PUMP_Lib V23 Examples_Description V110 3ADR023042M9901

8/18/2019 PUMP_Lib V23 Examples_Description V110 3ADR023042M9901

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Example Description V110

PS563- WATER Li br ar y Package PUMP_AC500_V23 Pumpi ng Li br ar yAppl i cat i on Exampl es


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Simple Pumping - Water LibraryIntroduction and Examples Description 0 AC500 / Issue: 09.2015

Content

1. INTRODUCTION TO DOCUMENT ............................................................................. 3

1.1 Scope of the document .................................................................................................... 3

1.2

Overview of the Content ................................................................................................... 3

1.3 Compatib il ity ..................................................................................................................... 3

1.4

Safety Instructions ............................................................................................................ 3

2. Overview of Water Pumping Library ........................................................................ 4

2.1 Introduction ....................................................................................................................... 4

2.1.1 Application Blocks ........................................................................................................... 5

2.1.2 Auxiliary Blocks ............................................................................................................... 6

2.1.3 Optimization Blocks ........................................................................................................ 6

2.2 Preconditions for the Use of the PUMP_AC500_V23 Library ....................................... 7

2.3

Overview of the PUMP_Library Components accord ing to their Call Names ............. 7

3.

Configuration ............................................................................................................. 9

3.1 Automation Bui lder configurat ion ................................................................................... 9

3.2 ACQ810 dr ive conf iguration ........................................................................................... 10

4. Example programs .................................................................................................. 11

4.1

Example – Simple Level Control in PM 564 .................................................................. 12

4.1.1.1 Station configuration ............................................................................................................ 12

4.1.1.2 Pump interface ..................................................................................................................... 13

4.1.2 Pumping programs ....................................................................................................... 14

4.1.2.1 Level control ......................................................................................................................... 14

4.1.2.2 Auto-change function ........................................................................................................... 15

4.1.2.3 Retain data function ............................................................................................................. 16

4.1.3 Simulation Pump Station .............................................................................................. 16

4.1.3.1 Tank Simulation ................................................................................................................... 16

4.1.4 Visualization .................................................................................................................. 17

4.2 Example – Simple Boost Control in PM 564 ................................................................. 18

4.2.1 Configuration Programs ................................................................................................ 19


4.2.1.2 Pump Interface ..................................................................................................................... 19

4.2.2.1 Boost control ........................................................................................................................ 19

4.2.2.2 Auto-change function ........................................................................................................... 20

4.2.2.3 Retain data function ............................................................................................................. 20

4.2.3 Simulation Pump Station .............................................................................................. 20

4.2.4 Visualization .................................................................................................................. 21

4.3

Example – Multi Pump Boost Cont rol w. auxil iary functions in PM 573 .................... 22

4.3.1 Configuration Programs ................................................................................................ 23



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4.6 Quick Start Guide for Example Programs ........................................................................ 38

5. REVISION HISTORY ................................................................................................ 42


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1. INTRODUCTION TO DOCUMENT

1.1 Scope of the document

The manual is intended as introduction for configuring and using the water library in the example program.This document gives a short introduction to water pressure boost and level application and describes thesoftware architecture of the water library by using it in an example program. Further functional description ofthe water library and details of the blocks are available in on-line help of IEC-61131-3 Editor.

1.2 Overview of the Content

Chapter 2 gives an Introduction to the water pumping and the Pump library.

The example programs described in chapter 4 are designed for controlling and monitoring of water pressureboost control and level control. In this chapter five example programs are explained in Detail:

Example Name Complexity Applicationblock

Chapter

Example_PM564_PUMP_Level_simple.project Simple pumping Level control 4.1

Example_PM564_PUMP_Boost_simple.project Boost 4.2

Example_PM573_PUMP_Boost_complete.project Complete multipump

4.3

Example_PM573_PUMP_Boost_traditional.project Complete traditionalpump setup

4.4

Example_PM573_PUMP_Boost_complete_sim.project

Complete multipump; with drivesimulation:

4.5

All projects do have a simple simulation of pumps and a tank to enable a simple test and familiarization.

1.3 Compatibility

In the application programs the serial communication (MODBUS RTU) is used to transfer and receive databetween AC500 PLC and ACQ810 drives and is described in more detailPUMP_AC500_V23.lib can be also used with any other communication protocol (or drive) supported byPS553 ACS drives library.. User needs to configure PS553 ACS drives library accordingly to establish thecommunication between the drives and the AC500 PLC.

The example program explained in this document is compatible with theo Simple pumping function water library, for theAC500 PLCo ACS drives family.

1.4 Safety Instructions

The user must follow all applicable safety instructions and the guidelines mentioned in the user documents ofthe ABB products used in the example program

o Read the complete safety instructions for the ACQ810drive before installation and commissioningthe drive. The complete safety instructions are given at the beginning of the ACQ810 user’s manual.

o Read all safety instructions of the AC500 PLC.See System description AC500 (2CDC125015M0201 [English]) orthe online help in IEC-61131-3 Editor(Help > Contents >Target System > AC500 / S500 > Introduction > Overview > Regulations).


