SIRIUS SIMOCODE pro V: Prevention of Pump Blockages by Changing the Direction of Rotation

Transcription

1 Application Example 08/2015 SIRIUS SIMOCODE pro V: Prevention of Pump Blockages by Changing the Direction of Rotation SIRIUS SIMOCODE pro V

2 Warranty and Liability Warranty and Liability Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These Application Examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Application Examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of Siemens AG. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens' products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry ID: , V1.0, 08/2015 2

3 Table of Contents Table of Contents Warranty and Liability Task Solution Overview Hardware and software components Validity Components used Mode of Operation Logic blocks used Explanation of the logic Embedding Detecting faults in the conveying flow Switching on via the control station Switching on in the conveying direction (ON>) Switching on in the opposite direction (ON<) Switching off via the control station or in the event of a fault Revoking the ON> command Revoking the ON< command Manual reversal in the other direction of rotation Reversal in the opposite direction when a conveying fault has been detected Fault shutdown after n reversals Drive start after fault shutdown Resetting the fault counter during operation Blockage in the opposite direction Cyclic communication with the controller Cyclic receive Cyclic send Configuration and Project Engineering Requirement Default values Configuring the SIMOCODE pro V Parameterizing the SIMOCODE pro V Installation and Commissioning Installing the hardware Installing the software (download) Commissioning Operation of the Application General information on operator control and monitoring Control stations list Control stations selection Online monitoring options in TIA Portal Scenarios Scenario 1: Blockage is not cleared Scenario 2: Blockage is cleared Scenario 3: Blockage in the opposite direction Timestamping Configuring time synchronization and parameterizing timestamping 51 Entry ID: , V1.0, 08/2015 3

4 Table of Contents 8 References History Entry ID: , V1.0, 08/2015 4

5 1 Task 1 Task Figure 1-1: Schematic representation Blockages of pumps, sieves or screens caused by solids are a major problem in conveying wastewater. In the worst-case scenario, this can result in flooded tanks, unwanted water leakage or motor failures. What is at least required is unscheduled work to manually clear the blockages. In many cases, blockages in the conveying flow can be cleared by short-term reversal of the conveying direction if necessary multiple times. To initiate this, imminent blockages must be detected. Suitable criteria for this can be derived from the electrical power supply of the pump drive. Entry ID: , V1.0, 08/2015 5

6 2 Solution 2.1 Overview 2 Solution 2.1 Overview Diagrammatic representation The task is solved using the flexible, modular SIMOCODE pro motor management system for motors in the low-voltage range. Figure 2-1: Components and wiring (diagram) PLC 7 PROFIBUS DP, PROFINET IE, MODBUS RTU SIMOCODE System wiring SIRIUS SIMOCODE pro V Basic Unit SIRIUS Digital module SIRIUS Operator panel SIRIUS Molded case circuit breaker SIRIUS Current / voltage measuring module SIRIUS Reversing contactor combination PG/PC Basic unit (BU) A SIMOCODE pro V motor control unit with PROFIBUS interface is installed in the application example. However, you can also use basic units with PROFINET IE or MODBUS RTU. The basic parameterization corresponds to a reversing starter. Identifying irregularities in the conveying flow In this application example, the SIMOCODE basic unit uses the motor current i max and the power factor cos φ to identify irregularities in the pump s conveying flow. To this end, the associated current/voltage measuring module picks off the three-phase motor voltage and the three-phase motor current at the feeder. Entry ID: , V1.0, 08/2015 6

7 2 Solution 2.1 Overview Clearing blockages in the conveying flow Digital module (DM1) Operator panel (OP) Thanks to a comprehensive selection of logic modules implemented in the basic unit such as truth tables, counters and timers that can be interconnected as desired, a logic was implemented that, in the case of an identified irregularity in the conveying flow, briefly reverses the pump drive up to three times. This gives the drive the chance to successfully move to a normal travel range. If it succeeds, this prevents the imminent forced shutdown. In this example, the status feedback, ON<, OFF and ON>, is output to indicator lights. As the SIMOCODE pro V basic unit can only provide one relay output for ON< for this purpose, two relay outputs of the digital module are used for OFF and ON>. In the example, the motor feeder can also be controlled using the operator panel as the control station. In addition, current measured values, operating data and diagnostic data or status information can be displayed on the operator panel. Communication with a PLC The application example can be run without communication with a PLC. For the cyclic send and receive data, however, the Standard interconnections of the reversing starter (see chapter in \3\) apply so that the drive can be operator controlled and monitored provided that the communication is parameterized accordingly. Chapter describes additional application-specific data exchange with a controller. The fieldbus interface of the SIMOCODE pro V PROFIBUS version used in the sample project corresponds to the default parameterization and has PROFIBUS address 2. Advantages Using SIMOCODE pro, you can prevent faults in automated processes and costly plant downtimes and ensure optimum motor load. SIMOCODE pro allows you to avoid faults in your system and detect pending errors at an early stage. This application example helps you minimize maintenance work. For the benefits the SIMOCODE pro motor management system offers compared to a conventionally designed motor feeder, please refer to or, for example, the SIMOCODE pro manuals (\3\, \4\, \5\) which provide specific information. Scope This application example does not contain a general description of... the hardware components listed in Table 2-1. It provides references to the relevant manuals and system descriptions. See the References in chapter TIA Portal. the SIMOCODE ES configuration software. Basic knowledge of these topics is required. Required knowledge Understanding the application example requires general knowledge of low-voltage controls and distribution, digital circuit engineering and automation technology. You also need basic knowledge of SIMOCODE pro. Being able to handle the SIMOCODE ES option package in TIA Portal is an advantage. Entry ID: , V1.0, 08/2015 7

