiency projects such as installing energy efficient lighting replacing full voltage starters with drives programming a low energy state for when equipment is not in use and shutting off machines during non production hours Generating Electricity Consumption Reports In this section we will guide you through a series of steps to generate electricity consumption reports in FTEM software Step by Step Instructions 1 Click on Reports tab on the left navigation pane 2 Click on a group level in the left navigation tree and click on a consumption report In this example we selected Efficient Industries Plant 1 group level and the Initial Consumption report As highlighted in the below screenshot this is a pre configured aggregate consumption report for all the three cereal production lines a z Logged in as Start Page Charts Plus Hel l FactoryTalk EnergyMetrix cate Mv Start Page x ChartsPlus Help System N Meters Re ports E Layout Save Re
11. Power Factor report As highlighted in the below screenshot this is a pre configured power factor report for the Power Factor line actoryTalk EnergyMetrix posean Mystar Page PcharisPlus Help Le Administrator System Meters Reports Plus Custom ayout Save Restore Collapse View generated reports Report Information Select By Mew all report jobs Report name Power Factor Report EI Global Reports ery PowerFacor SOS SO z Efficient Industries wer Fac E Eficient Industries Plant 1 wing aE j Owo acor 3 Electricity Bene EJ Billing Analysis Report file PowerFactor rpx a 8 Cereal Pro E E Consumption Improvement Report Report parent group Eficient industries Plant 1 l Factory EJ Demand Report 3 a Packaging _ E Initial Billing Report PIPOT Apa PDF E ET Initial Consumption Report Report Parameters Power Factor Report lt 2 Time zone UTC 06 00 Central Time US amp Canada T C Predefined Previous Month Custom Start date 1718 2014 Pick End date 2117 2014 Pick Calculation interval Days 3 You now have the capability to View Edit and Delete the selected report You also have the capability to add a new report or build a new one on top of the existing report 4 You can view the demand report in various file formats pdf excel html rtf tiff This can be achieved by selecting the appropriate Exp
12. Production Line Meter Data ree ee meee eee oe Calendar Trend as Power Quality Summary Time zone UTC 06 00 Central Time US amp Canada V Show grid lines Expor Data No meter tags selected Dec January 2014 Feb Sun Mon Tue Wed Thu Fri Sat Feb March 2014 Apr Select meter tags type to display on graph Sun Mon Tue Wed Thu Fri Sat Select meter tags type to display on graph Real Energy Net Real Power Demand 23 45 a 9 10 11 12 13 1415 16 17 18 20 21 22 9 of 68 4 Change the date range from Jan 18 2014 to March 19 2014 The aggregate electricity demand trend for all the three cereal production lines during the two billing cycles will be shown System Meters i Reports CPAP UN VIe e BLANA MAAV ter T AA FEV VUU IVP WV VUI I VuU vuvI Custom Meter Data Meters Trend Calendar Trend Power Quality Summary ayout Save Restore Collapse Efficient Industries Plant 1 Time zone UTC 06 00 Central Time US amp Canada 7 Show grid lines Export Data E Electricity zl 4 Cereal Production D Friendly O Production Line 3 750 mra Lt E Melzerflakes Production Line a ee re ee ee ee es ee ee so 8 Mittenpuffs Production Line S me ee eee ere e ee eee 0 ee econd Billing Cycle he fem D Main Incoming 2 500 O z Packaging Air Compressors 2 250 a 3 A BRG S OTR M o UEEE EE E EN A E j
13. all power quality events associated with the selected PowerMonitor Click on the View link beside the Sags Dips category to view a list of all voltage sag events Power quality events from 1 1 2014 through 4 30 2014 Category Occurrences Latest Occurrence Mean Std Deviation Trend of Occurrences View Undervoltage 2 3 6 2014 11 45 44 AM Delete View Overvoltage 1 3 6 2074 11 08 39 AM Delete 4 The Power Quality Event Details page lists detailed information pertaining to all the voltage sag events with the selected PowerMonitor Power Quality Event Details Sags Dips power quality events from 1 1 2014 through 4 22 7014 Device ld Device Name Event Date Time Trip Point Magnitude Duration Waveform 2 Main Incoming V2_Sag 3 6 2014 11 45 44 AM 80 180 2 V 60000 ms View Delete 2 Main Incoming V2_Saq 3 6 2014 11 45 44 AM 90 180 2 V 60000 ms View Delete 2 Main Incoming V2_Sag 3 6 2014 10 44 54 AM 90 2112 V 60000 ms View Delete 2 Delete 2 Main Incoming Vi_Sag 3 6 2074 10 31 46 AM 90 1874W 50 ms View Delete 2 Main Incoming Vi_Sag 3 6 2014 10 28 04 AM 90 2114V foams View Delete 5 Click on the View link of the fourth voltage sag event to view the corresponding waveform Below is the V1_Sag at 10 31 46AM that lasts 41 6 ms On this waveform page you also have options to choose different voltage and current channels 29 of 68 Main Incoming 5 x Datestime of waveform 3 6 2014 10 31 46
14. billing cycles Thus monitoring and analyzing data would be greatly beneficial to identify various energy efficiency opportunities and also to validate the cost savings achieved after implementing these opportunities Moreover users can see which processes are the most energy intensive for which to focus energy saving initiatives Viewing Electricity Demand Trends What industrial energy users often don t realize is that electricity demand charges can be as high as 50 of their utility bill This charge is based on the highest 15 minute or 30 minute interval of electric demand throughout a billing cycle With a PowerMonitor 500 on their Main Line Efficient Industries noticed that on Mondays at the beginning of the first shift there was a large peak load contributing to their demand charges Investigating more the plant management figured out that this was happening when the operators were turning ON a majority of their heavy equipment at the same time They realized that cost savings can be achieved by staggering their equipment start ups and shifting them to off peak time periods either manually or using Rockwell Automation controllers Using the energy demand trends feature in FTEM software you have the ability to view the real time electricity demand kW data from the power monitors installed across the manufacturing plant This data is greatly beneficial to analyze the demand aspect of the utility bill analyze the electricity dem
15. ee ee ee e a a a ee E 1 750 1 18 2014 1 25 2014 2 1 2014 2 8 2014 2 15 2014 2 22 2014 3 1 2014 3 8 2014 3 15 2014 Dec January 2014 Feb Feb March 2014 Apr Selecta meter tag to display on graph Sun Mon Tue Wed Thu Fri Sat Sun Mon Tue Wed Thu Fri Sat Units Domain s WMeter Tag 3 nae See a Efficient Industries Piant 1 Bectricity Packaging Air 2 8 L g git 23 4 2 Compressors Total Real Pow 12 13 14 15 1617 9 10 11 12 Demand In order to view the aggregate real power demand information of all the power monitors in a group click the Meter group name and select Real Power Demand tag from the Select a meter tag to display on graph dropdown list If the steps 3 amp 4 are repeated for all the power monitors the aggregate and individual real power demand information can be viewed on the same graph Note The aggregate real power demand graph can be viewed online only when all the individual power monitors in the selected Meters group have real power demand information From the above trend you can notice the start up spikes during first shift on Mondays in the first billing cycle Efficient Industries deployed Rockwell Automation s controllers to stagger their equipment startups and thus reduced their demand charges during the second billing cycle 17 of 68 Generating Electricity Demand Reports In this section we will guide you through a series of steps to generate electricity demand report
16. options under the Report Parameters section a By selecting the Predefined option you have an option to quickly select the time duration based on standard sets such as Previous Month Previous Year Year to Date etc b By selecting the Custom option you now have the capability to specify exact date and time duration during which you want to view the consumption report In this scenario enter Jan 18 2014 12 00 am and February 17 2014 12 00 am as start and end dates to view the consumption report for the first billing cycle Time zone UTC 06 00 Central Time US amp Canada Predefined Previous Month gt Custom Start date haszo OOOO Pick Starttime 12 00AM End date 27 2014 End time 12 00AM 6 Upon making these selections you can click on View button to view the consumption report of the selected meters p Di a Reports ce E lee ee 7 You will notice an initial report generation message and then be able to view the report in the selected format Please note from the below screenshot that the electricity consumption for all the production lines during the first billing cycle is 1 787 314 kWh 13 of 68 Please wait while we generate your report Fa cto ryTa IK EnergyM etrix Efficient Industries Plant 1 Efficient Industries Plant 1 Initial Consumption Report 1 18 2014 12 00 AM to 2 17 2014 12 00 AM Time Zone UTC 06 00 Central Time U
17. or pressure that pushes current through a circuit Ohm Z Unit of measure for impedance which resists or impedes the flow of current Resistance R Inductive Reactance X1 Capacitive Reactance Xc Direct Current DC Volts and Amps always push and flow in the same direction Alternating Current AC Current changes direction many times per second Hertz Hz Unit of measure for Frequency changes of direction per second 60 Hz in USA 50 Hz in EU single Phase vs Three Phase Single phase generators have a single winding Three phase generators have three windings Real Power P The rate of energy transfer Produces heat mechanical work and chemical work Voltage and current are in phase Reactive Power Q Voltage and current are not in phase Reactive power Is stored in magnetic and electric fields Apparent Power S Dictates the capacity requirements of the system Power Factor Ratio of Real to Apparent Power Power factor can be Leading or Lagging Lagging means the load is more inductive Leading means the load is more capacitive Leading Power Factor can be undesirable Can cause voltage control problems Utilities may impose a Power Factor Penalty Energy Power Time Interval Units of measure Watt hours Wh kWh MWh Demand Average rate of energy transfer during each Demand Interval Demand Interval set by the energy provider
