Batch - Technical Report

TEC 3601
Batch Fill and Mix Station

The Implementation of a PLC System to Control and Monitor a Batch Process
Presented by Joey Mercier Presented to John Sturtridge
April, 2011
CAMBRIAN COLLEGE
Batch Fill and Mix Station Statement of Authorship
April, 2011
I,________________________, hereby solemnly confirm that the work submitted for assessment is my own and its contents are expressed in my own words. Any uses of the works of any other author, in any form (ideas, equations, figures, texts, tables, programs), are properly acknowledged at the point of use. A list of the references used is included.
Table of Contents
Statement of Authorship ii
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List of Equations List of Figures List of Tables List of Symbols Executive Summary Introduction Purpose Background Scope Sequence of Operation PLC Program Long Comments Memory Mapping Troubleshooting Aid Power-Up Delay Scaling Weight Comparators and Solenoid Valve Control Cycle Control and Drum Counter Conversion to Internals for Bit Offset Masked Inputs Set Inputs of ICMP / Outputs of DRUM Pulse Timer
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vi vi vii viii ix 1 1 1 4 5 7 7 8 8 8 8 9 9 9 10 10
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Mixer Speed Control 1/2 Mixer Speed Control 2/2 Process E-Stops and Reset Set Read from Drum Location Limit Switches Detect Drum Locations Sequencer Step Initiator ICMP and Sequencer PLC Card Health 1/2 PLC Card Health 2/2 Workstation and Schematic Diagrams Actual PLC Rack and Workstation Main Schematic Diagrams PLC Input Cards DAI 540 00 115V Discrete Input ACI 030-00 4-20 Analog Input PLC Output Cards DRA 840-00 Relay Output Card ACO 020-00 Analog Output Card Traffic Cop Interfacing with RSView32 Using ANIMATE with RSView32 Interacting with ProWorx via KEPServer
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10 11 11 12 12 12 12 13 13 14 14 15 15 15 15 16 16 16 16 17 18 19
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The Graphical User Interface The Login Screen The Process Display Screen The Monitor Screen The Alarms Screen The PLC Card Health Screen Using the Altivar 31 Electronic Drive Advantages of Using an Electronic Drive Parameter Settings Conclusion Recommendations References Appendix A Mixer Motor Speed Control Appendix B Batch Processing PLC Schematics Appendix C PLC Program Appendix D Omega DMD-466 Specifications Appendix E Altivar 31 Electronic Speed Drive Characteristics and Specifications Appendix F Parameter Settings for the Altivar 31 Electronic Drive
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Batch Fill and Mix Station List of Equations