8 2 Solution 2.2 Hardware and software components 2.2 Hardware and software components Validity This application example can be implemented with... SIMOCODE pro V basic units (PROFIBUS DP, PROFINET IO, MODBUS RTU) SIMOCODE ES software (2007, V13) Components used The example was created with the following components: Hardware components Table 2-1: Hardware components Component Article number Note SIMOCODE pro V basic unit (PROFIBUS version) SIRIUS current/voltage measuring module 2 1 Connection cable to the measuring module (length: 30cm) 1 3UF7010-1AB V DC 1 3UF7010-1AU00-0 3UF711x-1yA00-0 (with x=0) 1 3UF7935-0AA00-0 SIRIUS digital module 1 3UF7300-1AB00-0 Connection cable to the basic unit (length: 2.5cm) SIRIUS operator panel with display Connection cable to the operator panel (length: 50cm) 1 3UF7930-0AA UF7210-1AA UF7932-0AA00-0 Also possible: V AC/DC x=0,1,2,3,4 (depending on the required connected loads of the motor) y=a,b (depending on the type: straight-through current transformer or busbar connection)... other length can also be used optional 3 (if you want to connect, for example, indicator lights for status feedback to the Protection/Control function block)... other length can also be used optional 4 1 In addition, you require a 24V DC power supply. 2 If your application does not require the evaluation of the power factor cos φ (see chapter 3.2.2), you can also use a pure current measuring module 3UF710x-1yA00-0. However, in this case, you have to replace the measuring module in the device configuration in the configuration of the supplied example (see 2 in Table 4-1). 3 When the digital module is not used, it has to be deleted from the device configuration in the configuration of the supplied example (see 2 in Table 4-1). 4 When the operator panel is not used, it has to be deleted from the device configuration in the configuration of the supplied example (see 2 in Table 4-1). Entry ID: , V1.0, 08/2015 8

9 Alternative Siemens AG 2015 All rights reserved 2 Solution 2.2 Hardware and software components Component Article number Note SIRIUS PC cable 1 3UF7941-0AA00-0 SIRIUS circuit-breaker 1 3RV2311-0AC10 SIRIUS contactor 2 3RT2015-1FB42 SIRIUS wiring module top SIRIUS wiring module bottom Motor 1 - Bus connector for PROFIBUS PROFIBUS bus cable 1 3RA1913-3D 1 3RA1913-3E 1 Sold by the meter 6ES7972-0BA52-0XA0 (without PG socket) or 6ES7972-0BB52-0XA0 (with PG socket) 6XV1830-0JH10 to connect the basic unit to the development system or other circuit-breaker, depending on the required connected loads of the motor and the user wishes regarding the design. or other contactors, depending on the required connected loads of the motor and the user wishes regarding the design. for reversing starters, for S00 contactor assemblies depending on customer requirement optional; or other PROFIBUS connector type with switchable terminating resistor optional; or other PROFIBUS bus cable Other small accessories are not included in the above list. Software components Table 2-2: Software components Component Article number Note SIMOCODE ES V13 Standard Floating License (on DVD) SIMOCODE ES V13 Standard Floating License (as a download) 3ZS1322-5CC11-0YA5 3ZS1322-5CE11-0YB5 You can also use the text-based Basic version or the Premium version with parameterization and diagnostics via PROFIBUS/PROFINET. Hardware Support Packages Entry ID (free download: \6\) optional for... SIMOCODE pro V MR SIMOCODE pro V PN, FW V1.2 Driver for SIRIUS USB PC cable 3UF7941-0AA00-0 Entry ID (free download: \7\) Including installation guide Entry ID: , V1.0, 08/2015 9

10 2 Solution 2.2 Hardware and software components Sample files and projects The following list contains the files and projects that are used in this example. They can be downloaded from the appropriate Industry Online Support page. Table 2-3: Sample files and projects Documents _SIMOCODEproV_PumpBlockagePrevention_V1d0_en.pdf _SIMOCODEproV_PumpBlockagePrevention_CODE_V1d0.zip Note... this document TIA project Entry ID: , V1.0, 08/

11 3 Mode of Operation 3 Mode of Operation Figure 3-1: Blockage prevention function diagram Entry ID: , V1.0, 08/

12 3 Mode of Operation 3.1 Logic blocks used The function diagram in Figure 3-1 to which the following explanations refer only shows the additional blockage prevention logic (in the following referred to as logic ). Figure 3-1 does not include the standard interconnections of the reversing starter that forms the basis. 3.1 Logic blocks used The pump blockage prevention logic implemented in the SIMOCODE pro V uses the following blocks that can be freely interconnected: Table 3-1: Logic blocks used Symbol & & TT 4 Explanation Truth table A truth table allows you to implement a logic operation of digital signals. For purposes of illustration, Figure 3-1 shows the truth tables as gates or a combination of gates. Truth tables with the following input/output quantity frameworks are available: 3I/1Q, 2I/1Q and 5I/2Q. For details, please see chapters 12.3, 12.4 and 12.5 of the system manual \3\. Counter 1 + Q 4 R Valu Timer 1 R 30s with opening Signal conditioning 1 R IN Signal conditioning 2 R 1 IN Counter Each positive edge at one of the counter inputs (+/-) increments/decrements the count. The application example uses only the + counter inputs. When the defined limit is reached ( 4 in the left-hand figure), the output (Q) is set to true. The reset input (R) is used to reset the counter to 0. The count is available as an output. For details, please refer to chapter 12.6 of the system manual \3\. Timer In the example, it is parameterized with closing delay or with opening delay. Runtime and output can be reset via a reset input (R). For the exact output response, please refer to the respective timing diagrams in chapter 12.7 of the system manual \3\. Signal conditioning In the example, signal conditioning is parameterized as... edge rising with memory. The signal is only reset by true at the reset input (R). Negation For details, please refer to chapter 12.8 of the system manual \3\. Entry ID: , V1.0, 08/