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2. Overview of Water Pumping Library

2.1 Introduction

The PUMP Library is intended for smaller pump stations (or pump skids) and medium sized stations. Itcontains the block for the basic functionalities as well as advanced functions for very different applications.This version is usable for 1-3 pumps as can be seen in the below picture, and assumes the use of drives foreach pump or at least one in the traditional setup.

The minimal sensor equipment for boost control applications is a pressure (or flow) sensor, for level control alevel sensor. Often additionally also at the input a sensor is placed e.g. for advanced protection.The two main pumping applications in water and waste water are:

o Boost (typically pressure boost) control: Used in Network feeding or lift applications

o Level control: Used for tank or reservoir filling or emptying applications

For both applications a special application block is available, which has all the needed basic functionality, sothat with minimal programming and mainly configuration an application can be setup.Further auxiliary and optimization blocks are part of the library, which help in putting additional advancedfunctionality with again minimal programming effort.This block type concept helps in always having the necessary functionality without using too much PLCresources (Memory) and keeping the applications as simple as possible. Therefore the Pumping library can

be used throughout the AC500 Platform, starting from the small AC500eco.The next picture shows the blocks and their use for an application for small pump stations or sets. The mainapplication block is in the middle of the picture, dotted blocks are optional. The number in brackets showshow often such a block is used in a setup with 3 pumps.


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This picture shows a simple but typical application for small pump station or pump-skid (suitable e.g. als for AC500eco also with 3 pumps). It uses the BOOST_CTRL and the PID. The Station as such is configured bythe STATION_CONFIGRURATION block with an ID, Name and Nr. of used pumps.Dotted blocks are optional depending on the application. The PUMP_INTERFACE block is used for detailedconfiguration of each pump and for interfacing to the drives/actuators. The interface blocks allow a variety of Actuators (one drive with direct-on-line hard- or soft-switched “DOL” pumps, Drive controlled pumps anddiscrete- or bus- connection to the drive(s)).

Note

The parameter and status exchange between the different blocks is done by a structuredvariable (symbolized by the light blue layer in the above picture) which is connected to allblocks with control functionality. It contains substructures depending on the function anduse.

This concept minimizes memory usage, the connection work and still allows advanceddiagnosis if necessary.

2.1.1 Appl ication Blocks

o Boost control works with a closed loop control signal, typically coming from a PID controller witha pressure (or flow) sensor. The PID gives a speed set point for the boost pumping station. Theboost control block then distributes start/stop and speed commands, depending on its chosenoperating mode and parameters, to e.g. a multi-pump setup. The boost application is typicallyused for

o network feeding to control a pressure in the network over a wide range of flow, which isgiven by the varying demand in the network.

o Irrigation, where either pressure or the flow is controlled to achieve a uniform andcontrolled irrigation.

o The Level control block works with discrete definable Levels to switch the pumps and setappropriate fixed speeds. Level control is used e.g.

o for pumping water between reservoirs or to fill a reservoir to a defined level in orderprovide water reserves or direct network feeding.

o for lift stations (“emptying mode”) where e.g. in waste water applications a waste water

reservoir needs to be prevented from overflowing and the water is emptied into furtherreservoirs.


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In addition to these main application and control blocks a set of auxiliary and optimization function blocksexist in the library.

2.1.2 Auxiliary Blocks

The auxiliary blocks provide necessary additional functionality in a modular way, to further minimizeprogramming needs and mainly do configuration instead.

o PID control with extended functions for pumping applications with this library

o Auto-change functionality (ensures distribution of operation hours on the pumps)

o Station Configuration, Pump Interface Blocks simplify configuration and interfacing to the drives.

o The retain block stores selected values which have to sustain through power failures.

2.1.3 Optimization Blocks

The optimization blocks help in further optimizing the pumping station operation by providing additionalinformation or functionality to save energy and protect the equipment (pumps, pipes, tanks).

o The Flow Calculation block estimates with the help of the drives measured power output and fewpump curve data points of the PQ curve the actual flow, which can save a separate instrumentand its integration work.

o The Energy Calculation block totalizes the flows and energy consumptions and providesEfficiency values. If no flow-meter is there, the Flow calculation block can be used.

o The Sleep function helps to save energy in PID operation if demand is low (e.g. at night in anetwork) and works closely together with PID and boost block.

o The Protection block provides advanced protections features for pump, pipe and tank based onthe available information in the station.

o The Anti-Jam block provides a configurable cleaning function per used pump with a drive.

The below picture shows a complete overview of the concept and options with the pump library, includingauxiliary and optimization blocks.

For further details please check the application examples and their documentation, which are provided with

the PS563-WATER library product package and are also available for download from www.abb.com/plc “Application Examples” (choose “English” as language for the page first). Please check also if a more up todate version exists as a download.


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2.2 Preconditions for the Use of the PUMP_AC500_V23Library

Note

The application version of the library PUMP_AC500_V23.lib is tested with the equipmentand configuration used in the attached example programs "Example_PM573_Boost_Ctrl.pro".This example uses a PM573. A reduced Program for the Ac500 eco is available as well.