18. pes OS LA i E Sh eee AH i MaS set e O a Er Power Factor o DIROS OOA A X a H U DOAS DOAN A D M First Billing Cycle i 1 18 2014 1 25 2014 2 1 2014 2 8 2014 2 15 2014 2 22 2014 3 1 2014 3 8 2014 3 15 2014 Dec January 2014 Feb Feb March 2014 Apr Select meter tags type to display on graph Sun Mon Tue Wed Thu Fri Sat Sun Mon Tue Wed Thu Fri Sat Units Domain s WMeter Tag aar E A Efficient E Plant ee a SE ae ae iba air ee Production Real Pow er Deme EEEE TEETE 19 20 21 22 23 2425 16 17 18 20 21 22 Select the Real Energy Net tag to view the aggregate electricity consumption along with electricity demand for the two billing cycles 10 of 68 6 Custom Meter Data Meters Trend Calendar Trend sf Power Quality Summary Layout Save Restore Collapse 3 Efficient Industries Plant 1 Time zone UTC 06 00 Central Time US amp Canada V Show grid lines Export Data Electricity J Cereal Production D Friendly O Production Line 2 000 000 i La Melzerflakes Production Line 1 800 000 Eig Mittenpuffs Production Line i Energy Efficiency an Factor 1 600 000 Projects LJ ran 1 400 000 l HVAC 1 200 000 w Main Incoming i 1 000 000 G Packaging 2 Air Compressors pues XQ Chiller eee m Power Factor 400 000 200 000 0 1 250 4 18 2014 1 25 2014 2 1 2014 28 2014 2 15 2014 2 22 2014 3 1 2014
19. view ALL the alarms associated with the selected power monitor You can scroll through the entire list and view the alarms associated with Power Quality as depicted in the below picture 9 PM5000 103_M6_DNet ls i x VI Power Enerav Demand O Setpoints Waveforms Harmonics Logs Wirina sA Ba C Show active alarms only Show all alarms Alarm Active Metering Status Voltage Phase V2 False Metering Status Voltage Phase V3 False Metering Status Voltage Over Range Indi False Metering Status Ampere Over Range Indi False Metering Status Wiring Diagnostics Active True Over Range Information V1G Over Range False Over Range Information V2G Over Range False Over Range Information V3G OverRange False Over Range Information VNG OverRange False IH Over Range Information 11 Over Range False Over Range Information 12 Over Range False Over Range Information I3 Over Range False Over Range Information l4 Over Range alse Power Quality Status Sag Indication Dete False Power Quality Status Swell Indication Det False Power Quality Status Transient Indication False ogs Status Data Log Full Fill And Stop alse Logs Status Event Log Full Fill And Stop False Logs Status Setpoint Log Full Fill And Stop False Logs Status PowerQuality Log Full Fill An False Logs Status Energy Log Full Fill And Stop False Logs Status Waveform Full False Logs Status TriggerData Full Fill And Stop False Output P
20. wire so that the burden of the wiring does not overload the CT and reduce system accuracy When wiring a PowerMonitor 5000 to existing CTs and metering devices the current sensing circuits of the PowerMonitor 5000 must be wired in series with the CT secondary and current sensing circuits of the existing metering devices Do not install overcurrent protection or non shorting disconnecting means in CT secondary wiring Connect the current sensing circuit to a low impedance earth ground at only one point Pay particular attention to the correct phasing and polarity of current sensing connections The diagrams use the dot convention to indicate transformer polarity The dot indicates the H1 and X1 terminals on the primary and secondary of the CT respectively Phasing of the CTs must correspond to the phasing of the voltage sensing connections The following wiring diagrams indicate typical current sensing connections to various types of power systems 43 of 68 Three Phase 3 or 4 wire 3 CTs Line L1 L2 L o N if used Voltage Mode Any 3 phase mode Shorting terminal l block by user Powermonitor 5000 l A Z ee a E lel S D ei AJo i de CTs by user i CT4 if j used ae LLL LLL i QO Load Ground Three Phase 3 wire 2 CTs Line L1 L2 L o Voltage Mode Any 3 phase 3 wire mode Shorting terminal block by user Powermonitor 5000
21. 03_M6_DNet L1 N Voltage 278 1 L2 N Voltage 282 3 v L3 N Voltage 283 0 v Avg L N Voltage 21v L1 L2 Voltage 485 1 v L2 L3 Voltage 4923 v L3 L1 Voltage 486 7 v Avg L L Voltage 488 0 v Pos Seq Voltage 488 7 vy Neg Seq Voltage a V Zero Seq Voltage eo V VoltageUnbal 09 L1 Current L2 Current L3 Current Avg Current N Current Last Cycle Frequency Average Frequency Voltage Rotation Pos Seq Current Neg Seq Current Zero Seq Current Current Unbal Logged in as Why Start Page Administrator Device Information Device Setup Device Configuration Device Viewer E Enable device E Enable real time logging E Enable auto data repopulation E Enable PQ events logging Parent group Factory Device class PowerMonitor 5000 M6 on EtherNetiP Time zone UTC 06 00 Central Time US amp Canada Name P M500OMG Live Motes Time sync Monthly Device username Device password p Click the Device Viewer link on the Device Setup page to access the real time data page The information is displayed on the VI tab This page also has the capability to select the Pause button to capture a particular dataset at any point of time and to select the Continue button to continue to view the real time data after the information has amps amps amps hoe Enerav Demand VO Setpoints Waveforms Harmonics Loas Wir
22. 3 8 2014 3 15 2014 Dec January2014 Feb Feb March 2014 Apr Sun Mon Tue Wed Thu Fri Sat Sun Mon Tue Wed Thu Fri Sat Units Domain s Meter Tag Efficient Industries Plant 1 Alay at 1 z hes ce be A Bar Hide Remove EN 1 Gectricity Cereal zs G amp 8 FMT 2 2 4 G fa El eS Eee Production Real Pow er Derr Wis 4 1 16 if 9 10 11 12 13 14 15 Efficient Industries Plant 19 20 21 22 232425 16 17 18 20 21 22 Bar Hide Remove n 1 Bectricity Cereal An a7 an an An a an a ar an ay Aan An Production Real Energy Net Click on Friendly O Production Line on the left and select Real Energy Net to view the electricity consumption of this line Repeat the same for the other production lines to view corresponding individual electricity consumption trends Meter Data Trend Calendar Trend Meter Setup Time zone UTC 06 00 Central Time US amp Canada v V Show grid lines Expor Data 2 000 000 3 750 1 800 000 4 3 500 1 600 000 3 250 1 400 000 3 000 4 1 200 000 2 750 pogo g 1 000 000 2 500 4 800 000 2 250 4 600 000 2 000 400 000 1 750 4 200 000 4 1 500 7 eT Ce es ee ee ee ee ee ee ee ee ee eee ee ee 4 25 2014 2 1 2014 2 8 2014 2 15 2014 Select a meter tag to display on graph v Units Domain s Meter Tag kw Efficient Industries Plant 1 Electricity Cereal Production Real Power Demand Efficient Industries Plant 1 Electricity
23. 4 Create an Electricity Group in the Engineering Sub Domain Under Groups click on the Engineering sub domain under Efficient Industries Plant 1 and click Add Select Engineering for the Parent Group Do NOT Check This group is a domain Enter Electricity for the Name Enter 15 for the Default log rate Enter Efficient Industries Plant 1 for the Report title line 1 Enter Engineering Electricity for the Report title line 2 Click Save http localhost FTEnergyMetrix default aspx fay gt Page Safety Tools FactoryTalk EnergyMetrix ares Mestat Page x ChartsPius Help Log oul System Meters Reports _ Custom Add Group 2 System Status Groups Parent group E 3 f Efficient Industries Plant 1 Devices Roles and Users Rate Schedules Multi Purpose Report Scripts il Alarm Setup Unit Setup Configuration Default log rate 15 Configuration Report iHa li g Reports titie g Efficient Industries Plant 1 F My User Settings About Reports title line Engineering Elecicity CS lt s CS S S Layout Save Restore Collapse Name iaci Engineering Electricity Electricity Meters Not Assigned to Group Contribution factor a Save Factor Cancel 5 Create a Steam Group in the Engineering Sub Domain Under Groups click on the Engineering sub domain under Efficient Industries Plant 1 and click Ad
24. 4M Displayed Segment Total cycles 13 Previous fi of 1 Hegt VIVA Wa vA M 2 13 Show chame IM ET PF PF PF fF ff Show makes T FO OF FO PF PP The ability to identify various voltage sags allows industrial customers to deploy sag mitigation products such as Uninterruptible Power Supplies UPS and Dynamic Sag Correctors DySC This is often critical in safeguarding electronically controlled equipment i e process controllers programmable logic controllers variable frequency drives that are often sensitive to deviations in supply voltage helping to avoid costs in the form of equipment replacement and plant downtime 30 of 68 Viewing Harmonic Data When nonlinear devices such as a drive is present in an electrical system the sinusoidal voltage waveform is distorted into one comprised of frequencies that are multiples of the fundamental 60 Hz Having harmonics present in your system can lead to overheated transformers and other electrical distribution equipment drives shutting down and circuit breakers tripping The PowerMonitor 5000 can be used in conjunction with FTEM to understand how much harmonic waveform distortion is present in the electrical system This is expressed for individual harmonics as well as cumulatively in the form of Total Harmonic Distortion THD Step by Step Instructions 1 Click on the System tab on the left navigation pane 2 Click on the Factory group level in the left naviga
25. 8 0 048290 Yo of Reading 0 010730 0 000420 0 010244 0 007477 0 000973 0 006298 b of Reading 0 010703 0 000267 0 011646 0 008774 Tolerance 0 05 0 05 0 10 0 05 0 05 0 10 Tolerance 0 05 0 05 0 10 0 05 0 05 0 10 Tolerance 0 05 0 05 0 10 0 05 Note The PowerMonitor 5000 surpasses Class 0 2 Energy and Demand specifications Offset Count 1 393473 4 847005 0 000000 8 212891 4 847005 0 000000 Offset Count 8 993083 0 210286 0 000000 16 227783 0 210286 0 000000 Offset Count 6 164551 1 997477 0 000000 11 437826 Gain 0 999708 0 999101 0 000000 1 001226 0 999101 0 000000 Gain Yo 0 999223 0 998526 0 000000 1 000431 0 998526 0 000000 Gain 0 999655 0 999062 0 000000 1 000945 Displaying Data Log The PowerMonitor 5000 webpage publishes Energy Logs General Logs Event Log Time of Use Alarm Min Max 48 of 68 etc and Data Logs csv format that can be downloaded Allen Bradley EZA elatio auesl eee General_Logs Event Log csv 100 Time of Use Log csv 2 Load Factor Log csv 2 Alarm Log csv 100 Setpoint_Log csv 76 Min Max Log csv 82 PPPPPPPPOR From the navigation menu at the left click LoggingResults gt General_Logs Click the Min_Max_Logs csv link Alternative File Open Method Right click and Save csv file Close the file after you rev
26. AvgLLTHO 686 684 Avg THD 12 67 12 57 Graph Grid V Hide fundamental 15 0 12 0 9 0 6 0 B vi v2 Bu W L2 kVAR Voltage references WEE SAEN 4 This page also has the capability to select Pause to capture a particular dataset at any point of time and to select the Continue button to continue to view the real time harmonics data Upon detection of significant harmonic distortion harmonics can be mitigated with passive and active filters offered by our Encompass Partners Specific to drive harmonic mitigation line reactors isolation transformers and common mode chokes can be utilized Viewing Real Time RT Voltage and Current Data Using this feature you have the ability to view the live voltage current frequency and phase rotation data from the power monitors Step by Step Instructions 1 Click on the System tab on the left navigation pane 2 Click on the Factory group level in the left navigation tree and then the PM5000 M6 Live PowerMonitor 32 of 68 FactoryTalk EnergyMetrix sen Jve S Reports i Custom Layout Save Restore Collapse m J System Status _ Groups Devices Efficient Industries Plant 1 Ei Main Incoming E Packaging Roles and Users Rate Schedules Multi Purpose Report Scripts 2 Al Aarm Setup f Unit Setup A9 Configuration u E Configuration Report been captured iJ PM5000_1