13 3 Mode of Operation 3.2 Explanation of the logic i max Symbol Limit monitor 1 Explanation Limit monitors In the example, the limit monitors are used to monitor the motor current for undershooting or overshooting of limits and the power factor is monitored for undershooting of a limit. When the relevant limit is reached, the digital output changes to true. When parameterizing the limit monitor, you can define in which motor operating state it will be evaluated. For all limit monitors in the example, the default setting (0.5s) for a configurable delay of the signaling output was not changed. For details, please refer to chapter in the system manual \3\. 3.2 Explanation of the logic Embedding When you configure the preconfigured reversing starter application (Parameters > Device configuration in the project tree), the Control Stations and Protection/Control function blocks are interconnected according to Figure 3-2 by default. Figure 3-2: Reversing starter, standard interconnection To embed the blockage prevention logic, the interconnection of the ON commands is separated. The enabled control commands ON<, ON> and OFF from Control Stations are supplied to the logic as inputs (shown in green in Figure 3-1 and Figure 3-3). The logic outputs are interconnected with the ON plug of Protection/Control (shown in red in Figure 3-1 and Figure 3-3). The enabled control command OFF from Control Stations remains connected to the OFF plug of Protection/Control. Entry ID: , V1.0, 08/

14 3 Mode of Operation 3.2 Explanation of the logic Figure 3-3: Reversing starter with blockage prevention logic embedded Detecting faults in the conveying flow In normal operation, the pump motor operates in a nominal range with regard to its torque. Depending on the type of the specific application in the process, a conveying fault can manifest itself both as a value above and below the nominal range. Both a significant overload with in the worst case total blocking of the motor and a considerable load off the motor up to no-load operation can be interpreted as a fault. To detect this, the application example measures the following parameters: motor current and voltage. The SIMOCODE pro V basic unit calculates the power factor from the phase displacement. An analysis of the motor current and power factor limits eventually indicates a fault in the conveying flow. In the overload range, there is a disproportionately significant increase in the motor current so that, due to its steep characteristic, it is well suited to be used as a trip criterion. In the underload range, however, the power factor has a steep characteristic and, in this range, is better suited as a trip criterion than the motor current. The logic in the SIMOCODE pro V basic unit detects a fault in the conveying flow when the value of the motor current is outside a defined nominal range defined by limit monitor 2 (below nominal range) and 3 (above nominal range) (inputs 1 and 2 of truth table TT9)... or the value of the power factor is below a defined limit defined by limit monitor 4 (input 3 of truth table TT9). The three limit monitors are parameterized such that they respond only when... the motor is running. the start operation has completed (i.e., not before the Class time you set when parameterizing overload protection in Parameters > Motor protection has elapsed; for the trip class, please see CLASS in the glossary of \3\). there is no test position (TPF) (see chapter 11.4 in \3\). Entry ID: , V1.0, 08/

15 3 Mode of Operation 3.2 Explanation of the logic The fault will only be evaluated if the drive is running in the conveying direction, i.e., if the QE1 socket of the Protection/Control function block is true (input 5 of truth table TT9). In Local 2 mode ( local operation or using operator panel), you can activate/deactivate processing of the fault using button 1 of the operator panel. In Remote mode, fault processing is activated via bit 0 of the Cyclic receive byte 1 interface. The interconnection of counter 2, signal conditioning 3 and truth table TT4 is used for this purpose. At output 1 of truth table TT9, the fault signal is available for further processing Switching on via the control station It is assumed that the non-maintained command mode is not checked. This is the default configuration (see the Parameters>Motor control>control function>operating mode menu). Figure 3-4: Default parameterisation: no non-maintained command mode With this setting, the SIMOCODE device, according to the locking of contactors, saves the ON> or ON< command without requiring the user to interconnect appropriate logic blocks. Therefore, an ON command is triggered by a pulse (locally, for example, by a pushbutton) at the respective control station. Switching on in the conveying direction (ON>) Signal conditioning 1 remembers the enabled control command ON> provided by the Control Stations function block. Although, with the no non-maintained command mode default configuration, the ON commands are maintained commands, the ON> command must be additionally saved via signal conditioning 1 to ensure that the fault logic can switch the drive back on in the conveying direction after automatic reversal. Via input 1 of truth table TT2, the ON> command is switched through to the Protection/Control function block provided that input 2 is false, which corresponds to normal, faultless operation. Switching on in the opposite direction (ON<) Moving in the opposite direction can be initiated by the active control station; however, this is not part of normal operation. Via input 2 of truth table TT7, the ON< command provided by the Control Stations function block is switched through to the Protection/Control function block. The control command is saved due to the no non-maintained command mode default configuration. Entry ID: , V1.0, 08/

16 3 Mode of Operation 3.2 Explanation of the logic Switching off via the control station or in the event of a fault Switching off the drive via the active control station is implemented by the fact that the enabled control command OFF of the Control Stations function block is interconnected with the OFF plug of the Protection/Control function block. This connection is created by default when you configure a reversing starter. The blockage prevention logic is only used for reversal operations, it is not used for switching-off via the OFF plug of Protection/Control. Shutting down the drive in the event of a fault is performed by the Protection/Control function block according to the parameterization of the SIMOCODE device. To ensure that the drive does not automatically switch back on after an OFF command, it must be ensured that the ON commands of the logic to the Protection/Control function block are revoked when switching off the motor. Revoking the ON> command In the logic, the ON> command to Protection/Control is revoked by resetting signal conditioning 1: The commands OFF and ON< from the Control Stations function block and the general fault from the Status General fault function block are ORed via truth table TT1 and supplied to signal conditioning 1. Revoking the ON< command It is assumed that the enabled control command ON< from Control Stations is no longer true when the drive is being shut down. If the ON< command is triggered, for example, by a pushbutton, this is the case. As the ON< command is not saved in the logic, resetting the ON< command to Protection/Control is not necessary provided that the reverse motion command was given manually via the active control station. If, however, the ON< command is present due to the automatic reversing operation caused by a forward blocking, the drive is switched off by resetting timer 1. For this purpose, the enabled OFF command at the output of the Control Stations function block is interconnected with the reset input of timer 1 via the truth tables TT5 and TT Manual reversal in the other direction of rotation Motor control is parameterized such that direct reversal via the active control station is possible without requiring the user to give the stop command (see Table 4-2, step 6). As the ON> command is saved via signal conditioning 1, it must be additionally deleted in the logic by resetting the signal conditioning when reversing in the opposite direction. For this purpose, the ON< command from the Control Stations function block is interconnected with the reset input of signal conditioning 1 via truth table TT1. As the ON< command is not separately saved in the logic, direct reversal back to the conveying direction is implemented without additional logical interconnections provided that the motion in the opposite direction is based on a manual command. If, however, the ON< command is present due to the automatic reversing operation caused by a forward blocking, manual direct reversal back to the conveying direction is implemented by resetting timer 1. For this purpose, the enabled ON> command at the output of the Control Stations function block is interconnected with the reset input of timer 1 via the truth tables TT5 and TT8. Entry ID: , V1.0, 08/