ABB ACQ810 drive is used with AC500 PLC via Modbus RTU communication. Any other combination with AC500, other busses or drives equipment should work as well,but is not separately tested

Note

The Function Blocks of the PUMP_AC500_V23 library are only working in the RUN mode ofthe PLC. Usage of these libraries in the simulation mode will not provide any valid or usablediagnostic information

The Function Blocks of the library PUMP_AC500_V23.lib are available in AC500 control systems with aruntime system of version V 1.3 and above.

2.3 Overview of the PUMP_Library Components according totheir Call Names

Block Name Function

Appl ication Funct ion blocks

PUMP_LEVEL_CTRL Level control application block for filling or emptying of thetank/container.

PUMP_BOOST_CTRL This block runs the single pump/ multi pump/ traditional pumpingstations up to three pumps

Auxi liary- and Configuration- Funct ion blocks

PUMP_PID This function block uses PID for closed loop control of pressure

PUMP_FLOW_CALC Provides a flow estimation from drive power and pump curve values

PUMP_STATION_CFG Configures pump station parameters

PUMP_RETAIN_DATA Stores important values in retain memory for power loss situations

PUMP_INTERFACE Configures and Interfaces to the pump, or the “Drive of the pump”

Optimization Blocks

PUMP_SLEEP This block uses sleep mode of the pump to maximize energy savingat the time low demand.

PUMP_ANTIJAM Pump cleaning functionsPUMP_AUTOCHANGE Changes Sequence of the pumps in the application control blocks

PUMP_PROTECTION This block used for protection of the system against low or highpressure and flow.

PUMP_ENERGY_CALC Calculates and Totalizes Energy and Flow Values and derived valueslike efficiency and savings

Simulation Blocks

PUMP_TANK_SIMU This function block is Simple simulation of the water tank foremptying and filling mode

PUMP_DRIVE_SIMU This function block is Simple simulation of the drives and PLCcommunication

PUMP_DOL_SIMU This function block is Simple simulation of the Direct OnLine (DOL)pumps.


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For all blocks except retain a visualization is available in the library.


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3. Configuration

This chapter describes how to configure the ACQ810 drive and AC500 PLC for use with the exampleprograms. The examples are all using Modbus RTU (except the one with the drive simulation). Other Bussesor discrete connection via IO can be used as well.

The instructions in this chapter are intended to be used after the mechanical and electrical installation hasbeen completed, as explained in AC500 and ACQ810-quick installation guide. The document does not coverthe instructions related to mechanical and electrical installations to commission the AC500 and the ACQ 810drives

FSCA is the field bus adapter which needs to be mounted for Modbus communication on the ACQ810drives. The communication cable must connect the ACS500 COM1 port and the FSCA module on the ACQ810 drive. For the detailed information related to the communication the FSCA user manual must bereferred.

3.1 Automation Builder configuration

The user must install the Automation Builder.Once the AB is installed the example program can be opened.

The same MODBUS setting must be given both in the automation builder project and in the drive parameters

1. In CBP, in the left pane, select the Interfaces.2. Right Click COM1 and select Plug Device. A new window will open and then select COM1 –

Modbus.3. In the right pane (Module parameters), configure the following parameters:

Name Value

RTS control Telegram

Baud Rate 19.2kbit/s (Same as in the Drive)

Parity None (Same as in the Drive)

Data Bits 8 (Same as in the Drive)

Stop Bits 1 (Same as in the Drive)

Operation Mode Master

Address 0

Since the mode of communication selected in MODBUS – RTU, the COM1 port is configured to establish thecommunication between the PLC and the drive. The configuration is given in the following picture.


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3.2 ACQ810 drive configuration

The ACQ810 parameterization can be done either using the keypad mounted on the drive or the “drives

studio” tool. The drives studio tool can be downloaded from www.abb.com/drives.

In the following table the parameter list is given. This parameterization is required to establish the MODBUScommunication between the AC500 and ACQ810. All motor related parameters must be configured as per actual configuration.User can set drive parameters for the Modbus communication using drive studio or keypad. ACQ810 driveparameter list and values are as follows

Parameter Name Value

1001 EXT1 COMMANDS FBA, Selects the source of start and stopcommands for externalcontrol location 1 (EXT1).

2101 REF1 SEL EFB ref1, Speed reference selection

5004 FBA REF1 Speed

5005 FBA REF2 Raw

5006 FBA ACT1 P.01.01 Motor Speed

5007 FBA ACT2 P.01.23 Motor Power

5801 PROTOCOL ENABLE MODBUS RTU

5803 STATION ID 1 This parameter indicates slave ID. No twodrives on the same network can have thesame ID

5804 BAUD RATE 19.2kbit/s (192)

5805 PARITY 8 None 1

5806 CONTROL PROFILE 0, ABB Classic


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4. Example programs

The example programs described in this chapter are designed for controlling and monitoring of waterpressure boost control and level control. In this chapter five example programs are explained in Detail:

Example Name Complexity Applicationblock

Chapter

Example_PM564_PUMP_Level_simple.project Simple pumping Level control 4.1

Example_PM564_PUMP_Boost_simple.project Boost 4.2Example_PM573_PUMP_Boost_complete.project Complete multipump

4.3

Example_PM573_PUMP_Boost_traditional.project Complete traditionalpump setup

4.4

Example_PM573_PUMP_Boost_complete_sim.project

Complete multipump; with drivesimulation:

4.5

All projects do have a simple simulation of pumps and a tank to enable a simple test and familiarization.