27. D D omainMeter Engineering Electricity Ee i 4 l 2 Ss ae ayout Save Restore Collapse Meter Data Trend Calendar Trend J fe Efficient Industries Plant 4 J f Engineerin Meters Domain Electricity Change the Type from Manual to Electric For the Device select Power House a PowerMonitor 5000 Enter Power House as the Name Select appropriate time zone Click Save 62 of 68 Add a Meter Assigned to Groups Contribution factor Name Power House Notes UTC 05 00 Eastern Time US amp Canada 2 Add Meter Tags Click the Meter Setup Tab Click Add a new meter tag Domain Meter Engineering Electricity Power House Metertype Electric Device class PowerMonitor 5000 Calendar Trend Trend Meter Setup eae ae cary delete Meter Information Type Electric Assigned to Groups Contribution factor Device Power House Name Power House Notes ae UTC 05 00 Eastern Time US amp Canada Meter Tags Add a new meter tag ID Type Name Log Rate Alarms Add a new alarm Enabled Severity Hame Meter taq Trigger Email 63 of 68 3 Select device tag to load data from the dropdown menu Select Real Power Demand Change the log rate to 1 minute in order to capture data for this lab The default is 15 minutes for logging Return to meter screens Add a Meter Tag Meter tag type Device Real Power Demand Meter tag name
28. Files i e user can upload a scanned copy of Utility Energy Bill to Custom page Note The right View Pane is updated only after a sub category is selected of any given tab Tree Item 55 of 68 http localhost FTEnergyMetrix default aspx Windows Intern E Base Server 2008 R2 Standard x64 m gt gt gt a x ut Favorites 3 E Suggested stes E Web Sice Galery 7 FactoryTalk EnergyMetrix nn uy Stat Page Ex ChansPius Helo Logout Meters Reports Custom My Start Page Layout Save Restore Collapse System Status Your start page has not been configured yet Click the Configure My Start Page link below 3 Groups Configure My Start Page J Dewces Roles and Users G Rate Schedules Multi Purpose Report Scripts Qj Alarm Setup Unit Setup ZB Configuration LJ Configuration Report amp My User Settings E About Select the Parent Domain Efficient Industries Plant 1 under Groups and click Add Elhttp flocalhost FTEnerayMetrix default aspx a GJ E ap Page Safety Toos FactoryTalk EnergyMetrix gos Mestat Page ChartsPius Help Logout System y Meters Reports Custom Layout Save Restore Collapse G Devices 4 G Roles and Users Rate Schedules Multi Purpose Report Scripts Al Alarm Setup I This group is a domain Name Eficient Industries Plant 1 Notes w Unit Setup a
29. L19 Utilizing the PowerMonitor 5000 M6 and FactoryTalk EnergyMetrix 2 10 for Energy Management and Power Quality Analysis For Classroom Use Only LISTEN es Rockwell Allen Bradley Rockwell Software Automation Important User Information This documentation whether illustrative printed online or electronic hereinafter Documentation is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware software and firmware The Documentation should only be used as a learning tool by qualified professionals The variety of uses for the hardware software and firmware hereinafter Products described in this Documentation mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements including any applicable laws regulations codes and standards in addition to any applicable technical documents In no event will Rockwell Automation Inc or any of its affiliate or subsidiary companies hereinafter Rockwell Automation be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of or reliance o
30. M 4695 6 167670 5 4366 Woa e012 12 37 00 PM 4695 6 167600 7 4366 WOOT 12 36 00 PM 4695 6 167530 6 4356 Y22012 12 35 00 PM 4695 6 167460 8 4366 YY2012 12 34 00 PM 4366 7 Click on the PowerMonitor 5000 M5 link on the top of Power House Meter screen Verify the Power House Meter is udpating PowerMonitor 5000 metering data Click on the I O tab Under Relays click Close or Open Relays Did you hear anything Close the Power House Realtime window Domain Meter Engineering Electricity Power House Meter type Electric Device clasg Power mnitor S000 MS Thy Meter Data k Trend Calendar Trend Meter Setup N 65 of 68 Loggeain as labadmin FactoryTalk EnergyMetrix System Meters Reports at Custom N ayout Save Restore Collapse E Efficient Industries Plant 1 3 f Engineering Electricity ORI Steam FE 8 Create the OPC Meter ControlLogix OPC Meter type Electric Meter Data My Start Page Domain Meter Engineering Electricity Power House Device class PowerMonitor 5000 M5 Trend Calendar Trend A Meter Setup Power House Vi Power Eneray Demand 1 0 Harmonics Logs Wiring Diag Diag L1 N Voltage L2 N Voltage L3 N Voltage Avg L N Voltage L1 L2 Voltage L2 L3 Voltage L3 L1 Voltage Avg L L Voltage Pos Seq Voltage Neg Seq Voltage Zero Seq Voltage 277 2 V 2807 v 2816 V 72785 v aaz v aasa v
31. Real Power Demand Value type Real Power Demand og rate 1 Number of demand fr periods Address 8465 24 Tag format 32 bit Floating Point Unit kw Number of decimals to Ot display l Scale 1 Offset fo Log delta reading Rollover value Trend log parameter Max consumption per ooo hour 4 Click Save Click Add to add the following tags Real Energy Net and Apparent Power Demand both with 1 minute log rates e Click on Return to meter screens after adding the tags Return to meter screens Add a Meter Tag 64 of 68 5 When you return to meter set up the tags should be displayed as shown below Click Read device tags to open up a new window Click Refresh to ensure that the tags are being updated Click Refresh again if Status shows as NS not scanned It may take couple clicks few seconds for the data to start updating Read device tags Add anew meter tag Type Name Units Log Rate Address 5 Real Power Demand 1 minute T j Apparent Power Demand 1 minute 3 Real Energy Net n 1 minute Meter type Electric r a a _OCO373O OWS tg Meter Data Trend Calendar Trend MeterSetup Time zone UTC 05 00 Eastern Time US amp Canada Date Time 5 9 2012 12 39 PM Get Data E Page gt Enter Data 1 Min Auto Data Apparent Power Real Energy Real Power Demand Net Demand Date Time kVA kWh kV WO2012 12 39 00 PM 4695 6 167 740 5 4356 WO2012 12 38 00 P
32. S amp Canada Cereal Production ID 4 Electric Real Energy Net kWh Friendly O Production Line 541 764 Melzerlakes Production Line 691 331 Mittenpuffs Production Line 354 199 Total s 1 787 314 Change the start and end date as February 18th 2014 12 00 am and March 19th 2014 12 00 am to view the consumption report for the second billing cycle Please note from the below screenshot that the electricity consumption for all the production lines during second billing cycle is 1 291 258 kWh Time zone UTC 06 00 Central Time US amp Canada C Predefined Previous Month Custom Start date 2 18 2014 Starttime 2 00AM End date 37192014 Endtime 1200AM i tit wt vu o o 14 of 68 FactoryTalk En ergyMetrix Efficient Industries Plant 1 Efficient Industries Plant 1 Initial Consumption Report 2 18 2014 12 00 AM to 3 19 2014 12 00 AM Time Zone UTC 06 00 Central Time US amp Canada Cereal Production ID 4 Electric Real Energy Net kWh Friendly O Production Line 393 775 Melzerflakes Production Line 641 212 Mittenpuffs Production Line 256 272 Total s 1 291 258 Based on the data listed in the report you would be able to analyze the electrical energy consumption data across different lines or areas of the manufacturing area during different time periods From the above scenario Efficient Industries Plant 1 was able to save about 496 056 kWh difference of consumption during both
33. Trend 4 Calendar Trend j Meter Setup Meter Setup Cea aa Delete Type tem S Assigned to Groups Contribution factor Device ControlLogix OPC z Steam 100 Name Steam Meter Notes Time zone UTC 05 00 Eastern Time US amp Canada Access path PE 06 E Addan e meter tag Meter Tags ID Type Name Units Log Rate Address Alarms Add a new alarm Enabled Severity Name Meter taq Trigger Email Type Steam Usage as the Meter Tag name Select Steam Usage for the Value Type Change the Log rate to 1 Click on OPC Browser to select the Boiler_House_Steam Val_Total_Steam tag from the OPC Tag Browser pop up window as shown in the screenshot below Click Save in the OPC Tag Browser Click Save Add a Meter Tag Meter tag type Device Meter tag name Steam Usage Value type Steam Usage x Log rate fi I Log on change of state Conditional logging expression Number of demand periods fi http localhost DeviceId 11 amp MeterId 31 Select OP lt Tag Windows Internet Explorer lei es OPC Tag Browser t save Access path PEOS Selected item Boiler_House_Steam Val_Total_Steam OPC Groups OPC Tags Boiler_House_Steam Cmd_AlarmReset Boiler_House_Steam Enablein Boiler_House_Steam EnableOut Boiler_House_Steam Inp_NumRowsVis Boiler_House_Steam Inp_Pulse Boiler_House_Steam Set_Calc_Interval Boiler_House_Steam Set_Critical_Flow Boiler_House
34. _Basic page allows us to organize basic configuration parameters of the meter In the next few steps we ll explore a few parameters of interest Lal Configuration DateTime Logging l SystemGeneral CommunicationsNative NetworkText Setpoints_1_5 l Setpoints_6_10 Setpoint_Outputs a Liste m Metering Basic f S ommand Leal LoggingResults Security 46 of 68 Allen Bradley TAS Ufo al ie alo 6 0 0 mannan SystemGeneral NetworkText N S 5 Home Gi MeteringResults Metering_Basic PowerQuality Metering_Mode ad Status Gd Statistics V1_V2_V3_PT_Primary ud Calibration V1_V2_V3_PT_Secondary add Eaa aan oe a 11_I2_13_CT_Primary Logging SystemGeneral I1_I2_I3_CT_Secondary CommunicationsNative 5 E VG_PT_Primary Setpoints_1_5 Setpoints_6_10 Setpoint_Outputs Data_Log Metering_Basic 14_CT_Secondary od Command od LoggingResults Nominal_System_LL_Voltage Security VG_PT_Secondary 14_CT_Primary Nominal_System_Frequency Realtime_Update_Rate Single cycle averaged over 8 cycles Demand_Source Internal Timer Demand_Period_Length_Minutes Number_Demand_Periods Forced_Demand_Sync_Delay Apply Changes The power monitor can be wired to monitor a Wye Delta Open Delta or single phase configuration In this lab we ll use the Wye mode Change the Metering_Mode to Wye 1 Change the Voltage values to 240 volts and the Current values to 5 amps 2 Set the Nominal_System_LL_Voltage to 416 volts Th
35. _Steam Set_EquipFaceplateAnimation Boiler_House_Steam Set_FaceplateAnimation Boiler_House_Steam Set_High_Flow Boiler_House_Steam Set_Meter_Pulse_Factor Boiler_House_Steam Sts_Controller_Trigger Boiler_House_Steam Sts_DeviceState Boiler_House_Steam Sts_Digital_Input_Fault Boiler_House_Steam Sts_EnergyAlarmTrigger Boiler_House_Steam Sts_Value1 Boiler_House_Steam Sts_Value2 Boiler_House_Steam Sts_Value3 Boiler_House_Steam Sts_Value4 Boiler_House_Steam Val_Steam_Per_Calc_Interval Daila a Cioaar Cto Dg im PE06 Offline 3 6 Online aan Boiler_House_Steam CIP_Electrical_Energy_MSG_AverageCurrent 3 CIP_Electrical_Energy_MSG_kWh 4 CIP_Energy_MSG_kWh 4 CIP_Instance844_MSG CIP_Instance844_VIF_PowerData CIPElecEnraykWh GQ CIPEnergykwh ClPEnergyTIMER Program MainProgram SLC_Type_VIF_PowerData z SLC_Type_VIF_PowerF53MSG i TIMER ii Boiler Hou am Val_Total_Steam 11 Click on Return to meter screens after adding the tags Return to meter screens Add a Meter Tag 67 of 68 12 Click Read device tags to open up a new window Click Refresh to ensure that the tags are being updated Click Refresh again if the statusshows as NS not scanned It may take couple clicks few seconds for the data to start updating Read device tags Type Name Units Log Rate Address Device Steam Usage Kibs 1 minute Boiler_House_Steam Val_Tot