17 3 Mode of Operation 3.2 Explanation of the logic Reversal in the opposite direction when a conveying fault has been detected The value true at output 1 of truth table TT9 supplied to the input plug of timer 1 sets the timer output. The timer is parameterized with opening delay. The delay time to be set depends on the application and corresponds to the time you want the drive to move in the opposite direction. For this purpose, the timer output is connected to the ON< plug of the Protection/Control function block via truth table TT7. At the same time, the motion command in the conveying direction is revoked via truth table TT2; this has the effect that also the fault signal at the output of truth table TT9 and therefore the timer input change back to false. Now the motor continues to rotate in the opposite direction until the timer expires provided that it is not prematurely reset via its reset plug. When the timer has expired, its output changes back to false, which revokes the ON< command via TT7 and gives the ON> command via TT2. For this logic to work, Save change-over command must be parameterized (see Table 4-2, step 6) Fault shutdown after n reversals Each positive edge of the fault signal at output 1 of truth table TT9 increments counter 1. This means it counts the runs in the opposite direction. When the counter reaches its parameterized limit n (in the application example: n=4), which means that the drive has already made n-1 reversing runs, the counter output is set to true and, via the External fault 1 function block, it initiates that no other reversing attempts are made, the drive is switched off and an appropriate fault message with a resulting general fault is generated Drive start after fault shutdown Like any fault, the fault message detected by the logic and generated via the External fault 1 function block requires acknowledgment. Therefore, the drive cannot be restarted before the fault has been acknowledged. It cannot be acknowledged before counter 1 has been reset. This is done via the truth tables TT3 and TT6 when one of the following actions is performed: The Test/Reset button on the SIMOCODE basic unit is pressed ( Test/Reset button socket of the BU inputs function block) The Test/Reset button on the SIMOCODE operator panel is pressed ( Test/Reset button socket of the OP buttons function block) Acknowledgment via a PLC (socket for bit 6 of the Cyclic receive byte 0 function block) Resetting the fault counter during operation Counter 1 defines the maximum number of reversing attempts to be made when conveying is blocked. If a blockage is cleared with fewer than the maximum number of parameterized reversing operations, the counter retains its current count. In this case, only the remaining number of reversals is available for another blockage clearing before fault shutdown would be performed. Therefore, the logic prematurely resets counter 1 in the following cases to ensure that the total number of parameterized reversing attempts is always available for future automatic reversing attempts: Entry ID: , V1.0, 08/

18 3 Mode of Operation 3.2 Explanation of the logic Manual motion in the opposite direction. For this purpose, the ON< socket of the Control Stations function block is connected to input 3 of truth table TT6. If no blockage is detected within a specific time interval (in the application example: 1h). For this purpose, timer 2 parameterized with closing delay is interconnected via signal conditioning 2 parameterized as a negation in such a way that it deletes counter 1 via Input 2 of truth table TT6 every hour by a pulse. However, each reversing run triggered by the logic resets timer 2 so that it does not fully expire and the fault counter is not deleted Blockage in the opposite direction If the drive also blocks in the opposite direction, which is detected by limit monitor 1 that responds to a current maximum in reverse motion, the logic initiates immediate reversal back to the conveying direction. For this purpose, the relevant limit monitor resets timer 1 via the truth tables TT5 and TT8 (QE2 socket of Protection/Control) when a reverse motion is detected. According to the current count of counter 1, this is followed by more reversing attempts or fault shutdown of the drive, if necessary Cyclic communication with the controller Cyclic receive In addition to the cyclic receive data that has already been predefined for the reversing starter, the following interconnections have been created: Reset fault The socket for bit 6 of the Cyclic receive byte 0 function block is interconnected with input 3 of truth table TT3. If the SIMOCODE device is reset via communication after a fault, the fault counter counter 1 is interconnected via this interconnection (see also chap ). Deactivate blockage prevention logic The socket for bit 0 of the Cyclic receive byte 1 function block is interconnected with input 4 of truth table TT9. If the PLC transfers false or if no PLC is connected, the blockage prevention logic is active. If true, the limit monitors 2, 3 and 4 are not evaluated (see also chap ). Cyclic send In addition to the cyclic send data that has already been predefined for the reversing starter, the following interconnections have been created: Status device o.k. The socket of the Status device o.k. binary connection block is interconnected with the plug for bit 0 of the Cyclic send byte 1 function block. If the SIMOCODE device operates correctly, the controller receives true. Blockage message The socket of the External fault 1 function block is interconnected with the plug for bit 1 of the Cyclic send byte 1 function block. Therefore, the PLC receives true if a blockage in the conveying flow could not be automatically cleared and the drive is stopped (see also chap ). Fault counter counter 1 The analog output of counter 1 is interconnected with input 1 of the Cyclic send byte 4/9 function block. This ensures that the current number of reversals Entry ID: , V1.0, 08/

