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Quick Startup Guide for SIMOVERT MASTERDRIVES 6SE70 VC

Standardized Pump Application

Section 1: Features and Function Description

Section 2: Physical Connections

Section 3: Parameter Adjustments

Section 4:Adding the Custom Pump Menu to Simovis

Version 1.0 July 1, 2000

We reserve the right to modify functions, technical data, standards, drawings and

parameters.

We have checked the contents of this document to ensure that they coincide with

the described hardware and software. However, deviations cannot be completely

ruled-out, so we cannot guarantee complete conformance. However, the

information in this document is regularly checked and the necessary corrections will

be included in subsequent editions. We are thankful for any recommendations or

suggestions.

NOTE:

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, please contact your local Siemens office.

Further, the contents of these instructions shall neither become a part of nor modify any prior or existing agreement, commitment or relationship. The sales contract contains the entire obligation of Siemens Energy & Automation. The warranty contained in the contract between the parties is the sole warranty of Siemens Energy & Automation. Any statements contained herein do not create new warranties nor modify the existing warranty.

Note:

This Standardized Pump Application Note is not an autonomous document, but is intended to direct users to the section in the Operating Instructions which are important for start-up. Thus, these brief instructions can only be completely valid when used in conjunction with the Operating Instructions. It is especially important to observe the warning and information regarding potential hazards in the Operating Instructions.

Warning:

Electrical equipment has parts an components which are at hazardous voltage levels.

If the warning information in the detailed Operating Instructions is not observed, this can result in severe bodily injury or material damage.

Only appropriately qualified personnel may work with this equipment.

These personnel must be knowledgeable with all of the warning information and service/maintenance measures of the Operating Instruction.

Perfect and safe operation of this equipment assumes professional transport, storage, erection and installation as well as careful operating control and service.

Section 1:

Features and Function Description

Standardized Pump Application

1.1 Features

1.2 Function Description

1.3 Signal Flow Charts

Note:

Refer to Operating Instruction Manual for power and control connections.

1.1

Features

Many pumping applications require similar control methods and the purpose of this application note was to attempt to standardize and offer a simplified commissioning process. The MASTERDRIVE VC is will suited for building a customized control scheme by taking advantage of the numerous Free Function Blocks.

1.1.1 Flow Rate By using programmable X-Y tables it is possible to calculate the approximate flow rate in any appropriate units. For the purpose of this application note “Gallons per Minute” has been selected. The final calculated value can be either viewed as a custom parameter (n044) or exported via standard communication protocol through connector

KK602.

1.1.2 Low Tank Level Direct Input

A digital input has been dedicated to detect when the tank level has

reached a minimum level.

In the Hand or Local mode, this triggers the drive to remain running, but forces the speed reference to zero. Once the low level switch is satisfied, the speed reference is automatically released.

In the Remote or Auto mode, this triggers the drive to remain running, but forces the speed reference to zero. Once the low level switch is satisfied, a programmable time delay, prevents the drive from releasing the speed reference too early. This allows the tank to raise the fluid level, preventing frequent pump interruptions.

A programmable alarm message A64 has been included to indicate

the low tank level.

1.1.3 External Interlock

A digital input has been dedicated to act as a permissive to fault the

drive if co-ordinated equipment upstream should stop functioning. A fault code F35 to be triggered under these conditions.

1.1.4 External Fault Reset A digital input has been dedicated to act as a fault reset. This input has been programmed to be active in both the Hand and Auto conditions.

The fault reset has also been used to automatically restart the drive provided the original start command is still active.

1.1.5 Hand/Auto Switch Preprogrammed as part of the TP170 functionality.

1.1.6 Analog Input #1 This analog input has been pre-programmed as the Auto Speed Reference.

1.1.7 Analog Outputs Preset Two analog outputs have been dedicated for Actual Speed Feedback and Motor Current.

1.1.8 Digital Outputs Preset Two digital outputs have been pre-programmed to provide status for Drive Running and Drive Fault.

1.2 Function Description 1.2.1 Flow Rate Two X-Y tables have been pre-loaded with curves to

1.2 Function Description

1.2.1 Flow Rate Two X-Y tables have been pre-loaded with curves to simulate the pump curve. In the default table a y=x 2 curve was used. A second table using y= x 3 was created and can be selected by changing parameter U180 = 1. This can be changed using the special Pump Application Menu Simovis or Drive ES Basic. (See section 1.2.10 for details). A direct entry via the PMU or OP1S is also possible.

The maximum flow rate must be entered into parameter U018. For example if the pump is rated to handle 150 Gallons / Minute at top speed, then this value should be entered at U018.

If the flow rate is 2000 Gallons / Hour, enter 2000 in parameter U018.