36. a from the installed power monitors This data is greatly beneficial to check the correlation of electricity consumption with the production data and determine energy intensity per product energy consumption across different shifts equipment that are left ON unnecessarily during weekends check utility billing accuracy etc After monitoring the electrical energy consumption over the course of the first billing cycle Efficient Industries implemented energy savings initiatives such as installing energy efficient lighting replacing full voltage starters with drives programming a low energy state for when equipment is not in use and shutting off machines during non production hours As a result Efficient Industries was able to visibly see energy and cost savings achieved from their initiatives 8 of 68 The list of steps to view the cumulative electricity consumption trends of the cereal production lines in the FactoryTalk EnergyMetrix software are described below Step by Step Instructions if Click on the Meters Tab and Select the Cereal Production Group 2 Select the Trend Tab 3 kes ti do tag Custom ayout Save Restore Collapse Efficient Industries Plant 1 amp Electricit j E Cereal Production a Z nendiy 3 4 Factory Sees Fan 3 4 Packaging E Air Compressors E Chiller E Power Factor E roduction Line 0 Melzerflakes Production Line bse lf Mittenpuffs
37. a listed in the report you would be able to analyze the electrical demand during different time periods From the above scenario Efficient Industries Plant 1 was able to save about 402 1 kW difference of electricity demand during both billing cycles Generating Power Factor Reports Utilities charge industrial customers for low power factors typically for power factor less than 0 85 Electrical equipment that generates inductive loads such as motors creates current that is not in phase with the current supplied by the electric utility Inductive loads cause the current waveform to lag behind the voltage waveform This causes a portion of the energy to return to the source hence leaving less usable power for the equipment With a PowerMonitor 500 Efficient Industries noticed that their power factor was around 0 73 during the first billing cycle The plant management has decided to improve the power factor by the use of capacitor banks In this below scenario Efficient Industries Power Factor line constitutes of a majority of the equipment contributing to the low power factor 20 of 68 The list of steps to generate the power factor report are described below Step by Step Instructions 1 Click on Reports tab on the left navigation pane 2 Click on a group level in the left navigation tree and click on a power factor report In this example we selected Efficient Industries Plant 1 group level and
38. aan v a7 v 4823 v Mas v Mon v s L1 Current 57546 amps L2 Current 55526 amps L3 Current 5356 1 amps Avg Current 55544 amps N Current 00 amps LastCycleFrequency 60 02 Average Frequency 60 01 Pos Seq Current 5530 3 amps Neg Seq Current 107 4 amps Zero Seq Current 113 3 amps Select the Meters Tab Navigate to the Steam Group under Engineering Click the Meters Tab on the right panel Click Add a new meter Change the Type from Manual to Steam For the Device select ControlLogix OPC Enter Steam Meter as the Name Select appropriate time zone Click OPC Browser and Select PE06 to the CompactLogix Click Save Logged in as FactoryTalk EnergyMetrix naamin MesatPaoe System 1 Meters Reports Custom Add a Meter Layout Save Restore Collapse al E Efficient Industries Plant 1 3 f Engineering Electricity S Power House El seam Meter Information Parent group stem o Type Sttam Device ControlLogxOPC O x Name Steam Meter ss i i C Notes Time zone UTC 05 00 Eastern Time US amp Canada Access path PEO6 P 9 Click Save to save Steam Meter 10 Add Meter Tags for the Steam Meter Click the Meter Setup Tab Click Add a new meter tag 66 of 68 OPC Groups Assigned to Groups Ca Domain Meter Engineering Steam Steam Meter Meter type Steam Device class OPC Server Meter Data di
39. al_Steam MeterTagsRealTimeRead Windows Internet Explorer go http localhost FTEnergyMetrix MeterJ gsRealTimeRead aspx MeterId 3 h 4 X S sng w Favorites 33 Suggested Sites feb Slice Gallery 7 meterTagsRealTimeRead fy D E mm Page Safety Tags Status Taq Name Address Value Last Read Time Steam Usage Boiler_House_Steam Val_Total_Steam 29456 5 9 2012 1 01 47 PM 13 Click on the Meter Data Tab a click Current oe ue a the a is being logged T Time zone UTC 05 00 Eastern Time US amp Canag Date Time 519 201 21 05 PM Get Data Page gt Enter Data i 1 Min Auto Data Steam Usage Date Time Kibs Sor2012 1 05 00 PM 295525 5 9012 1 04 00 PM 279522 5 S or2012 1 03 00 PM 279492 5 5 2012 1 02 00 PM 279462 5 Publication XXXX XX X EN P Month Year Supersedes Publication XXXX XX X EN P Month Year Publication XXXX XX X EN P Month Year Supersedes Publication XXXX XX X EN P Month Year Publication XXXX XX X EN P Month Year Supersedes Publication XXXX XX X EN P Month Year Publication XXXX XX X EN P Month Year Supersedes Publication XXXX XX X EN P Month Year Copyright 2011 Rockwell Automation Inc All rights reserved Copyright 2011 Rockwell Automation Inc All rights reserved Copyright 2011 Rockwell Automation Inc All rights reserved Copyright 2011 Rockwell Automation Inc All rights reserved
40. alk EnergyMetrix arsimin ME StatPaae Px ChansPius Help Logout Meters Reports Custom My Start Page Layout Save Restore Collapse System Status Your start page has not been configured yet Click the Configure My Start Page link below J Groups ai Devices Roles and Users G Rate Schedules Multi Purpose Report Scripts Qj Alarm Setup Unit Setup JB Configuration LJ Configuration Report amp My User Settings About We have created all the Groups and Devices ey al http localhost FTEnergyMe b Suggested Sites E Web Slice Gallery FactoryTalk EnergyMetrix O start Page fXcharisPlus Help Logout Administrator Device Status Groups E Efficient Industries Plant 1 Add a device show all child devices Cereal Production y Online not Online tag Mot i Factory Pennal i o n papel one E orn HE Disave Fackaging Domain Cereal Production E Efficient Industries Plant 1 Friendly Production Line E Cereal Production Friendly Production vo ES Melzerlakes Productic Mittenputis Production L Factory Packaging z Air Compressors E Chiller Power Factor Roles and Users Pe The PM5000M6 Live device is a live Power Monitor 5000M6 The other devices are disabled 7 of 68 Part 2 Energy Management In this section we work with an imaginary factory named Efficient Industries w
41. also have the capability to add a new report or build a new one on top of the existing report Reports 4 You can view the demand report in various file formats pdf excel html rtf tiff This can be achieved by selecting the appropriate Export type from the Report Information section Report name Demand Reet S Report template DemandAnaysis O Reportfile Demandanaiysisps H Report parent group Eficientindustries Pati i H xporttype PDF 5 5 You have options to view the electricity demand report during specific time durations by selecting appropriate Predefined or Custom options under the Report Parameters section 18 of 68 a By selecting the Predefined option you have an option to quickly select the time duration based on standard 3 th sets such as Previous Month Previous Year Year to Date etc b By selecting the Custom option you now have the capability to specify exact date and time duration during which you want to view the demand report In this scenario enter Jan 18 2014 12 00 am and February 17 2014 12 00 am as start and end dates to view the demand report for the first billing cycle Time zone UTC 06 00 Central Time US amp Canada C Predefined Previous Month custom Startdate iig2014 Pick Starttime 12 00AM End date 27 2014 End time 12 00AM 6 Upon making these selections you can click on View
42. and during different shifts develop a strategy to perform staggered startup of the plant equipment and evaluate the utility demand response programs for better incentives 15 of 68 In this below scenario Efficient Industries Air Compressors line constitutes of a majority of the equipment contributing to their electricity demand The list of steps to view the electricity demand trends of the meter installed on Air Compressors line are described below Step by Step Instructions 1 Click on Meters tab on the left navigation pane of the FTEM 2 Click on a Domain level and corresponding Meter group in the left navigation tree In this example we selected Efficient Industries Plant 1 domain level and the Packaging group Change the date range from Jan 18 2014 to March 19 2014 _ Custom nepeul t gt Layout Save Restore Collapse al E Efficient Industries Plant 1 Q Electricity Cereal Production S Friendly O Production Line H Melzer akes Production Line Mittenpuffs Production Line Factory KJ Fan SS Hvac K Main Incoming 3 Packaging 4 Air Compressors P KJ Chiller Power Factor Meter type Electric Device class PowerMonitor 500 Meter Data Kien gt Calendar Trend _ Meter Setup Time zone UTC 06 00 Central Time US amp Canada V Show grid lines Export Data No meter tags selected Dec Januar
43. ansansaeseseesersensansaneaees 15 Generating Power Factor Reports ccccccsssssssssscssssssssessssessssseesesssseesesseseesssacsesssseesesaeseesesacsesessacsesessacseseeseusesassesersassesarsansesanses 20 Generating Billing Reports a iccos0s anaes mocoscanstcencsssiedesiscaueenmasapaassicaniecdnensabcinnd lt nsed andsasoconectats dhaea sednd unslteenesauiasonscutd snucnpeniesdensltdeadedeneomenskd sauce 23 4 Part 3 Understanding Power Quality ccccssccsscsssssrssscssssssscsssesssceseecsseeseeseseseecessesaeeseesaseesaesaseesaeeeseesaseeseesaseesaesaseesates 28 NTO VMI WG OOS sahara ccs E ATE A E E AA O A oe ecto A A A E E AA 28 VIEWNg Vea IMO Dala cc esecincn sete energs oeeennt set and e ianea EEES EEEO NEER EAE EEEE ENEA OT EEEE EA ENTENATAN ETE 31 Viewing Real Time RT Voltage and Current Data cccccccssccssscssssscsssscsssecessseecsseecsssecessecessseesasseseseecesaeeesaseesasaesasateasateesaseess 32 EOR MEIN Sart E E EA AAA A EA AAE EE E EE E EE EE N 34 Viewing Wiring Information cccceccccssssssssscsscssssssssssessesscsecsessessesseseeseesessesseseeseesausesseseeseeseesaesausasseseesersarsansausanseseesersansansaneates 36 5 Appendix 38 PEPON TO oa e E ec A A E E E eee 38 B Configuring PowerMonitor 5000 Hardware c cccccscsscsssssssscsecsscsscsssessecseceecsecascessessesseseesaesassaseeseeseeseesaesatsasseseeseeseesaesaesatees 45 C Configuring FactoryTalk EnergyMetrix Software ccsscccssessccsss