19 3 Mode of Operation 3.2 Explanation of the logic performed until fault shutdown (see also chap ) or resetting of the value (see also chap ) is transferred to the PLC. Fault counter counter 2 The analog output of counter 2 is interconnected with input 2 of the Cyclic send byte 4/9 function block. Counter 2 counts all automatic reversals initiated by the logic. The count is transferred to the controller for statistical evaluation. For this purpose, the output of timer 1 at which a positive edge is recorded each time a fault is detected in the conveying flow is interconnected with the + plug of counter 2 (see also chap ). After an overflow (>65535), the counter restarts at 0. Entry ID: , V1.0, 08/

20 4 Configuration and Project Engineering 4 Configuration and Project Engineering Requirement Default values This chapter describes the configuration steps necessary for you to create the sample project. You will find helpful project engineering support, in particular if your required configuration differs from the supplied application example in terms of hardware and component parameterization. The software components listed in Table 2-2 are installed on your development system and you have opened a new software project or a project you want to extend/modify in TIA Portal. When you add a device from the hardware catalog to the project in TIA Portal, a default parameterization will be created. This default parameterization will be used as a basis in the following step tables. Parameters and settings in this application example that do not have to be changed regarding the default values will not be mentioned in the following sections. Note The configuration in TIA Portal offers various options. The following configuration steps represent one possible solution. Steps deviating from this approach to a greater or lesser extent can also lead to the same goal. To also meet the requirements of users using the text-based Basic version of SIMOCODE ES V13, all parameterizations were described without using diagrams. However, when installing the standard or premium version of SIMOCODE ES V13, the function diagram is displayed in the graphic editor where it can be edited. Entry ID: , V1.0, 08/

21 4 Configuration and Project Engineering 4.1 Configuring the SIMOCODE pro V 4.1 Configuring the SIMOCODE pro V Table 4-1: Table for configuring the SIMOCODE pro V In the project tree, go to Devices & networks. 2. Select the Network view. 3. Locate the SIMOCODE pro V in the version you are using and use drag and drop to move it from the Hardware catalog task card to the graphic area of the Network view. In the graphic area of the Network view and in the project tree, the SIMOCODE device is created as Control device_1 (name can be changed). Entry ID: , V1.0, 08/

22 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V In the graphic area, select the SIMOCODE device and go to the Device view. 2. Locate the IUM 0.3 3A current/voltage measuring module, the DM mono digital module and the OPD operator panel and drag these components from the Hardware catalog task card to the appropriate slots in the graphic area of the Network view. 4.2 Parameterizing the SIMOCODE pro V Table 4-2: Table for parameterizing the SIMOCODE pro V 1. In the project tree, select Parameters. Entry ID: , V1.0, 08/

23 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Go to the fieldbus interface. 2. Enter the communication parameters required for your project. 3. To be able to transfer all the send data described in chapter to the controller, select Basic type 1. Note The STEP 7 project does not contain a controller *) as it is not part of the core content of the example. The user is responsible for integrating and networking a controller in this project. At this point, it is worth noting that the blockage prevention logic can also be used with SIMOCODE pro V PN or MR independently of the bus system used. *) As the SIMOCODE device is not networked with a controller, it additionally appears in Unassigned devices in the project tree and is labeled as Not assigned in the Network view Go to Device configuration. 2. Make sure that the default setting for the SIMOCODE device is Reversing starter. Entry ID: , V1.0, 08/

24 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Go to Motor protection > Overload/Unbalance/Stalled rotor. 2. Set Set current Ie 1 (rated motor current of the connected motor). In the application example, it was set to 0.5 A. 3. The Class (trip class) influences the limit monitors 2, 3 and 4 (see chapter 3.2.2). They are parameterized such that they do not become active before the motor start is complete. When Class 10 (= default setting), the value defined for the start operation is 10 s. 4. Make sure that the stalled rotor response is deactivated (= default setting). Entry ID: , V1.0, 08/

25 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Go to Motor control > Control station. 2. Define the three control stations Local control (inputs 1 3 of the SIMOCODE basic unit (BU inputs)) PLC/PCS (bits of the cyclic communication (Cyclic receive byte 0) Operator panel (buttons 2 4 (OP buttons)) for the ON>, OFF and ON< commands according to the figure above. Local control Operator panel Conveying direction ON> (button 2) Opposite direction ON< (input 1) OFF (input 2) Conveying direction ON> (input 3) Opposite direction ON< (button 3) OFF (button 4) Entry ID: , V1.0, 08/

26 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Go to Motor control > Control function. 2. Check Save change-over command to select this mode. 3. Interconnect the ON< and ON> control commands with the outputs of the appropriate truth tables, as shown in the figure. 4. In Timers, set the interlocking time required for your application. With the 2 s parameterized in the example, the switch-on interlocking of a reversing operation can be monitored well Open Outputs > Basic unit. 2. As shown in the figure, interconnect outputs 1-3 of the basic unit (BU outputs) with plugs 1 QE1, 2 QE2 and QLE< (ON<) of the Protection/Control function block. Entry ID: , V1.0, 08/

27 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Open Outputs > Operator panel LEDs. 2. Assign LED 1 of the operator panel (OP LED) to the Status remote mode binary connection block. 3. Interconnect LEDs 2-4 with plugs QLE> (ON>), QLE< (ON<) and QLA (OFF) of the Protection/Control function block, as shown in the figure Open Outputs > Digital module Interconnect outputs 1 and 2 of the digital module (DM1 outputs) with plugs QLA (OFF) and QLE> (ON>) of the Protection/Control function block, as shown in the figure. Entry ID: , V1.0, 08/

28 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Open Outputs > Cyclic send data. 2. In addition to the standard interconnections of the reversing starter, assign the Device o.k. signal of the Status device o.k. binary connection block and the output signal of the External fault 1 function block to bits 0 and 1 of the Cyclic send byte 1 interface. 3. Interconnect the values of counters 1 and 2 used in the logic with inputs 1 and 2 of Cyclic send byte 4/9. Entry ID: , V1.0, 08/

29 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V Go to Standard functions > External fault > External fault Assign the binary output of counter 1 a to the input of the External fault 1 function. 3. In Response, select Trip. 4. Select the marking to be displayed, for example, on the operator panel with display in the event of a fault. Entry ID: , V1.0, 08/