Once the library package is installed, the help files of the water library can also be found in the IEC-61131-3Editor – help.

In the Help Contents tab, expandTarget System > AC500 / S500 >Water Library

o Getting help on a specific function blockIn IEC-61131-3 Editor, select the title of the function block and press F1.

The library view also contains information on the function blocks and their inputs and outputs. Press Alt +Enter to enter the library view.


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4.1 Example – Simple Level Control in PM 564

This program Example_PM564_PUMP_Level_simple.project supports following major functionalities

1. Configuration of pump station with three pumps, each driven by motor and ACQ810 drive

2. Level control application block

3. Auto change function to optimize the duty cycle of the pump

Since the project is meant for a simple pumping station which controls level and uses few special functions,PM 564 is an ideal CPU selection.

The right side picture shows the screenshot of the POU’s in the example project

The application example “Example_PM564_PUMP_Level_simple.project“, has folders in which theprograms are put as per their functions. There are two main folders in the project, Simple Pumping andSimulation Pump Station.

1) Simple Pumping – It has two folders, Configuration programs and Pumping programs. The folder“Configuration Programs“ has programs related to configuration of station, settings of pumps and thedrive communication. The “Pumping Programs“ folder contains the application related programs,level control, auto-change and retain data.

2) Simulation Pump Station – in this folder additional function blocks are provided, which allows asimple simulation of a water process called PUMP_TANK_SIMU4.1.1 Configuration Programs

4.1.1.1 Station conf iguration

To configure the pumping station the function block PUMP_STATION _CFG is used.


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This function block creates the station ‘Station1’, with three pumps in the network. As discussed, each pumpis driven by the drive-motor combination.

The variable tsStationData is created as a global variable in the application program with the data typePUMP_STATION_TYPE.

This tsStationData is an IN/OUT variable which links all the function blocks of the water library.

4.1.1.2 Pump interface

The PUMP_INTERFACE block needs to be inserted for each pump. In the project Pump1_Interface,Pump2_Interface and the Pump3_Interface programs call the PUMP_INTERFACE function bock. Thisblock serves to configure the pump library parameters and interface to its drive as the actuator

As in this case each pump is driven by the motor-drive combination the function block takes the actual ready,operating and the tripped status from the drive status word. Similarly it transfers the drive start command andspeed reference to the drive.

Note

The PUMP_INTERFACE function block needs a unique pump identification number rangingfrom 1-3 in this version of the library.

Note

If the priority of all the pumps is entered same then the starting sequence of the pump is inthe order of its Pump Id i.e. 1, 2 and 3.If the user enters different priority values for each pump then the starting sequence ofpumps is based on the ascending order of the priority. Ex: Pump with the priority value 1starts first and the priority value 2 starts later.

Note

If the PUMP_INTERFACE is used to configure the pumps with the boost application then allthe pumps must have the same value of the FOLLOWER_MODE, which is setting thefollower mode of this pump in the boost operation.


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As it can be seen in the above screen shot the pump interface takes inputs from the drive status and thensends the outputs to control the drive.

The following picture explains the interface between this function block and the ACS drive communicationblocks.

This function block also calculates the actual runtime of each pump. If the user wants to reset the actualruntime of any pump = 0seconds, he/she needs to toggle the input PUMP_RUNTIME_RESET to TRUEvalue.

4.1.2 Pumping programs

4.1.2.1 Level control

Prg1_PumpLevelCtrl program calls the PUMP_LEVEL_CTRL function block, which is designed forcontrolling a station of 1 to 3 pumps that is used for either emptying or filling a container.

The level control functionality is activated by setting parameter level mode to Emptying or Filling. Thestart levels for the pumps (as well as the alarm levels) are set by parameters.


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Note

The FB needs to define the various levels. These levels are accepted in a particular order,which depends on the emptying or the filling mode.

Emptying mode :LOW_LEVEL < STOP_LEVEL < START_LEVEL_1 < START_LEVEL_2 <START_LEVEL_3 < HIGH_LEVELFilling mode :LOW_LEVEL < START_LEVEL_3 < START_LEVEL_2 < START_LEVEL_1 <STOP_LEVEL < HIGH_LEVEL

Note

The level control function block is not designed to operate for the traditional pumpingstation. It is only used for the pumping station where all the pumps are run by the drives.

4.1.2.2 Auto-change funct ion

This function is a special feature of the water library. Prg2_Autochange program calls thePUMP_AUTOCHANGE function block which is used to optimize the duty time between multiple pumps byvarying the sequence in which pumps are started as the required pumping capacity increases.