44. arge 3 588 5 kW 1 94 6 961 65 Subtotal 26 363 03 Customer Charges Description Quantity Rate Charge Customer Charge 29 0 Day s 0 9205 26 69 Subtotal 26 69 26 of 68 From the above scenario Efficient Industries Plant 1 was able to save about 31 043 difference of electricity costs during both billing cycles through various energy efficiency initiatives Thus monitoring and analyzing data would be greatly beneficial to identify various energy efficiency opportunities and also to validate the cost savings achieved by implementing these opportunities 27 of 68 Part 3 Understanding Power Quality Power quality events generally referring to deviations from an ideal sinusoidal voltage waveform can lead to significant cost in the form of plant downtime and equipment replacement cost There are several types of electrical disturbances but the ones with the greatest effects on industrial customers are voltage sags transients and harmonics Viewing Voltage Sags Voltage sags are one of the most important power quality problems facing many industrial customers They are a reduction in AC voltage that can last from 0 5 cycles to 1 minute These are usually caused by system faults or heavy startup current due to switching on loads and can result in damaged equipment data corruption errors in industrial processing and system halts Step by Step Instructions 1 Click on the Meters tab on the left navigation pane
45. as FactoryTalk EnergyMetrix abaamn MestatPaae Pe Meters Y Reports Mf Custom h Device Status Refresh Show all child devices System Status Legend C Online Online not fully scanned C Online tag error s E Groups Layout Save Restore Colapse J Devices Domain Electricity 3 EE Efficient Industries Plant 1 There are no devices in the selected group s FE Engineering Electricity Jj J _ Roles and Users J J Rate Schedules FJ Multi Purpose Report Scripts A Alarm Setup Unit Setup a p Configuration J Configuration Report ff My User Settings i ee ee Once the device configuration displays in the right view pane select Electricity for the Parent Group Select PowerMonitor5000 M5 on EtherNet IP for the Device Class Enter Power House as the Name Leave the Device User name Password blank Security is not eabled for this lab Check Enable device Enable real time logging and Enable auto data repopulation Enter AB_ETHIP 1 192 168 1 5 for the Communication path Click Save 2 Click on Test Connection and Verify Connection Successful Perform the test connection three more times to ensure the first test did not reflect a cache status 60 of 68 labadmin FactoryTalk EnergyMetrix vr MvStartPage System N Meters Reports Custom Device Setup System Status Groups _ 4 f Efficient Industries Plant 1 Device Info
46. button to view the demand report of the selected meters a Cl a Reports We Pan Mam Foam 7 You will notice an initial report generation message and then be able to view the report in the selected format Fa cto ryTa Ik EnergyM etrix Efficient Industries Plant 1 Efficient Industries Plant 1 Demand Report 1 18 2014 12 00 AM to 2 17 2014 12 00 AM Time Zone UTC 06 00 Central Time US amp Canada kW Peak Demand Summary Air Compressors 4025 1 kW 100 0 2 16 2014 5 00 00 PM Total 4 025 1 kW 100 0 Worst Case Peak Demand Analysis Air Compressors 4025 1 kW 100 0 2 16 2014 5 00 00 PM Total 4 025 1 kW 100 0 Please note from the below screenshot that the electricity demand during the first billing cycle is 4 025 1 kW 19 of 68 8 Change the start and end date as February 18th 2014 12 00 am and March 19th 2014 12 00 am to view the demand report for the second billing cycle Please note from the below screenshot that the electricity demand during second billing cycle is 3 623 kW FactoryTalk En ergyMetrix Efficient Industries Plant 1 Efficient Industries Plant 71 Demand Report 2 18 2014 12 00 AM to 3 19 2014 12 00 AM Time Zone UTC 06 00 Central Time US amp Canada kW Peak Demand Summary Air Compressors 3 623 0 kW 100 0 2 24 2014 2 00 00 PM Total 3 623 0 kW 100 0 Worst Case Peak Demand Analysis Air Compressors 3 623 0 kW 100 0 2 24 2014 2 00 00 PM Total 3 623 0 kW 100 0 Based on the dat
47. d Select Engineering as the Parent Group Do NOT Check This group is a domain Enter Steam as the Name Enter 15 for the Default log rate Enter Efficient Industries Plant 1 for the Report title line 1 Enter Engineering Steam for the Report title line 2 Click Save AOA 58 of 68 el http localhost FTEnergyMetrix Default aspx FactoryTalk EnergyMetrix Logged in as labadmin System Meters Reports Layout Save Restore Collapse System Status Groups E Efficient Industries Plant 1 gt E i etic fp A E ap Pager Safety Tools My Start Page x ChartsPlus Help Logot Add Group aco axxs Parent group Engineering I This group is a domain Name Steam Devices Roles and Users Rate Schedules Multi Purpose Report Scripts All Alarm Setup w Unit Setup Configuration J Configuration Report 2 My User Settings About Default log rate 15 Reports title ee Efficient Industries Plant 1 Reports title line 5 Engineering Steam Meters Not Assigned to Group Meters Assigned to Group Contribution factor Contrib factor Save Canc Set up Devices and Meters in a FactoryTalk en project Devices are physical entities that FactoryTalk EnergyMetrix communicates with over a network Setting up a device in FactoryTalk EnergyMetrix establishes communication and creates database definitions for the
48. ds From the above scenario Efficient Industries Plant 1 was able to improve the power factor to 0 88 by using capacitor banks Generating Billing Reports Using this feature you have the ability to view the utility billing reports based on the electricity measurements such as electricity consumption kWh electricity demand kW and power factor from the power monitors combined with the respective rate schedules of the manufacturing plant This data is greatly beneficial to check the accuracy of utility billing prioritizing energy efficiency projects based on energy costs negotiating a better rate structure with utilities etc The list of steps to generate a billing report are described below Step By Step Instructions 1 Click on Reports tab on the left navigation pane of the FTEM 2 Click on a group level in the left navigation tree and click on a billing report In this example we select Efficient Industries Plant 1 group level and the Billing Analysis report 23 of 68 5 Reports System Meters C Reports S Custom A Layout Save Restore Colapse pa View generated reports i View all report jobs J Global Reports ies Plant 1 ing Analysis sum ption Improvement Report EJ Demand Report EJ Initial Billing Report EJ Initial Consumption Report E Power Factor Report Cr Cer C e eere Report name Billing Analysis Report template Billing R
49. eport file Billing rpx Report parent group Efficient Industries Plant 1 Rate schedule Alliant Cg 2 TOD Export type Report Parameters Timezone UTC 06 00 Central Time US amp Canada v O Predefined Previous Month w lt i lt lt lt Custom Start date 2 18 2014 Pick Start time 12 00 AM End date 3 19 2014 Pick End time 12 00 AM Auto run report jobs Name Notes Schedule Add a new report job Select By Meters You now have the capability to View Edit and Delete the selected report You also have the capability to add a new report or build a new one on top of the existing report You can view the billing report in various file formats pdf excel html rtf tiff This can be achieved by selecting the appropriate Export type from the Report Information section In this section you also have the capability to run the billing reports based on different rate schedules The rate schedule for Efficient Industries is Alliant Cg 2 TOD Report Information Report name Billing Analysis Report template Billing Report file Billing rpx Report parent group Efficient Industries Plant 1 Rate schedule Alliant Cg 2 TOD xport type PDF_ V d S lt 4 You have options to view the billing report during specific time durations by selecting appropriate Predefined or Custom options under the Report Parameters sect
50. for higher voltages e Neutral voltage and ground voltage connections 10 Current sensing wiring openings e Nominal input current 5 amps e Use current transformers CTs to connect to power system 40 of 68 11 Virtual wiring correction indicator Indicates that the sensing voltage and or current wiring has been modified in the power monitor configuration Connecting via USB The USB Device port can be used to set up a temporary point to point connection between a personal computer and the PowerMonitor 5000 unit This connection is used for configuration data monitoring diagnostics and maintenance by using the unit s built in web pages The USB Device port is a standard USB Mini B receptacle You need to install drivers to enable USB communication You may download the USB drivers from the http www rockwellautomation com compatibility web page Configuration Lock The configuration lock is a switch located on the PowerMonitor 5000 When the configuration lock is switched into the lock position it prevents unauthorized changes to the PowerMonitor 5000 unit setup The configuration lock is shown in the PowerMonitor 5000 image below Configuration Lock e g Wiring Voltages and Current Voltage sensing The PowerMonitor 5000 is capable of monitoring a variety of three phase and single phase circuits Circuits rated up to 690 VAC line to line may be connected directly Higher voltages require potential transformers PTs also known a
51. from the below screenshot that the power factor during the first billing cycle is 0 73 Efficient Industries Plant 1 Factory Talk EnergyMetrix Efficient Industries Plant 1 Power Factor Report 1 18 2014 to 2 17 2014 Time Zone UTC 06 00 Central Time US amp Canada Overall Power Factor 0 73 Overall Power Factor Period Power Factor 0 00 T j T I W21 72014 1 25 2014 1 20 2014 2 2 2014 2 6 2014 2 10 2014 2 14 2014 Day Real Energy Reactive Energy Power Factor 1 18 2014 1 005 0 166 7 0 80 1 19 2014 4017 3 3 233 6 0 7T 120 2014 4665 9 4 848 0 0 69 8 Change the start and end date as February 18th 2014 12 00 am and March 19th 2014 12 00 am to view the power factor report for the second billing cycle Please note from the below screenshot that the power factor during second billing cycle is 0 88 22 of 68 Factory Talk EnergyMetrix etn dusts Pla Power Factor Report 2 18 2014 to 3 19 2014 Time Zone UTC 06 00 Central Time US amp Canada Overall Power Factor 0 88 Unity 0 80 0 60 E Overall Power Factor 0 40 Period Power Factor 4 20 00 I I I j I I 2212014 2 25 2014 4 1 2014 S 5f2014 aN 2014 A2014 3 17 2014 Day Real Energy Reactive Energy Power Factor 2 18 2014 6 496 1 3 676 6 0 87 2 19 2014 6 225 4 3 513 3 0 87 2 20 2014 5 5727 3 586 7 0 84 Based on the data listed in the report you would be able to average power factors during different time perio