Free Function Blocks Consumed

Fixed Setpoints (2) Multiplier Blocks (2) X-Y Tables (2) Analog Signal Switches (1) Connector to Parameter Display (1)

1.2.2 Low Tank Level Direct Input

Digital Input #4, Binnector B16, Terminal 6 on X101is dedicated as a input for preventing the pump from operating without an appropriate

amount of source material to prevent cavitation.

important or a proximity switch is not available then place a jumper between terminals 6 and 1 on X101 to defeat this protection.

If cavitation is not

A programmable alarm message A64 has been included to indicate the low tank level. This will inform operators why the drive is running but the motor and pump are not turning.

Free Function Blocks Consumed

Analog Signal Switches (2) Programmable Time Delay (1) Connector to Alarm Function (1)

1.2.3 External Interlock Digital Input #6, Binnector B20, Terminal 8 on X101is dedicated as an input for co-ordination of upstream equipment. If the operation of the pumping system requires upstream equipment to be functioning, then in the event upstream equipment fail or stop and immediate shut- down in the drive will occur. Fault code F35 will be displayed to indicate this has occurred. If the condition is momentary and the upstream permissive is satisfied, then the drive will immediately begin re-pumping without having to issue a new start command. See point 1.2.4 External Fault Reset for details.

If co-ordination of upstream equipment is not required then place a jumper between terminals 8 and 1 on X101 to defeat this protection.

No Free Function Blocks were consumed

P575.i1 = 20 P575.i2 = 20

1.2.4 External Fault Reset Digital Input #5, Binnector B18, Terminal 7 on X101has been programmed as the remote source for drive fault reset. Faults can be reset by either the “P” key on the PMU, which is always active or this remote connection. The programming makes this remote connection active in either the Hand or the Auto configurations.

If a fault were to occur to the drive, a fault message would be displayed on the PMU or OP1S. When input #5 is toggled high then low, the fault message will be cleared if the source of the fault has been removed. Once the reset to the fault has occurred, the drive will immediately restart and resume to the active speed reference setting. If for safety reasons this is not appropriate, change P554 from the default value of 618 to 22. This will force the drive to be restarted after the fault has been cleared.

Free Function Blocks Consumed

AND elements (1)

1.2.5 Hand/Auto Switch The TP170A will control the status of P590, this in turn will

1.2.5 Hand/Auto Switch The TP170A will control the status of P590, this in turn will control whether the drive is in Hand (“local”) Operation or Remote Operation.

In the Hand operation, the PMU will control the start/stop and the up/down arrows will control the speed setpoint, by using the built-in Motor Operated Pot (MOP). Fault Reset, Low Tank Level, and External Interlock functions are still active through the remote digital inputs.

In the Auto operation, the Terminal inputs will control the start/stop and Analog Input #1 will be the source of the speed reference. Fault Reset, Low Tank Level, and External Interlock functions are active in Auto operation.

No Free Function Blocks were consumed

P590 = 14

1.2.6 Analog Input #1 This analog input has been pre-programmed as the Auto Speed Reference. The reference can be connected at terminals 15 and 16 on

X102.

1.2.7 Analog Outputs Preset Two analog outputs have been dedicated

Actual Speed Feedback has been pre-programmed and available at terminals 19 and 20 on X102.

1.3 Signal Flow Diagrams

Look at TP170A Main Screen. Is Drive in “Local Mode” or “Remote Mode”?.

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For “Remote Mode” Jump to Point “A”.

The following buttons on the TP170A Main Screen are active; Local Jog: As long as button is pressed the drive will operate at 5% speed. Fault Reset: If a fault occurs, it can be reset by pressing this button. To Start Drive: Will start the drive and ramp to speed selected by “Input Local Speed Reference Setpoint” Ramp Stop: Will appear when “To Start Drive” is activated, and when depressed will ramp the drive to a stop. Input Local Speed Ref: When selected a speed reference setpoint can be entered.

To select PUMP APPLICATION, Press Pre-loaded Applications;

Fan:

Selects Fan Application. Suitable for general applications.

Pump:

Selects Pump Application. Suitable for general applications.

Pump-Jack:

Selects Pump-Jack Application. Not-Suitable for general applications.

Extruder:

Selects Extruder Application. Suitable for general applications.

Winder:

Selects Winder Application. Suitable for Dancer control applications.

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For other applications listed, please refer to separate instruction set.

The Pump Application Screen will become the display screen for normal control and monitoring. This screen

gives Start/Stop control, Gallons / Hour display, Fault Reset, Low Tank Warning. To monitor using “Overview” or Graphic Display select “Main Screen Button” in lower right hand corner.