30 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 12. In Logic modules > Truth table 3I/1Q > Truth table 1, define the signals and logic of truth table 1 (TT1 in Figure 3-1). The logic corresponds to an OR operation with three inputs. I1 I2 I3 13. In Logic modules > Truth table 3I/1Q > Truth table 2, define the signals and logic of truth table 2 (TT2 in Figure 3-1). By default, the unused input 3 is false. I1 I2 & I3 (false) Entry ID: , V1.0, 08/

31 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 14. In Logic modules > Truth table 3I/1Q > Truth table 3, define the signals and logic of truth table 3 (TT3 in Figure 3-1). I1 I2 I3 15. In Logic modules > Truth table 3I/1Q > Truth table 4, define the signals and logic of truth table 4 (TT4 in Figure 3-1). I1 I2 I3 & & & Entry ID: , V1.0, 08/

32 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 16. In Logic modules > Truth table 3I/1Q > Truth table 5, define the signals and logic of truth table 5 (TT5 in Figure 3-1). I1 I2 I3 17. In Logic modules > Truth table 3I/1Q > Truth table 6, define the signals and logic of truth table 6 (TT6 in Figure 3-1). I1 I2 I3 Entry ID: , V1.0, 08/

33 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 18. In Logic modules > Truth table 2I/1Q > Truth table 7, define the signals and logic of truth table 7 (TT7 in Figure 3-1). The logic corresponds to an OR operation with two inputs. I1 I2 19. In Logic modules > Truth table 2I/1Q > Truth table 8, define the signals and logic of truth table 8 (TT8 in Figure 3-1). I1 I2 & - Entry ID: , V1.0, 08/

34 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 20. In Logic modules > Truth table 5I/2Q > Truth table 9, define the signals and logic of truth table 9 (TT9 in Figure 3-1). Only output 1 of the truth table is combined. I1 I4 I2 & Q1 I3 I5 Entry ID: , V1.0, 08/

35 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 21. In Logic modules > Counter > Counter 1, select input + (increment), reset and the limit value for counter In Logic modules > Counter > Counter 2, select input + (increment), reset and the limit value for counter In Logic modules > Counter > Counter 3, select input + (increment), reset and the limit value for counter 3. Entry ID: , V1.0, 08/

36 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 24. In Logic modules > Timer > Timer 1, select input, reset, the with opening delay type and the limit value for timer In Logic modules > Timer > Timer 2, select input, reset, the with closing delay type and the limit value for timer In Logic modules > Signal conditioning > Signal conditioning 1, select input, reset and the edge rising with memory type. Entry ID: , V1.0, 08/

37 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 27. In Logic modules > Signal conditioning > Signal conditioning 2, select input and the type inverting. 28. In Logic modules > Signal conditioning > Signal conditioning 3, select input, reset and the edge rising with memory type. 29. In Logic modules > Limit monitor > Limit monitor 1, parameterize the Limit value function block for the upper current limit in reverse motion. In Active status, select always on. Specify the limit in %, referring to the motor current on the input plug. If necessary, select a marking. Entry ID: , V1.0, 08/

38 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 30. In Logic modules > Limit monitor > Limit monitor 2, parameterize the Limit value function block for the lower current limit in the conveying direction. The limit monitor should only be active when the motor is running and after the start operation has completed (if the motor is running, except TPF, with startup override (run+)). Specify the limit in %, referring to the motor current on the input plug. If necessary, select a marking. 31. In Logic modules > Limit monitor > Limit monitor 3, parameterize the Limit value function block for the upper current limit in the conveying direction. The limit monitor should only be active when the motor is running and after the start operation has completed (if the motor is running, except TPF, with startup override (run+)). Specify the limit in %, referring to the motor current on the input plug. If necessary, select a marking. Entry ID: , V1.0, 08/

39 4 Configuration and Project Engineering 4.2 Parameterizing the SIMOCODE pro V 32. In Logic modules > Limit monitor > Limit monitor 4, parameterize the Limit value function block for the cos φ lower limit in the conveying direction. The limit monitor should only be active when the motor is running and after the start operation has completed (if the motor is running, except TPF, with startup override (run+)). Specify the limit in %, referring to the motor current on the input plug. If necessary, select a marking. 33. Compile Control device_1 to identify any errors and save its parameterization If necessary, complete your configuration by networking the SIMOCODE pro V as a PROFIBUS slave with a controller that has also been configured in TIA Portal (PROFIBUS master). This allows read and write control access to the interconnected cyclic send and receive data. Entry ID: , V1.0, 08/

40 5 Installation and Commissioning 5.1 Installing the hardware 5 Installation and Commissioning 5.1 Installing the hardware Note Always follow the installation, mounting and wiring guidelines for the individual components provided in the appropriate manuals and accompanying notes. Table 5-1: Table for installing and wiring the hardware 1. Mechanically install the components shown in Figure Establish the power wiring as indicated in Figure phase infeed SIRIUS circuit-breaker SIRIUS current/voltage measuring module SIRIUS reversing contactor assembly Motor 3. Follow the short instructions given in \3\ to wire the SIRIUS SIMOCODE pro V basic unit as a reversing starter. If as intended in the application example you want to indicate the ON<, OFF and ON> states in local control by indicator lights or illuminated pushbuttons, use output OUT3 (terminal 7) of the basic unit to signal counterclockwise rotation ON<. Apply the 24V contact supply to terminal If as intended in the application example you want to indicate the ON<, OFF and ON> states in local control by indicator lights or illuminated pushbuttons, use output Out1 (terminal 21) of the digital module to signal the OFF stop state and output Out2 (terminal 22) to signal clockwise rotation ON>. Apply the 24V contact supply to terminal 20. If you do not need state signaling in local control, you can remove the digital module from the configuration (see step 2 in Table 4-1): In the Device configuration of Control device_1, right-click the digital module and in the context menu, left-click Delete. 5. As indicated in Figure 2-1, establish the SIMOCODE system wiring between the following components: SIRIUS SIMOCODE pro V basic unit SIRIUS current/voltage measuring module SIRIUS digital module SIRIUS operator panel For the respective cables, please refer to Table 2-1. Furthermore, please refer to chapter 14.5 System interfaces in \3\. 6. Use the SIRIUS USB PC cable to connect your development system to an available SIMOCODE system interface. In the application example, this interface is on the operator panel. 7. Physically establish the PROFIBUS connection to any controller (PROFIBUS master). Entry ID: , V1.0, 08/