There are three auto-change modes selectable by parameter auto-change style1) Fixed intervals: The starting sequence is shifted periodically at pre-defined intervals auto-change

interval.Example: in this case since there are three pumps with IDs 1, 2, 3 so the original sequence to run apump station becomes Pump1, Pump2 and Pump3. For the auto-change style = 1 and auto-changeinterval 1hour. After every 1 hour if the situation is such that there are one or two pumps operatingsuch that there is at least one pumps spare, then the sequence changes from 1-2-3 to 2-3-1. Due to

which the pump with the highest runtime goes to stop.

2) Runtime equalization (Hour count): The starting sequence is rearranged when the differencebetween the runtimes of two pumps exceed a limit. In the new sequence, the pump with the lowestruntime will be started first; the pump with the highest runtime will be started last.Example: in this case since there are three pumps with IDs 1, 2, 3 so the original sequence to run apump station becomes Pump1, Pump2 and Pump3. For the auto-change style = 2 and auto-changeruntime difference equal to 1hour. So if actual runtime difference between any two pumps exceedsthis limit, and the situation is such that there are one or two pumps operating and minimum onepumps spare, then the sequence changes from 1-2-3 to 2-3-1. Due to which the pump with thehighest runtime goes to stop.

3) Auto-change when stopped (All stop): The starting sequence is shifted every time the pump stops.


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4.1.2.3 Retain data funct ion

PUMP_RETAIN_DATA function block is designed to retain the data such as last operating sequence andthe pump runtime. This function block record the last data before the PLC power is switched off.Especially when the auto change function is used, then PUMP_RETAIN_DATA helps to retain the lastsequence in which the pumps need to operate.

4.1.3 Simulation Pump Station

Simple simulation blocks on the process side are part of this example. The PUMP_TANK_SIMU functionblock is used for a simple tank simulation.

4.1.3.1 Tank Simulation

Function block PUMP_TANK_SIMU basically simulates a tank with inlet, pumps and outlet flows. Thetank volume is calculated using height, depth, and width. The operation of the tank is selected (filling oremptying) using the MODE input. Inlet flow, outlet flow and individual pump flow are used to calculatecumulative water level in the tank. This water level is also converted to pressure (at the bottom = outlet ofthe tank).

The actual flows of the pumps are connected to this function block as inputs. The output then can befurther used as a feedback to level control or boost control (or more exactly PID e.g. pressure).

The water volume can be set to an INITIAL_LEVEL using SET_LEVEL input in order to start a meaningfulsimulation with a start level.

Note

Pump Flow Calc function block is not used in this program. User needs to connect flowsignal to PUMP1_ACT_FLOW, PUMP2_ACT_FLOW, and PUMP3_ACT_FLOW inputs ofthe Tank Simulation Function Block.


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Note

This kind of simple simulation is intended only for simple off-site tests when hardware andthe water process are not available.It can be used for lab type simulation only. It cannot be used to fully and accurately simulatea real installation.

4.1.4 Visualization

The visualization screenshot shown below is used to control the example programs and the simulation ofthe pump station and also to diagnose the actual status of the pump functions.

On the right hand upper part of the visualization the “Simulation controls” section enables the user to startthe simulation, enable level control function block and to start/ stop the level control function block.

Start Simu is used to start the simulation and water level will change depending upon inflow and outflow

of the tank.

Initial Volume can be set using set volume.


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4.2 Example – Simple Boost Control in PM 564

This program Example_PM564_PUMP_Boost_simple.project supports following major functionalities


2. Boost control application block


Since the project is meant for a simple pumping station which controls boost and uses few special functions,PM 564 is an ideal CPU selection.


The application example “Example_PM564_PUMP_Boost_simple.project“, has folders in which the programsare put as per their functions. There are two main folders in the project, Simple Pumping and SimulationPump Station.

1) Simple Pumping – It has two folders, Configuration programs and Pumping programs. The folder“Configuration Programs“ has programs related to configuration of station, settings of pumps and thedrive communication. The “Pumping Programs“ folder contains the application related programs,Boost control, auto-change and retain data.

2) Simulation Pump Station – in this folder the function block PUMP_TANK_SIMU is provided tosimulate the filling/ emptying process.


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4.2.1 Conf iguration Programs


This is already explained in earlier chapter. Please refer 4.1.1.1 for details.

4.2.1.2 Pump Interface



4.2.2.1 Boost control

Prg1_PumpBoostCtrl program calls the PUMP_BOOST_CTRL and PUMP_PID function block which isdesigned for controlling a station of 1 to 3 pumps that is used for either emptying or filling a container.

Boost functionality is activated by setting parameter operation mode to single, multi pump and traditionalpump. Traditional mode takes care of conventional (only one pump with drive and remaining pumps withDOL) pumping configuration , while multi pump takes care of unconventional (all pumps with separatedrives) pumping configuration.

Note

For this Function Block start and stop speed of the slaves needs to be defined in particularorder.START_SPEED_SLV_1 < START_SPEED_SLV_2 ,STOP_SPEED_SLV_1 < STOP_SPEED_SLV_2 ,STOP_SPEED_SLV_1 < START_SPEED_SLV_1 andSTOP_SPEED_SLV_2 < START_SPEED_SLV_2

Note

Function Block inputs OP_MODE and MASTER_LOC should not be changed while pump isrunning.