Low Tank Warning:

Monitors a digital input for a normally closed Prox switch for Low Level, and

Gallons / Hour:

will remove the speed reference if activated. Based on a X-Y Table a calculated flow rate is determined.

Auto Fault Reset:

Will configure the drive to restart on any momentary fault. Note Safety must

Immediate Stop:

be addressed anytime equipment is allowed to automatically restart. Will bypass the speed ramps and coast the motor.

Section 2: Physical Connections Standardized Pump Application 2.1 Control Connections 2.2 TP170A Connections Version 1.0

Section 2:

Physical Connections

Standardized Pump Application

2.1 Control Connections

2.2 TP170A Connections

2.1 Control Connections X101 1 TP170A 2 3 4 5 CBP2 6 7 8 9

2.1 Control Connections

X101 1 TP170A 2 3 4 5 CBP2 6 7 8 9
X101
1
TP170A
2
3
4
5
CBP2
6
7
8
9

Auto Speed Reference 0-10Volt (Default) +/- 10 Volt 4-20 mA

Not Used

Speed Feedback

Current Feedback

X102

15

16

17

18

19

20

21

22

+24 VDC

Common

Running Confirmation

Fault Status

No Connection

Low Tank Limit

External Fault Reset

External Interlock

On/Off

Tank Limit External Fault Reset External Interlock On/Off Analog Input 1+ Analog Input 1- Analog Input

Analog Input 1+

Analog Input 1-

Analog Input 2+

Analog Input 2-

Analog Output 1+

Analog Output 1-

Analog Output 2+

Analog Output 2-

2.2 TP170A Connections

+24 Vdc 1 2
+24 Vdc
1
2
2.2 TP170A Connections +24 Vdc 1 2 X101 To CBP2 Using Standard Profibus Connections Page 16
X101
X101

To CBP2 Using Standard Profibus Connections

Section 3: Parameter Adjustments Standardized Pump Application 3.1 Process Adjustment Parameters Version 1.0 July 1,

Section 3:

Parameter Adjustments

Standardized Pump Application

3.1 Process Adjustment Parameters

3.1 Process Adjustment Parameters U018i1: Rated Gallons/Hour Default:1500 Gallons/Hour U008i1: Max Pump Speed Calibration

3.1 Process Adjustment Parameters

U018i1: Rated Gallons/Hour Default:1500 Gallons/Hour

U008i1: Max Pump Speed Calibration

Default:100%

U297i1: Auto Fault Restart Delay Default:3.0 Seconds

U303i1: Low Tank Prox Switch Delay Time Default:3.0 Seconds

Section 4: Inserting Simovis Application Specific Menus Standardized Pump Application 4.1 Overview 4.2 Inserting

Section 4:

Inserting Simovis Application Specific Menus

Standardized Pump Application

4.1 Overview

4.2 Inserting “Project” Files

4.3 Inserting “System” Files

4.4 Using the Pre-Loaded Pump Application Menu

4.1 Overview The purpose of creating the Application specific menus were to allow Drive Users

4.1 Overview

The purpose of creating the Application specific menus were to allow Drive Users the ability to look at all the key parameters for an application in one area. Menus were created under the Free Parameterization area to allow this access. Since the function of these parameters are specific to this application, the names of the parameters have overwritten. In order to allow Drive Users the flexibility to revert back to the standard parameter names, new application firmware menus were added.

4.2 Inserting Project Files

Project files contain the application specific menus, that will be used for the Fan Application. The install file pumpproj.zip will load the required files into the pre-loaded Simovis on a Computer. The files will be copied to C:\Siemens\Simovis\Projects\MasterDrive CUVC.

4.3 Inserting System Files

System files contain the application specific firmware. The install file pumpsys.zip will load the required files into the pre-loaded Simovis on a Computer. The files will be copied to C:\Siemens\Simovis\System\MasterDrive CUVC.

4.4 Using pre-loaded fan application menus

Start Simovis and add a MasterDrive CUVC to the network. The firmware options have been expanded to include versions 3.0, 3.1, 3.2 and the new 3.P. Commission the drive and motor using the appropriate version as specified in r69 of the drive. Once commissioned, download the following Simovis download file Pump Application with TP170A.dnl.

After download is complete without errors, close drive screen and right click your mouse on the drive on the BUSCON screen. A menu will pop up allowing the firmware to be re-selected. Select firmware 3.P. Open the drive by double-clicking on the line item. Simovis will activate a warning message indicating that version 3.2 firmware has been detected. Ignore this warning and select the Drive Menu. Within the Free Parameter Screen a selection of important parameters have been made and descriptions altered to suit this application.

Here is the actual menu for the Pump Application.

altered to suit this application. Here is the actual menu for the Pump Application. Page 24