41 5 Installation and Commissioning 5.2 Installing the software (download) 5.2 Installing the software (download) Table 5-2: Installing the software (download) 1. To enable your development system (PG/PC) to communicate with the SIMOCODE device via the USB PC cable, install the associated driver. SIEMENS Industry Online Support provides the download and an installation guide (\7\). 2. Make sure that... the hardware has been completely installed and wired (see chapter 5.1). the 3-phase power circuit is de-energized or has been disconnected using the SIRIUS circuit-breaker. the power supply of all components is on. 3. If you are using the supplied _SIMOCODEproV_PumpBlockagePrevention_CODE_V1d0.zip archive, extract it to a directory on the hard drive of your development system. 4. In TIA Portal, open the project you have just extracted, SIMOCODEproV_PumpBlockagePrevention, or your own project that has already been modified. 5. Download Control device_1 to the SIMOCODE basic unit. Entry ID: , V1.0, 08/

42 5 Installation and Commissioning 5.2 Installing the software (download) 6. When downloading for the first time, the Extended download to device window opens Select the SIRIUS PtP interface type and the number of the used COM interface. For the specific COM interface number the SIMOCODE device uses, please refer to the installation notes for the driver for the SIRIUS USB PC cable, \7\. 2. Leave Show all compatible devices checked (default setting). 3. Select Start search. 4. Check, wether the correct device has been found. 5. Start downloading and follow the instructions/information displayed on the screen. Successful download is indicated as follows: NOTICE The download is aborted with an error if the SIMOCODE device is in Remote/Automatic mode, an On command is present or the motor is running. Entry ID: , V1.0, 08/

43 5 Installation and Commissioning 5.3 Commissioning 5.3 Commissioning A specific commissioning routine is not required. Provided that you have performed the hardware and software installation described above, you only have to connect the power circuit to the 3-phase system or switch on the SIRIUS circuit-breaker. The next steps are described in the following chapter, 6 Operation of the Application. Entry ID: , V1.0, 08/

44 6 Operation of the Application 6.1 General information on operator control and monitoring 6 Operation of the Application 6.1 General information on operator control and monitoring Control stations list The configuration allows the following control stations (see step 5 in Table 4-2): Local control station, e.g. illuminated pushbutton Figure 6-1: Local control station Opposite direction ON (BU input 1) OFF (BU input 2 low active) Conveying direction ON (BU input 3) Operator panel with display Figure 6-2: Operator panel Blockage prevention On/Off (button 1) Message External fault 1 Conveying direction ON> (button 2) Opposite direction ON< (button 3) OFF (button 4) On the operator panel, blockage prevention can only be (de)activated in Local 2 mode (see Control stations selection ) using button 1. However, the LED in button 1 always indicates the correct blockage prevention status regardless of the mode (Local 2 or Remote). On the operator panel, a blockage that cannot be cleared is indicated by... the GEN LED. FAULT (flashing red), External fault 1 with the text Blocked on the display. Reset External fault 1 Entry ID: , V1.0, 08/

45 6 Operation of the Application 6.1 General information on operator control and monitoring The right one of the two softkeys is used for fault acknowledgment. PLC (via PROFIBUS) The drive is switched on and off via bits 0-2 of the Cyclic receive byte 0 interface. The relevant switching signals from the PLC must not be present permanently. The required signal behavior is the same as for pushbuttons. Bit 0 Opposite direction ON< Bit 1 OFF Bit 2 Conveying direction ON> The blockage prevention logic can also be (de)activated via PROFIBUS. This is done via bit 0 of the Cyclic receive byte 1 interface. However, this requires that Remote mode (see Control stations selection ) be selected. A blockage that cannot be cleared generates External fault 1. This fault is transferred to the PLC with bit 1 of the Cyclic send byte 1 interface. The fault is acknowledged via bit 6 of the Cyclic receive byte 0 interface. Control stations selection Two modes are available: Local 2 and Remote (see step 5 in Table 4-2). You select the mode via bit 5 of the Cyclic receive byte 0 interface. When bit 5 = true, Remote mode has been selected. Local 2 The drive is operated either locally using pushbuttons or via the operator panel. If no PLC is connected, bit 5 of the Cyclic receive byte 0 interface is always false and therefore Local 2 is automatically selected. Remote The drive is operated either using a PLC (PROFIBUS) or via the operator panel. The PLC may, but need not, be configured in the same project as the SIMOCODE device. Online monitoring options in TIA Portal When going through the following scenarios, it is useful to monitor some data and situations online in TIA Portal. To go online, perform steps 1 and 2 as shown in Figure Figure 6-3: Going online When the online connection between your PG/PC and the SIMOCODE device has been established, double-click in the project tree to go to Commissioning ( 3 in 5 It is possible that the extended go online dialog appears, which largely corresponds to the one from 6 in Table 5-2. Follow the instructions, start the search for the SIMOCODE device and eventually close the dialog using the Go online button. Entry ID: , V1.0, 08/

46 6 Operation of the Application 6.1 General information on operator control and monitoring Figure 6-3). The following menu items are relevant to the scenarios: Faults, Measured values and Service data / statistical data. Indication of the Conveying flow blocked fault (in the Faults menu item) If a blockage can t be cleared, this results in the parameterized External fault 1. Figure 6-4: Fault indication online in TIA Portal Monitoring motor current and cos φ (in the Measured values menu item) The Measured values menu item allows you to monitor the current current and power factor values to compare them to the set values of the limit monitors. Figure 6-5: Measured values online in TIA Portal Entry ID: , V1.0, 08/