PUMP_PID is used for closed loop control of the process parameter such as pressure. The set point andactual values are compared and error value is feed in as an input to the PID. PID output is calculatedbased on proportional gain KP, Integral Time TN and Derivative time TD. The PID output is then scaledand converted into required speed reference to the drive. PID_SPEED_REF is internally connected to thePUMP_BOOSTPCTRL.

The PUMP_PID sends the speed reference based on the process demands to the PUMP_BOOST_CTRLand then PUMP_BOOST_CTRL controls the start/stop sequence for the pumps based on the processrequirements.


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Note

PUMP_PID Function Block works in the range of 0 – 100 % of set and actual value.KP,TN, TD needs to calibrated as per process requirement.



4.2.2.3 Retain data funct ionPUMP_RETAIN_DATA function block is designed to retain the data such as last operating sequence andthe pump runtime. This function block record the last data before the PLC power is switched off.Especially when the auto change function is used, then PUMP_RETAIN_DATA helps to retain the lastsequence in which the pumps need to operate.

Note

1. All the pumping function programs which are using the data structure - STATION_DATAmust be called in the same task (it can be freewheeling or cyclic)2. The retain data MUST be first in the list. This is to make sure that the data structure getsupdated with the last retained value before any pumping function uses it..


PUMP_TANK_SIMU function block is used for tank simulation 4.2.3.1 Tank SimulationThis is already explained in earlier chapter. Please refer 4.1.3.1 for details.


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Note

Pump Flow Calc function block is not used in this program. User needs to connect flowsignal to PUMP1_ACT_FLOW, PUMP2_ACT_FLOW, and PUMP3_ACT_FLOW inputs ofthe Tank Simulation Function Block.

4.2.4 Visualization

The visualization screenshot shown below is used to control the simulation of the pump station and alsoto diagnose the actual status of the pump functions.

On the right hand top Simulation control section enables the user to start the simulation, enable PID, andenable Pump Boost function block and to start/ stop the pump boost function.

Start Simu is used to start the simulation and water level will change depending upon inflow and outflowof the tank.



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4.3 Example – Multi Pump Boost Control w. auxil iaryfunctions in PM 573

This program Example_PM573_PUMP_Boost_complete.project supports following major functionalities




4. Additional pumping functionalities

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep, Pump_Energy_Calc

Since the project is meant for a pumping station which controls Boost and uses all additional specialfunctions, PM 573 is an ideal CPU selection.



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The application example “ Example_PM573_PUMP_Boost_complete.project“, has folders in which theprograms are put as per their functions. There are two main folders in the project, Simple Pumping andSimulation Pump Station.

1) Simple Pumping – It has two folders, Configuration programs and Pumping programs. The folder

“Configuration Programs“ has programs related to configuration of station, settings of pumps and thedrive communication. The “Pumping Programs“ folder contains the application related programs,Boost control, auto-change and retain data.

2) Simulation Pump Station – in this folder the function block PUMP_TANK_SIMU is provided tosimulate the filling/ emptying process

3) Additional Functionalities – It has three folders, Pump1, Pump2 and Pump3. Each folder containsspecial functions like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep. Thesefunction blocks provide additional features to the pump and they are used only if they are requiredfor process.












PUMP_RETAIN_DATA function block is designed to retain the data such as last operating sequence andthe pump runtime. This function block record the last data before the PLC power is switched off.Especially when the auto change function is used, then PUMP_RETAIN_DATA helps to retain the lastsequence in which the pumps need to operate.


PUMP_TANK_SIMU function block is used for tank simulation




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NoteNot all pumps can be rotated in the reverse direction.

There are various modes in which the anti-jam works,, which is decided by the input TRIGGER.

A) In auto mode, i.e., when the anti-jam needs to be called in the pump boost operations:

Note

In this version of the library the anti-jam auto modes i.e. TRIGGER = 1, 2, 3 are onlypossible with the PUMP_BOOST_CTRL and not the PUMP_LEVEL_CTRL. However theanti-jam manual mode i.e. TRIGGER = 4, is possible in both boost control and the levelcontrol functionalities.

The anti-jam works for the following trigger:

1. TRIGGER = 1, master enabled: the pump which is designated as master performs the anti-jam

operation when ever started.2. TRIGGER = 2, follower enabled: the pump which is the designated slave performs the anti-jam

operation whenever started.

3. TRIGGER = 3, at start: whenever the pump starts is performs the specified anti-jam operation.

B) Manual mode of anti-jam operation

4. TRIGGER = 4, manual mode:

To perform the anti-jam operation in the manual mode it is important to perform following step:

a) Assign PUMP_ON = FALSE, from the PUMP_INTERFACE block, for the pump which requiresmanual anti-jam operation. This would not allow this pump to go in the pump boost or the level control

functionality, until PUMP_ON = TRUE again.

b) Enable the PUMP_ANTI_JAM function block by turning EN = TRUE.

c) Assign the input TRIGGER = 4

d) Enter all the anti-jam settings, i.e. time delays, speeds and no. of steps.

e) Give the rising edge input FALSE->TRUE, to the START_MANUAL

The above steps would start the anti-jam operation, which would stop at the end of designated time andsteps.