52. from the webpage Configure the PowerMonitor 5000 using a web browser In the field the initial configuration is by using the power monitor s USB web interface Once initial setup is complete you can continue configuring the PowerMonitor 5000 unit by using either its USB or network Web interface by using optional software or by communicating with the power monitor s data table In this lab we will configure the PowerMonitor 5000 using EtherNet IP 45 of 68 Basic Meter Configuration Basic metering and all other features can be configured through the web interface This web interface can be accessed through both the USB device port and the IP Address Up to this point we have done all configurations through the USB device port We will now use the EtherNet IP port to access the web interface and configure the basic metering for the PowerMonitor 5000 Select the Internet Explorer PowerMonitor 5000 shortcut on your desktop The PowerMonitor 5000 web interface will display in your browser with the IP Address of the PowerMonitor in the Internet Explorer address bar If you are not directed to the web interface type the IP Address of the PowerMonitor 5000 192 168 1 5 into the address bar Click Enter and the PowerMonitor 5000 home page will display Navigate to the basic metering folder From the navigation menu on the left click Configuration gt Metering Basic The Metering_Basic page displays as shown on the next page The Metering
53. hich has 3 cereal production lines Friendly O Melzerflakes and Mittenpuffs We will take you through a list of scenarios to demonstrate how deploying PowerMonitors and FactoryTalk EnergyMetrix FTEM software helps to identify potential energy efficiency projects and demonstrate savings Any industrial electricity bill is typically comprised of 4 components Standard Service Charge Electricity Consumption kWh Electricity Demand kW and Power Factor As a part of this lab we will guide you through a series of steps to analyze the data and validate the savings achieved through energy efficiency initiatives This section is comprised of four main parts Viewing Electricity Consumption trends amp Generating consumption reports Viewing Electricity Demand trends amp Generating demand reports Generating Power Factor reports Generating Billing reports Viewing Electricity Consumption Trends PowerMonitor devices and FactoryTalk EnergyMetrix software can be used to drive accountability and results when looking to reduce energy consumption and consequently energy costs In this scenario Efficient Industries purchased three PowerMonitor 1000s to achieve real time monitoring of electricity consumption for each cereal production line Using the energy consumption trends feature in FTEM software you have the ability to view the real time net electricity consumption kWh and net reactive energy consumption kVARh dat
54. iew its content Commanding PowerMonitor 5000 actions From the navigation menu at left click Command gt System_Registers E d From the Command_Word_One dropdown select Force Relay Output 1 On 49 of 68 System_Registers Command_Word_One No Action x No Action Command_Word_Two Set KWh Register Set KVARh Register Set KVAh Register Set KAh Register Clear All Energy Registers Set Status 1 Count Set Status 3 Count Set Status 4 Count Force KYZ Output On Force KYZ Output Off GForce Relay 1 Output On aero Dutour of be Remove Force from Relay 1 Force Relay 2 Output On Click the Apply Changes button System_Registers Command_Word_One Command_Word_Two Apply Changes X a m Did you hear the click of the relay turn on From the Command_Word_One dropdown select Remove Force from Relay 1 Once selected click the Apply Changes button PLEASE DO NOT Restore Factory Default settings The EtherNet IP address settings will change and you will lose communications with the unit 50 of 68 Wiring Diagnostics The PowerMonitor 5000 features virtual wiring diagnostics We will be able to demonstrate wiring diagnostics in the lab as we have the power monitor wired with three phase power From Command gt System Registers gt Command Word Two select Perform Wiring Diagnostics Click Apply changes Go to Status gt Wiring Diagnostics to view the diagnostic results
55. ing Al 4 gt 33 of 68 Viewing Alarms Using this feature you have the ability to view active and all alarms associated with the Power Monitors Step by Step Instructions 1 Click on the System tab on the left navigation pane of the FTEM 2 Click on the Factory group level in the left navigation tree and then click on the PM5000M6 Live PowerMonitor Logged in as FactoryTalk EnergyMetrix My Start Page Administrator Meters nf Reports Device Setup Custom i m a N Oo Layout Save Restore Collapse Device Information pee PE System Status I Enable device Groups Devices Enable real time logging E Enable auto data repopulation E Enable PO events logging Parent group Factory Device class PowerMonitor 5000 M6 on EtherNetP Name PMS000M6 Live 4 Rate Schedules i UTC 06 200 itral Time US amp iada E Multi Purpose Report Scripts Time zone UTC 06 00 Central Time US amp Canada J Alarm Setup Time sync Monthly Unit Setup Device username m Configuration ie E Configuration Report Bie ct he 3 Click the Device Viewer link on the Device Setup page to access the alarms information on Alarms tab On this page you have the options to view Show active alarms only and Show all alarms 4 This page also has the capability to select the Pause button to capture the alarm sta
56. ion c By selecting the Predefined option you have an option to quickly select the time duration based on standard sets such as Previous Month Previous Year Year to Date etc By selecting the Custom option you now have the capability to specify exact date and time duration during which you want to view the billing report In this scenario enter Jan 18 2014 12 00 am and February 17 2014 12 00 am as start and end dates to view the billing report for the first billing cycle 24 of 68 Report Parameters Time zone UTC 06 00 Central Time US amp Canada C Predefined Previous Month Custom Start date haszo OOOO Pick Starttime 12 00AM End date 27 2014 End ime 12 00AM OOOO Upon making these selections you can click on View button to view the billing report of the selected meters p Di a Reports E E ae Gey e You will notice an initial report generation message and then be able to view the report in the selected format FactoryTalk EnergyMetrix Eai ai Pan Efficient Industries Plant 1 Billing Analysis 1 18 2014 12 00 AM to 2 17 2014 12 00 AM Time Zone UTC 06 00 Central Time US amp Canada Rate Schedule Alliant Cg 2 TOD Total Charge 119 438 29 Energy Charges Description Quantity Rate Charge On Peak Energy Charge 789 810 5 kWh 0 05797 45 785 31 Off Peak Energy Charge 997 503 0 kWh 0 03931 39 211 84 Subtotal 84 997 15 Demand Charge
57. is is equal to 240 volts times the sqrt of 3 Click Apply Changes Click OK on the confirmation pop up after every Apply Changes action Message from webpage X Uw A Configuration saved successfully Apply Changes Displaying Metering Results Data From the navigation menu at the left click MeteringResults gt RealTime_VIF_Power 47 of 68 Look over the voltage and current readings of the PowerMonitor 5000 A labeled image of the demo is shown below RealTime_VIF_Power Metering_Date_Stamp 31811 Metering_Time_Stamp 162329 Metering_Microsecond_Stamp 696632 V2_N_Volts 0 V3_N_Volts 0 VN_G_ Volts 0 Avg_V_N_Volts 57 565 V1_V2_Volts 115 102 V2_V3_Volts 0 V3_V1_Volts 0 Avg_VL_VL_Volts 115 102 I2_Amps 0 I3_Amps 0 I4 _Amps 0 Avg_Amps 0 588 Cranuianc Us ca n77 3 From the navigation menu at the left click on Calibration gt CalibrationData Phase i Phase 2 Phase 3 Parameter Voltage Current Power Voltage Current Power Parameter Voltage Current Power Voltage Current Power Parameter Voltage Current Power Voltage Test Input 347 5 1 735 120 2 500 0 300 Test Input 2 500 0 500 Test Input UUT Reading 347 021606 5 001143 1 735538 120 031860 2 500536 0 300145 UUT Reading 347 037231 4 999979 1 735178 120 008972 2 499976 0 300019 UUT Reading 347 037140 5 000013 1 735202 120 010529 b of Reading 0 006227 0 022850 0 030994 0 026550 0 02144
58. ject A typical setup is to organize meters into domain groups by energy type substation boiler room or other function A second domain is then set up to organize meters into energy accounting groups e Group A named collection of devices and meters that represent a subdivision of your enterprise such as a department or process e Domain A group that is assigned roles and users Users assigned to a domain may only access objects assigned to that domain This allows an administrator to restrict user access to specific parts of the system This lab will setup the FactoryTalk EnergyMetrix project for Efficient Industries Plant 1 Only a few selected Groups and Domains will be added for Efficient Industries Plant 1 Efficient Industries Plant 1 EFFICIENT INDUSTRIES PLANT 1 Parent Domair Engineering Subdomain l Accounting Subdomain Electricity Group Data Canter Subdomain Production 2 PMI 500 shipping Receiving DC PM W250 aevet Production 2 Subdomain Fuels Group 3 Mair P wu PM 100 use PM 5000 M 2 PM 1000 Stat f Ait Group Ajat TE Cy r Vv ater Maen N PAMA 1001 p topar Fe ui a i m Ar Flow Production 2 54 of 68 Engineering includes all of the energy data points and is subdivided into energy types for load profiling consumption reporting and power quality monitoring needs Accounting organized into production ancl shipping receiving departments for cost allocation analysis
59. lect RSLinx OPC server then click Save The Server should now show under Device Communications Click Save to add the device 61 of 68 FactoryTalk EnergyMetrix ey My Start Page ChartsPlus System Meters nf Reports Ls Custom Add Device Layout Save Restore Collapse out Sae sts Stans aD Ca i System Status Groups Device Information d Efficient Industries Plant 1 T ae M Enable device fs Engineering 4 Devices M Enable real time logging Gl EE SAE Industries Plant 1 Parent group Steam H f Engineering i Electricity Device class OPC Server on Ethernet 7 Be Powe Name ControlLogix OPC Roles and Users tes t Rate Schedules Time zone UTC 05 00 Eastern Time US amp Canada v Multi Purpose Report Scripts G E Efficient Industries Plant 1 i E Engineering Device Communications A Alarm Setup Ba Unit Setup FactolyTatk tive Data s rve i 2 Configuration EJ Configuration Report 4 My User Settings About OPC Servers fag RSLinx OPC Server io RSLinx Remote OPC Server Setting up PowerMonitor 5000 and ControlLogix OPC Meters 1 Create the PowerMonitor 5000 Meter Select the Meters Tab Navigate to the Electricity Group under Engineering Click the Meters Tab on the right panel Click Add a new meter Logged in as E FactoryTalk EnergyMetrix raami M Sat Page System Meters Y Reports x A