47 6 Operation of the Application 6.1 General information on operator control and monitoring Monitoring counters and timers (in the Service data / statistical data menu item) The Service data / statistical data menu item allows you to monitor the current values of the timers and counters of the blockage prevention logic.figure 6-6: Timers and counters online in TIA Portal Note When using the standard or premium version of SIMOCODE ES V13, the integrated CFC-based graphic editor allows you to conveniently monitor the input and output data of all function blocks and the signal flow online. Entry ID: , V1.0, 08/

48 6 Operation of the Application 6.2 Scenarios 6.2 Scenarios The following three scenarios are only a selection of possible processes Scenario 1: Blockage is not cleared Table 6-1: Instruction for Scenario 1 1. Make sure that the blockage prevention logic is on. 2. Check whether counter 1 has the value 0. If not, perform fault acknowledgment (RESET), for example, using the TEST/RESET button on the SIMOCODE basic unit to reset counter Start the drive with ON> (conveying direction). 4. Wait until the Class 10 time has elapsed, i.e., until the start operation has completed (10s). 5. Provoke or simulate a situation that causes one of the three limit monitors 2, 3 or 4 to respond (fault situation). CAUTION Avoid overloading your motor. Think about whether you can risk a blocking of your drive. For testing, you can parameterize a set current I e1 smaller than suitable for the motor and/or less critical limits for the limit monitors. 6. The motor stops and moves in the opposite direction once the interlocking time (2s) has elapsed. Counter 1 is incremented. 7. When timer 1 (30s in the example) has expired, the motor stops again and, once the interlocking time (2s) has elapsed, rotates back to the conveying direction. 8. As the fault is still present, the motor continues its motion in the conveying direction only until the start operation has completed (= Class 10 time elapsed, 10s). 6 and 7 listed above are executed 3 x. 9. When counter 1 has reached 4, the drive stops with External fault 1. This is indicated as follows: GEN LED. FAULT on the SIMOCODE device flashes red. GEN LED. FAULT on the operator panel flashes red. In the case of an operator panel with display, the Blocked fault is indicated. In the case of PROFIBUS communication, the fault is transferred to the PLC with true via bit 1 of the Cyclic send byte 1 interface. In TIA Portal, the Online view displays External fault 1 in Commissioning > Faults. 10. Acknowledge the fault in one of the following ways: Press the TEST/RESET button on the SIMOCODE pro V basic unit. Press the right softkey on the operator panel. Via PROFIBUS, transfer true to bit 6 of the Cyclic receive byte 0 interface. Acknowledgment resets counter Clear the blocking by ensuring that each of the limit monitors 2, 3 or 4 no longer responds. Entry ID: , V1.0, 08/

49 6 Operation of the Application 6.2 Scenarios Scenario 2: Blockage is cleared Table 6-2: Instruction for Scenario 2 1. Perform steps 1-5 of Scenario The motor stops and moves in the opposite direction once the interlocking time (2s) has elapsed. Counter 1 is incremented. 3. While the drive moves in the opposite direction, clear the blocking by ensuring that each of the limit monitors 2, 3 or 4 no longer responds. 4. When timer 1 (30s) has expired, the motor stops again and, once the interlocking time (2s) has elapsed, rotates back to the conveying direction. For the time being, timer 1 retains the value 1. After an hour (timer 2 has elapsed), timer 1 is reset to 0 provided that no other blockage has occurred during this period. If other blockages occur within this hour, only two reversing runs would be left to clear them before the drive would stop with External fault Scenario 3: Blockage in the opposite direction Table 6-3: Instruction for Scenario 1 1. Perform steps 1-5 of Scenario The motor stops and moves in the opposite direction once the interlocking time (2s) has elapsed. Counter 1 is incremented. 3. While the drive moves in the opposite direction (or even before), provoke or simulate a situation that causes limit monitor 1 to respond (fault situation). 4. The drive immediately starts a reversing operation and, once the interlocking time (2s) has elapsed, rotates back to the conveying direction. 5. As a fault of one of the limit monitors 2, 3 or 4 is also present, the motor continues its motion in the conveying direction only until the start operation has completed (= Class 10 time elapsed, 10s). 2 and 4 listed above are executed 3 x. 6. Continue with 9, 10 and 11 of Scenario Clear the blockage in the opposite direction by ensuring that limit monitor 1 no longer responds. Note A blockage in the opposite direction never causes a fault message, it only results in immediate reversal in the conveying direction. Entry ID: , V1.0, 08/

50 7 Timestamping 7 Timestamping SIMOCODE pro V can provide digital signals with timestamps, recording every signal change. For statistical evaluation, for example, the... automatic reversing run (output of timer 1), lower current limit in conveying direction reached (output of limit monitor 2), upper current limit in conveying direction reached (output of limit monitor 3), cos φ lower limit in conveying direction reached (output of limit monitor 4), signals could be recorded. For the following reasons... Timestamping is not part of the core content of this application example. Timestamping is only available for the PROFIBUS version of the SIMOCODE device. Timestamping requires that the used DP master supports the functions for time synchronization via PROFIBUS (see chapter Timestamping in \3\.... the sample project does not include timestamping of the above events. However, the following table provides a brief description of its configuration and parameterization on the SIMOCODE side. Entry ID: , V1.0, 08/

51 7 Timestamping Configuring time synchronization and parameterizing timestamping Table 7-1: Configuring and parameterizing time synchronization 1. In the project tree, select Parameters Open Standard functions > Time stamping. 2. To timestamp the events suggested above, make the entries as shown in the figure 3. Check Time stamping active. 4. Open the Properties of Control device_1 and in General, check Time synchronization. The Interval must match the configuration of the time master. Entry ID: , V1.0, 08/