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4.3.5.2 Pump Flow Calc

The flow calculation function provides a reasonably accurate (typically ±5…8%) calculation of the flowwithout the installation of a separate flow meter. The flow is calculated on the basis of pumpcharacteristics.

The user can define a PQ (power/flow) performance curve of the pump for the flow calculation function.The P (power input) and Q (flow rate) coordinates of five points on the curve are entered. The values areprovided by the pump manufacturer. All points defined should lie within the practical operating range ofthe pump.

Note

The flow calculation function is not to be used for invoicing purposesThe flow calculation function cannot be used outside the normal operating rangeof the pump.

4.3.5.3 Pump Protection

This Function Block contains protective functions for two-level analog pressure monitoring of both theinlet and outlet of the pump.

In analog monitoring, whenever the pressure being monitored meets the first limit, the drive indicates awarning, trips on a fault, or starts to follow a pre-defined reference. When the second limit is met, thedrive either stops or trips on a fault.

Flow monitoringThe control program has a monitoring function for flow that can be configured to generate an alarm or afault whenever the flow falls below or rises above predefined limits. The flow can either be calculated ormeasured using a flow meter connected to, for example, an analog input.


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4.3.5.4 Pump Sleep

The sleep function is suitable for PID control applications where the consumption varies, such as cleanwater pumping systems. When used, it stops the pump completely during low demand, instead of runningthe pump slowly below its efficient operating range.The water consumption falls at night. As a consequence, the process PID controller decreases the motorspeed. However, due to natural losses in the pipes and the low efficiency of the centrifugal pump at lowspeeds, the motor would never stop rotating. The sleep function detects the slow rotation and stops theunnecessary pumping after the sleep delay has passed. The drive shifts into sleep mode, still monitoringthe pressure. The pumping resumes when the pressure falls under the predefined minimum level and thewake-up delay has passed.


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4.3.5.5 Pump Energy Calculation

This function block calculates energy consumed by direct on line pumps and drive connected pumps.This is then used to calculate saved energy by using drives. CO2 emission reductions and money savedis also computed using energy saved.It also calculates efficiency of flow verses power. Instant, Hourly and 24 hourly (daily) efficiency iscalculated continuously.Total Volume and total Energy is calculated and connected as in out parameter to the function block. Toretain this data, Global retain variables needs to connected in the user program.


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4.4 Example – Tradit ional Pump Boost Control w. auxiliaryfunctions in PM 573

This program Example_PM573_PUMP_Boost_traditional.project supports following major functionalities

1. Configuration of pump station with single pump driven by motor and ACQ810 drive, and up to twoother motors switched e.g. via a relay or soft starter direct on to the grid “direct on-line” DOL.



4. Additional pumping functionalities for pump connected to ACQ810 drive

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep,

5. On / Off commands are generated for DOL motors.



The application example “ Example_PM573_PUMP_Boost_traditional.project“, has folders in which theprograms are put as per their functions. There are two main folders in the project, Simple Pumping and

Simulation Pump Station.1) Simple Pumping – It has two folders, Configuration programs and Pumping programs. The folder“Configuration Programs“ has programs related to configuration of station, settings of pumps and the


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drive communication. The “Pumping Programs“ folder contains the application related programs,Boost control, auto-change and retain data.

2) Simulation Pump Station – in this folder the function block PUMP_TANK_SIMU is provided tosimulate the filling/ emptying process.

3) Additional Functionalities – It has one folders i.e. Pump1. This folder contains special functions likePump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep. These function blocksprovide additional features to the pump and they are used only if they are required for process.





The pumping station involves the traditional pumps which mean that the Pump1 is driven by the drive andmotor and the other pumps are running the DOL motors or the motor with the soft starters.

Pump1 needs to be configured the same way as defined in the section 4.1.1.2. The feedback signals from

drive have to be attached to the READY, OPERATING, TRIPPED inputs. Similarly the control signalshave to be sent back to the drive i.e. PUMP_START and PUMP_REF to the drive.

For the pumps which are connected to the DOL motor or the soft starter, it is important to connect theTRIPPED signal, so that the pumping functions gets the status of an unhealthy motor. Since the DOLmechanism might not have a good feedback system so it is not mandatory to connect the READY andOPERATING input feedbacks to the PUMP_INTERFACE block. In the traditional pumps it is common notto have such feedbacks. However if the system can send the correct READY and the OPERATING

status, then the programmer is advised to connect it as this would help to calculate the pump runtime.

Any speed inputs such as nominal speed and the follower speed values given to the pumps has notsignificance since the traditional DOL operated motor runs at its own speed depending on the supplyvoltage.

However all other inputs which are mentioned below work in the same way for both, the traditional andthe multi pump with drives.‘PUMP_ID, PUMP_PRIORITY, PUMP_ON, FOLLOWER_MODE, STATION_DATA I/O.’