60. n this Documentation No patent liability is assumed by Rockwell Automation with respect to use of information circuits equipment or software described in the Documentation Except as specifically agreed in writing as part of a maintenance or support contract equipment users are responsible for e properly using calibrating operating monitoring and maintaining all Products consistent with all Rockwell Automation or third party provided instructions warnings recommendations and documentation e ensuring that only properly trained personnel use operate and maintain the Products at all times e staying informed of all Product updates and alerts and implementing all updates and fixes and e all other factors affecting the Products that are outside of the direct control of Rockwell Automation Reproduction of the contents of the Documentation in whole or in part without written permission of Rockwell Automation is prohibited Throughout this manual we use the following 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 m A ULILA 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 o
61. of the FTEM 2 Click on the Factory group level in the left navigation tree and then the Main Incoming meter Afterwards click on the Power Quality Summary tab on the right pane Logged in as FactoryTalk EnergyMetrix My Start Page fx ChartsPlus Help Administrator maces wees J a Domain Meter Efficient Industries Plant 1 Electricity Factory _ Custom P P Meter Data _ Meters Trend Calendar Trend Power Quality Summary J Layout Save Restore Collapse Power Quality Summary a E Efficient Industries Plant 7 C Electricity reee 60 Pm lt s s f Cereal Production Fro deined dais rangoj TZS D Z2 J Friendly O Production Line eae Spiers 1 Eng dat Go SJ Melzerflakes Production Line ee ee eee Ba Ey Power quality events from 1 1 2014 through 4 30 2014 7 Category Occurrences LatestOccurrence Mean Std Deviation Trend of Occurrences View Command Trigger 2 3 6 2014 2 33 13 PM Delete 4 View Harmonics 6 3 6 2014 2 25 19 PM Delete A GJ Ar Compressors View DC Offset 1 3 6 2014 12 21 47 PM Delete J Chiller X Power Factor View Power Frequency 1 3 6 2014 12 12 23 PM Delete View Imbalance 2 3 6 2014 12 02 30 PM Delete View Undervoltage 2 3 6 2014 11 45 44 AM Delete View Sags Dips 6 3 6 2014 11 45 44 AM 193 14 6 Delete View Overvoltage 1 3 6 2014 11 08 39 AM Delete 28 of 68 3 On this summary page you will be able to view the list of
62. ort type from the Report Information section Report name Power Factor Repot Report template PowerFactor O Report file PowerFactor rpx Report parent group Efficient Industries Plant 1 xport type PDF 5 You have options to view the power factor report during specific time durations by selecting appropriate Predefined or Custom options under the Report Parameters section a By selecting the Predefined option you have an option to quickly select the time duration based on standard sets such as Previous Month Previous Year Year to Date etc b By selecting the Custom option you now have the capability to specify exact date and time duration during which you want to view the power factor report In this scenario enter Jan 18 2014 12 00 am and February 17 2014 12 00 am as start and end dates to view the power factor report for the first billing cycle 21 of 68 Report Parameters Time zone UTC 06 00 Central Time US amp Canada C Predefined Previous Month custom Startdate iig2014 Pick Starttime 12 00AM End date 247 2014 Pick End time 2 00AM 6 Upon making these selections you can click on View button to view the power factor report of the selected meters Reports Si Pa am Kay 7 You will notice an initial report generation message and then be able to view the report in the selected format Please note
63. r death property damage or economic loss Attentions help you identify a hazard avoid a hazard e recognize the consequence gt i SLE Labels may be located on or inside the drive to alert people that dangerous voltage may be present gt aE bels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures gt Energy Monitoring and Visualization utilizing Factory Talk EnergyMetnx Table of Contents Energy Monitoring and Visualization utilizing FactoryTalk EnergyMetrix s sennmeeneneennneennneee nese 3 1 Beloio you TOG ins cate neat gate e E E E E n 4 POUEI A E E E 4 Tools amp prerequisites seen cptectcinaceas tuo steered actetponnadernesnceepesieteusatoctenacnsusedbasuesuepdseetates tos aseuunsdedhenuesteptauetocondiattessuaeseatadoastanteostenseatetscen 4 2 Part1 Logging Into Factory alk EMCrOW MEUIX vccrscussaneeioverdearnnneuontemnmasiiietamnvenid anrnawanuniendiaaesanaudn 6 3 Part2 Energy Management oeunsossd neotunneusqensaenesdexoestegneabiaydvmnatiiasnastesoerosdiwotadaewedreoesbveas sameveatansitsencbenselatueloantaanecian atone EEE 8 Viewing Electricity Consumption TTENS cccccecsesesssssssssssscssssrssessessessesecsessesseseesaesaesesseseeserseesaesaesaseeseeseeseesaesassaseeseesansansaneansass 8 Viewing Electricity Demand Trends c cccsccscsssssssssssssessessesscsessessessesausecsecsesseseeseesausecseseeseeseesaesausasseseeseesars
64. rmation Device Configuration fs Engineering Device Viewer Devices a Efficient Industries Plant 1 After Connection Successful Click on Device Configure to experience the configuration of PovverMonitor5000 through FactoryTalk EnergyMetrix OPTIONAL Z Enable device M Enable real time logging a Upload configuratin first fe Engineerin 5 i IZ Enable auto data repopulation Electricity iPower House jj Power House J Parent group Electricity v Steam Device class PowerMonitor 5000 M5 on EtherNetIP Roles and Users Name Power House j Rate Schedules Multi Purpose Report Scripts 3 F Efficient Industries Plant 1 i fs Engineering A Alarm Setup Time sync Monthly Unit Setup l Configuration Device username O E ET Configuration Report Device password p e My User Settings About Device Communications Communications path JAB ETH 1 192 168 1 50 Comm timeout seconds Comm retries 2 Max messages fi Enable comm loss alarm N Test Connection Connection successful Add an OPC Device Click on the System Tab Navigate to Devices and select Steam under the Engineering subdomain Click Add a device Select OPC Server on Ethernet for the Device class Enter Contro Logix OPC for the Name and ensure the Parent group is Steam Check Enable Device and Enable real time logging Click OPC Browser and a window will pop up Se
65. rrection LED is illuminated on the PM5000 From the navigation menu at left click Status gt Wiring Correction to verify Input_I1_mapping reads 1 This confirms the polarity of current Input_l1 has been properly inverted and saved successfully You may also view the MeteringResults gt RealTime_VIF_Power Page and note that the L1_kW and Total_kW are now negative 52 of 68 Wiring Corrections Wiring _ Correction Commands 4 Input Vi Mapping 1 Input V2 Mapping 2 3 Input_V3_Mapping Input Ti Mapping nput_I2_ Mapping Input_I3 Mapping 3 Last_Cmd_Rejection_Status D Rejection_Information 0 Return to the Command gt Wiring_Corrections page Remove the wiring correction Select Remove all wiring correction Click Apply changes Verify the virtual wiring correction LED is not illuminated on the PM5000 53 of 68 C Configuring FactoryTalk EnergyMetrix Software This part of lab also uses the VMImage This part of the hands on lab will briefly introduce you to the FactoryTalk EnergyMetrix web interface and how to use it to configure a FactoryTalk EnergyMetrix system You will first create domains and groups then configure devices PowerMonitor 5000 ControlLogix via RSLinx Classic OPC and meters view trends calendar trends and then configure and run Consumption Billing Reports in different currencies Pareto reports and Custom Reports using Excel Set up Groups and Domains in a FactoryTalk EnergyMetrix pro
66. s Description Quantity Rate Charge On Peak Demand Charge 3 588 5 kW 7 65 27 451 87 Customer Demand Charge 3 588 5 kW 1 94 6 961 65 Subtotal 34 413 52 Customer Charges Description Quantity Rate Charge Customer Charge 30 0 Day s 0 9205 27 62 Subtotal 27 62 25 of 68 Please note from the above screenshot that the electricity costs during the first billing cycle is 119 438 On peak periods are defined as specified time intervals of high utility demand during which energy costs are higher Note that while less energy was consumed during on peak hours the user is spending more money for on peak energy use 8 Change the start and end date as February 18 2014 12 00 am and March 19th 2014 12 00 am to view the billing report for the second billing cycle Please note from the below screenshot that the total electricity costs during second billing cycle is 88 394 FactoryTalk EnergyM etrix Efficient Industries Plant 1 Efficient Industries Plant 1 Billing Analysis 2 18 2014 12 00 AM to 3 19 2014 12 00 AM Time Zone UTC 06 00 Central Time US amp Canada Rate Schedule Alliant Cg 2 TOD Total Charge 88 394 66 Energy Charges Description Quantity Rate Charge On Peak Energy Charge 602 657 4 kWh 0 05797 34 936 05 Off Peak Energy Charge 688 600 6 kWh 0 03931 27 068 89 Subtotal 62 004 94 Demand Charges Description Quantity Rate Charge On Peak Demand Charge 2 536 1 kW 7 65 19 401 38 Customer Demand Ch
67. s in FTEM software Step by Step Instructions 1 Click on Reports tab on the left navigation pane 2 Click on a group level in the left navigation tree and click on a consumption report In this example we selected Efficient Industries Plant 1 group level and Demand Report report As highlighted in the below screenshot this is a pre configured demand report for all the Air Compressors line FactoryTalk EnergyMetrix start Page x ChartsPus Help Le Administrator System A Cen ayout Save Restore Collapse Reports is Meters View generated reports Report Information Select By Me View all report jobs Report name Demand Report O Global Reports R PE Demana marsis OOZ e EE Efficient Industries Plant sE Eficient Industries Plant 1 sakes 3 8 Electricity LJ Billing Analysis Report file DemandAnalysis rpx Cereal Productior m E Consumption m o epon Report parent group Eficient industries Plant 1 Factory CI Demand Report p Packaging LJ Initial Billing Report itil POF H on E Initial Consumption Report Report Parameters E Power Factor Report l l Time zone UTC 06 00 Central Time US amp Canada v C Predefined Previous Month x Custom Startdate 11g2014 Stattime 12 00AM End date 2172014 Endtime i200AM 5 a 3 You now have the capability to View Edit and Delete the selected report You
68. s voltage transformers VTs to step the voltage down Wiring must conform to all applicable codes and standards In particular suitable overcurrent protection must be provided by the user with current and interrupting ratings selected to protect the wiring Pay particular attention to correct phasing and polarity of voltage connections The diagrams use the dot convention to indicate transformer polarity The dot indicates the H1 and X1 terminals on the high side and low side of the transformer respectively It is essential to have correct wiring for the power monitor to calculate correct power demand and energy usage Power is a vector product in a typical 3 phase balanced system phase voltage current to next phase voltage current is 120 degrees apart and it s critical that current signals line up with voltage signals with correct polarity It is a common issue in the field to have incorrect wiring A simple method to identify a typical consumption inductive electric load such as motors transformer load MCC building automation arch furnace lighting etc with correct wiring will show positive kW positive KVAR and lagging power factor When it s determined that there is incorrect wiring the correction is not a convenient task as it often requires waiting until the next planned shutdown to make the correction The PowerMonitor 5000 wiring diagnostics and virtual wiring connections are helpful in achieving correct metering results withou