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This is already explained in earlier chapter. Please refer 4.2.2.1 for details. The prime difference is thevalue of the input OP_MODE. Since the pumping station is the traditional pump, the input OP_MODE = 1.It is not possible to operate the rotating master location i.e. MASTER_LOC = 0 when the OP_MODE = 1.The function block throws error code 16#4043 for such combination.


This is already explained in earlier chapter. Please refer 4.1.2.2 for details. In the traditional pumping stationit is not necessary that the user gets the proper feedback mechanism for the actual motor status. In thisversion of the library, because of this limitation, the traditional pump has not been provided the fixed autochange mode and the runtime difference auto change mode. This is because both the auto change modeneeds to understand if the pump is in standby or in the operating condition.

So the auto change style = 3 is suitable for the traditional pumping station. When this style is selected, theorder would change from 1-2-3 to 2-3-1 to 3-1-2 whenever the pump boost control is restarted.


PUMP_RETAIN_DATA function block is designed to retain the data such as last operating sequence andthe pump runtime. This FB record the last data before the PLC power is switched off. Especially when theauto change function is used, then PUMP_RETAIN_DATA helps to retain the last sequence in which thepumps need to operate.

4.4.3 Simulation Pump StationPUMP_TANK_SIMU function block is used for tank simulation



4.3.4 Visualization




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4.5 Example – Multi Pump Boost Control w. Drive Simulationin PM 573

This program Example_PM573_PUMP_Boost_complete_sim.project supports following majorfunctionalities




4. Additional pumping functionalities

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep

5. Simple Drive Simulation Function block is used to simulate also drive functionality. This functionblock simulates drive and generates status word and speed actual using control word and set speed.

The simulation of the drives enables a simple preparation and first testing of a new pumping stationproject fully on an office desk, only with the use of a CPU. All other parts as drives, pumps and water

tank is simulated.




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The application example “ Example_PM573_PUMP_Boost_complete_sim.project“, has folders in which theprograms are put as per their functions. There are two main folders in the project, Simple Pumping andSimulation Pump Station.

1) Simple Pumping – It has two folders, Configuration programs and Pumping programs. The folder“Configuration Programs“ has programs related to configuration of station, settings of pumps and thedrive communication. The “Pumping Programs“ folder contains the application related programs,Boost control, auto-change and retain data.

Additional Functions – It has three folders, Pump1, Pump2 and Pump3. Each folder contains

special functions like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep.These function blocks provide additional features to the pump and they are used only if theyare required for process.

2) It has two folders, Tank_Simulation and Simulation_Drive_Comm_Block.The folder Tank_Simulation contains the function block PUMP_TANK_SIMU used for tank

simulation This is already explained in earlier chapter. Please refer 4.1.3.1The folder Simulation_Drive_Comm_Block contains thee function blocks PUMP_DRIVE_SIMU to

simulate the drive functionality including the the power consumption of the drive.

The following diagram shows how application and simulation blocks are interconnected:




4.5.1.2 Pump InterfaceThis is already explained in earlier chapter. Please refer 4.1.1.2 for details.


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PUMP_TANK_SIMU function block is used for tank simulation



4.5.4 Visualization






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4.5.5 Additional Functionalities Additional Function blocks like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep areavailable for each pump.These Function Blocks can be used by pumps as per process requirement.

4.5.5.1 Pump Antijam


4.5.5.2 Pump Flow calc


4.5.5.3 Pump Protection


4.5.5.4 Pump Sleep



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4.6 Quick Start Guide for Example Programs

All above example programs are tailor made and hence all the necessary interconnection are done for allthe function blocks. These programs can be downloaded to the PLC and once drive communication isestablished with PLC, user can run this application.

All necessary function block are called in Task Configuration.

Al l the funct ion blocks are cal led in freewheeling task except Pump Energy Calculat ion andSimulation. Both these programs need to be in cycl ic task of 50 ms.

Step 1.) Open the example “xyz” in Automation BuilderCheck and adapt the example project configuration if necessary (see chapter 3.1)

Step 2.) Configure your drives (see chapter 3.2)

Step 3.) Start the AC500 IEC-61131-3 Editor program

Step 4.) Download the program to your PLC(Clean and Rebuild all is recommended, go to Run)

Step 5.) Open the visualization “xyz”Buttons “Enable PI” an “BOOST” are already enabled by default


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“Start pump boost starts” the pump boost application, which defines which drive needs to be turned on andthe follower / slaves sequence. Drive Set point is generated by the difference of set and actual value ofPUMP_PID. If demand is more then the drives turn on one by one.

Step 7.) Press” Set Volume” sets the volume of tank using set Volume value given to the simulationFunction Block. Now all the drives are running as actual value of PID is still less than set value


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As demand decreases means Actual value is approaches set value of PID, all the drives starts to switch offas defined in Pump Boost CtrlPump 2 and 3 has been turned off as demand decreases.

---------------------------------------------------------------------------------------

Note All the other example programs can be run using similar steps.


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5. REVISION HISTORY

Rev. ind. Page (P)Chapt. (C)

Description DateDept./Init

V01 All Example water library document first release 17/10/2013

DMLP

V110 All Simulation function block description and screenshots areupdated based on the new library V110.

15/09/2015IDC/NKS


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