69. ss Wiring Diagnostics amp Wiring Corrections information 4 This page also has the capability to select the Pause button to capture a particular dataset at any point of time and to select the Continue button to continue to view the real time voltage phasor information 36 of 68 E PM5000 103 M6 DNet sss E X VI Power Enerav Demand O Setpoints Waveforms Harmonics Loas wena jiams Diaa l Wiring Tests Command Status Waiting Command Perform Test Voltage Input Missing Test passed Current Input Missing Test passed L97 to C89 Passed L85 to C98 Passed L52 to L95 Passed Voltage Input Inverted Test passed Current Input Inverted Test passed Voltage Rotation Unknown 0 Current Rotation Unknown 0 m Phasor Diagram V1 486 1 v 0 0 degrees v2 4884 v 119 8 degrees 3 v3 4876 v 240 1 degrees 1 50 A 19 8 degrees 12 48 A 139 8 degrees 13 46 A 259 9 degrees The Real Time Device Viewer gives the user additional functionality to monitor real time power data 37 of 68 Appendix A Power 101 The PowerMonitor 5000 uses basic electrical principles to function and operate This appendix briefly describes electrical and power terms that are pertinent to the PowerMonitor 5000 functionality Ampere Amp I Unit of measure for current flowing in a circuit Volt V Unit of measure for a potential
70. ssscsssessseeseceseseecessesaseeseesessesaeseseesateesaesaseesaesaseesarsaseesasesanses 54 3 of 68 Before you begin About this lab Attendees will learn about how to use Rockwell Automation s Power Monitoring products in conjunction with FactoryTalk EnergyMetrix to optimize industrial customers power and energy usage e Part 1 Logging into FactoryTalk EnergyMetrix e Part 2 Energy Management Covers using Energy Management Trends and Reports to understand and take action on energy data e Part 3 Power Quality Covers using Power Quality Metrics to understand and identify mitigation for power quality issues Tools amp prerequisites Part 1 2 3 and 4 Lab VMWare image This image has FactoryTalk EnergyMetrix 2 10 and RSLogix 5000 V21 installed PowerMonitor 5000 M6 unit connected to 240V PanelView Component 600 Color Touch to demonstrate the Display Monitor Application 1426 DM is a C400 Note If not already running please select and run the Lab VMWare image on your workstation PC 4 of 68 5 of 68 Part 1 Logging Into FactoryTalk EnergyMetrix Open Internet Explorer The FactoryTalk EnergyMetrix login page is set up as the home page lt http localhost FTEnergyMetrix gt Log in with user name admin and password admin This login gives you administrator access to the Efficient Industries Plant 1 domain Login Windows Internet Explorer O x httosiiloc O a a ogin x eh 2o
71. store Collapse View generated reports Report Information Select By Mew all report jobs Report name initial Consumption Report Global Reports Report template Consumption E Eficient Industries Plan J E Efficient Industries Plant 1 Electric ity LJ Billing Analysis Report file Consumption rpx 3 a c E Consumption Improvement Report Report parent group Efficient Industries Plant 1 f Ts Friendly i Demand Cea E PoF E Los sa Time zone UTC 06 00 Central Time US amp Canada Packaging C Predefined Previous Month Start date 1 18 2014 Starttime 1200AM End date 2717 2014 Pick End time 12 00AM a E A 3 You now have the capability to View Edit and Delete the selected report You also have the capability to add a new report or build a new one on top of the existing report Reports 12 of 68 4 You can view the consumption report in various file formats pdf excel html rtf tiff This can be achieved by selecting the appropriate Export type from the Report Information section Report name initial Consumption Repot sssi lt is sS Report template Consumption H Report file Consumption rps Report parent group Eficientindustries Pati s i i SC iS CEvorttpe POF STD 5 You have options to view the consumption report during specific time durations by selecting appropriate Predefined or Custom
72. t changing the physical wiring connections 41 of 68 When wiring a PowerMonitor 5000 to existing PTs and metering devices the voltage sensing terminals of the PowerMonitor 9000 must be connected in parallel with the voltage sensing terminals of the existing metering devices The following wiring diagrams indicate typical voltage sensing connections to various types of power systems Here is just an example of Direct connect for WYE system Three Phase 4 wire Wye Direct Connect 690 VAC Line to Line Maximum Line L1 L2 L3 N Voltage Mode Wye Powermonitor 5000 Fuses by user BER _ve Cle V3 TI V4 Load Ground Three Phase 3 wire Open Delta with Two PTs Line L1 L2 L3 Voltage Mode Open Delta Powermonitor 5000 Fuses PTs by user by user Ground Load Current Sensing 42 of 68 Route the CT secondary wiring through the openings in the PowerMonitor 5000 as shown S E f X1 X2 To shorting terminal block and current transformer CT Use a shorting terminal block test block or shorting switch by user for CT wiring to permit safely servicing connected equipment such as the PowerMonitor 5000 without de energizing the power system Use 14 or 12 AWG maximum wiring between the PowerMonitor 5000 and the shorting block Use 14 AWG or larger wire between the shorting block and the CTs depending on the length of the circuit Longer circuits will require larger
73. tion tree and click on the PowerMonitor named PM5000M6 Live i Logged in as FactoryTalk EnergyMetrix MvStart Pane seem fi Meters Reports Device Setup Custom Layout Save Restore Collapse dg System Status Groups _ Devices I Enable device Electricity E Enable real time logging Cereal Production E Enable auto data repopulation E Enable PQ events logging oe id Fan fi HVAC Parent group Factory a oer i Device class PowerMonitor 5000 M6 on EtherNet iF Name PMS5000M6 Live Packaging Roles and Users Notes Rate Schedules n Multi Purpose Report Scripts Time zone UTC 06 00 Central Time US amp Canada on fill Alarm Setup Time sync Monthly F Unit Setup Device username ue p Configuration ET Configuration Report Device password 31 of 68 3 Click the Device Viewer link on the Device Setup page to access the harmonics data The magnitude of different orders of harmonics on the selected channels is displayed on the Harmonics tab Total Harmonic Distortion THD is calculated according to both IEEE and IEC standards Ef PM5000_103_M6_DNet gt xs VI Power Enerav Demand I O Setpoints avtom amos oa Wiring Alarms Diaa Voltage L L Current kW kVAR kVA V1 V2 V3 H 12 I3 l4 HRR T ITE T LT EZ ta T Ti EE TELS m m e ieee len CAM e i AA amp RA Avg L N THD 6 86 6 84 Clear All
74. tus at any point of time and to select the Continue button to continue to view the real time alarm status 34 of 68 9 PM5000_103_M6_DNet A VI Power Enerav Demand 1 0 Setpoints Waveforms Harmonics Logs Wirin Alarms isa Description Cid atm Active Metering Status Wiring Diagnostics Active True IEEE1159 DCOffset Condition V1 True IEEE1159 DCOffset Condition V3 True IEEE1159 Voltage THD Condition V1 True IEEE1159 Voltage THD Condition V2 True IEEE1159 Voltage THD Condition V3 True IEEE1159 Current THD Condition l1 True 1EEE1159 Current THD Condition I2 True IEEE1159 Current THD Condition 3 True IEEE519 ShortTerm TDD THD FAIL True IEEE519 LongTerm TDD THD FAIL True IEEE519 ShortTerm Individual Harmonic True IEEE519 LongTerm Individual Harmonic True IEEE519 ShortT erm 5th Harmonic FAIL True IEEE519 ShortTerm 7th Harmonic FAIL True IEEE519 ShortTerm 11th Harmonic FAIL True IEEE519 ShortTerm 23rd Harmonic FAIL True IEEE519 ShortTerm 35th Harmonic FAIL True IEEE519 LongTerm 5th Harmonic FAIL True IEEE519 LongTerm 7th Harmonic FAIL True IEEE519 LongTerm 11th Harmonic FAIL True IEEE519 LongTerm 13th Harmonic FAIL True IEEE519 LongTerm 17th Harmonic FAIL True IEEE519 LongTerm 23rd Harmonic FAIL True IEEE519 LongTerm 25th Harmonic FAIL True IEEE519 LongTerm 29th Harmonic FAIL True IEEE519 LongTerm 35th Harmonic FAIL True Click on Show all alarms to
75. ulse Overrun KYZ Pulse Overrun False Output Pulse Overrun Relay1 Pulse Over False Help Pause 35 of 68 Viewing Wiring Information Using this feature you have the ability to perform wiring diagnostics analyze the wiring correction status and execute the wiring connection commands Step by Step Instructions 1 Click on the System tab on the left navigation pane 2 Click on the Factory group level in the left navigation tree and then click on the PM5000M6 Live Power Monitor FactoryTalk EnergyMetrix oecon SS Mystar Page Administrator system f SS S Device Setup i Custom SS oes Se Copy Layout Save Restore Collapse Device Information r System Status _ Groups a I Enable device Devices E Enable real time logging E Enable auto data repopulation E Enable PQ events logging Parent group Factory Device class PowerMonitor 5000 M6 on EtherNetlP Name PMS000M6 Live 2 Packaging Roles and Users Notes Rate Schedules ry a R Tir F 2 i i 4 nie Panecu Rupa Sek Time zone UTC 06 00 Central Time US amp Canada a fill Alarm Setup Time sync Monthly Unit Setup Device username x Configuration a E Configuration Report an i ale 3 Click the Device Viewer link on the Device Setup page to access the wiring information on the Wiring tab On this page you have options to acce
76. y2014 Feb Feb March 2014 Sun Mon Tue Wed Thu Fri Sat Sun Mon Tue Wed Thu Fri Sat ls KO IN I Ie leo 2 Or Is 16 of 68 Apr Selecta meter tag to display on graph Selecta eee to display on graph Total Real eee mee ic Real Power Demand Click on Air Compressors meter from the group selected above in the left navigation tree and then click on the Trend tab in the right pane of FTEM Select Real Power Demand tag from the Select a meter tag to display on graph dropdown list to view the demand trend System Meters Reports VIH GAH VIGLI LINAGE MINU UIG F IAN NLIGULIVILY GLUNGAY NIYIN WVYVIIiVIiGooViao iaa Meter type Electric Device class PowerMonitor 500 Custom 2 Meter Data Trend Calendar Trend Meter Setup ayout Sa Restore Collapse Efficient Industries Plant 1 Time zone UTC 06 00 Central Time US amp Canada v V Show grid lines Export Data Q Electricity Cereal Production K Friendly O Production Line 4 250 J Melzerflakes Production Line 4 000 Start up Spike SJ Mittenpuffs Production Line 7 Factory te SJ Fan 3 500 7 Hvac 3 250 S Main Incoming m 3 000 Packaging Ss Air Compressors iat SJ Chiller 2 500 4 SJ Power Factor oon 2 000 7 oe ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee eee ee ee ee ee

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