EQUATION(1.1): THE ROTATIONAL SPEED OF A 3 PHASE MOTOR EQUATION (1.2): THE INDUCTIVE REACTANCE IN A COIL
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EQUATION (1.3): THE PHASE ANGLEOF THE STATOR AND ROTOR MAGNETIC FLUX IN A 3 PHASE MOTOR 27
List of Figures
FIGURE 1: PLC WORKSTATION FIGURE 2: ACTUAL PLC RACK FIGURE 3: TRAFFIC COP IN PROWORX FIGURE 4: THE ANIMATE SOFTWARE PROGRAM FIGURE 5: KEPSERVER SOFTWARE FIGURE 6: NAVIGATING MENUS IN THE RSVIEW32 GUI FIGURE 7: THE LOGIN SCREEN FIGURE 8: THE PROCESS DISPLAY SCREEN FIGURE 9: THE MONITOR SCREEN FIGURE 10: THE ALARM SCREEN FIGURE 11: THE ALARM LOG VIEWER FIGURE 12: THE PLC CARD HEALTH SCREEN FIGURE 13: FLOWCHART LEGEND FIGURE 14: BATCH PROCESSING MIXER SPEED FLOWCHART FIGURE 15: BATCH PROCESSING PLC SCHEMATIC DIAGRAM 1 OF 2 14 14 17 19 19 20 21 22 23 23 24 24 34 35 36
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FIGURE 16: BATCH PROCESSING PLC SCHEMATIC DIAGRAM 2 OF 2 FIGURE 17: PLC 115V DISCRETE INPUT CARD SCHEMATIC FIGURE 18: PLC ANALOG INPUT CARD SCHEMATIC FIGURE 19: PLC RELAY OUT CARD SCHEMATIC FIGURE 20: PLC ANALOG OUTPUT CARD SCHEMATIC
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List of Tables
TABLE 1: PARAMETER SETTINGS FOR THE ALTIVAR31 28
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List of Symbols
CMD CONT M CV CYC DDE E-Stop Freq. Drive GUI HMI INI ICMP INS/OUTS MX LM_SW LS MISCOMP=0 O/L POS PWR PLC PWM SV Command Contactor Contactor (except M4, which is a relay) Conveyor Cycle Dynamic Data Exchange Emergency Stop Frequency Drive, otherwise known as Electronic Speed Drive Graphical User Interface Human-Machine Interaction Initiate Input Compare Inputs/Outputs Interposing Relay Limit Switch Limit Switch Returns the value 0 is there is no comparison Overload Position Power Programmable Logic Controller Pulse Width Modulation Solenoid Valve
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Executive Summary
IMPLEMENTING A PROGRAMMABLE LOGIC CONTROLLER SYSTEM TO CONTROL AND MONITOR A BATCH PROCESS
As with all industrial processes, the costs of maintenance and operations, along with production, are the leading factors in determining profits. Mitigating lost production time as a result of maintenance is, therefore, one of the highest priorities of industries. Programmable Logic Controllers (PLC) offer the same operational control of a process as your standard relays and hardwired control schemes, but they also allow for expansion in terms of monitoring and control capabilities. This, in turn, lowers your down time and increases production, which ultimately results in increases in profit. Additionally, PLCs are a proven piece of
technology that have a much longer life than their electromechanical counterparts (e.g.: relays), and can handle many more
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components at a time (adding or removing input/output cards allow for total control over many things at once). A batch fill and mix station, specifically, consists of continuously adding ingredients together and mixing them, andfollows a general sequence that is repeated over and over. Furthermore, such a process is not keen on manual intervention. A properly programmed PLC is excellent at creatingsuch a sequence, based on the state and status of certain inputs/outputs, consequently completely automating the process. Using monitoring software in combination with the PLC makes the most powerful combination. Every bit of information about the ongoing process can be constantly monitored (by a user or a computer) and programmed to alarm if something was to go wrong, all without adding the slightest component. This seamless interaction between the PLC and the monitoring software greatly simplifies the whole troubleshooting experience, thus positively affecting production, down time, and maybe even employee morale (less pressure on the employees make it a less stressful environment). The mixing station of the batch process includes a mixer that usually operates at different speeds it ramps up and down. This
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ramping sequence allows for more even mixing and prevents the ingredients from being spilt during the startup of the motor (less initial shock ). The best way to control and vary the speed of a motor is with an electronic frequency drive. The latter allows for complete speed control with maximum torque, and improves motor efficiency. Moreover, it improves the power factor of the motor, removing the need for extensive power factor correction, which saves money and many foreseeable headaches. Choosing to implement a PLC and its dedicated monitoring software to control and monitor a batch fill and mix station will improve the overall process, which include (but isn t limited to) total productions and better, more proficient maintenance practices. In addition, it will allow for constant monitoring over the entire process, including faults and alarms. These accrued benefits will result in a higher return of investment, and make the batch fill and mix station a very efficient, lucrative industrial process.
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Introduction
Purpose
This report details the process of implementing a Programmable Logic Controller (PLC) to control, in its entirety, a batch process. The batch process in question is a fill and mix station, where two ingredients are poured into a drum and mixed for 50 seconds. After 10 completed drums, the process stops. It must be noted that there are theoretical limitations to this report. The entire process was created and tested theoretically in the PLC lab class. This means that the real inputs supposedly connected to the PLC discrete input cards are simulated with switches. Furthermore, the analog-in signal is simulated with a potentiometer, and the output of the analog out is simulated with an indicator (0 to 100%). With all of these simulations taken into consideration, and with my knowledge of field processes, I believe this report is still a very accurate depiction of an actual batch fill and mix station. I am confident that it would undoubtedly work if it ever were to be implemented in the field. This report also satisfies the academic requirements of the Electrical Engineering Technology program at Cambrian College.
Background
Batch processes are found in a myriad of production plants. Manufacturers, of
anything from cakes to computer chips, have numerous ways of organizing
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production. One of these methods is called batch production. This is when, instead of manufacturing things singly, or by continuous production [ ], items are manufactured in batches (Ellis-Christensen, 2010). Batch processing is the engine that drives the production of many different everyday goods, and in these systems, total automation is paramount; manual intervention is greatly undesirable, and can even become detrimental to the entire process. This is where PLCs come into play. Programmable Logic Controllers are the best method of controlling a process automatically, with a user being capable of troubleshooting and making changes to the system simply by interfacing with a computer. In this report, the
implementation of a PLC is done with the Modicon Quantum Series Automation PLC system. The PLC rack consists of ten slots six of which are filled with the
following cards: one CPS 114-20 power supply card, one CPU 454 12A controller card,two DAI 540-00 discrete inputs cards, one ACI 030-00 analog input card, one ACO020-00 analog output card, and one DRA 840-00 relay output card. The interface system used is the Microsoft Windows XP Service Pack 3 platform, and all the programming is done on ProWorx NxT version 2.20 Special 8. The
communications between ProWorx and the PLC controller is achieved through Modbus Plus. Modbus is a serial communications protocol published by Modicon in 1979 for use with its programmable logic controllers (PLCs). Simple and robust, it has since
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become one of the de facto standard communications protocols in the industry, and it is now amongst the most commonly available means of connecting industrial electronic devices (Drury, 2009). For the batch processing in this report, Modbus Plus is used, which is essentially an extended version of Modbus, with faster transmission speeds. The batch process also has a graphical user interface (GUI), which visually depicts the process as it unfolds. The software
used to achieve this is RSView32, and communications from the PLC to RSView32 is done with the aid of KEPServerEx v4.0. The advantages of using a PLC system to control an entire batch process are numerous, ranging from saving loads of money by reducing down time for troubleshooting, to having a constant visual indication of what is going on through the process at all times. Additionally, as mentioned above, in batch processes total automation is paramount, and a PLC is the best way to achieve this. Disadvantages to using a PLC are the initial setup costs and the setup itself;firstly, the schematic diagramstend to be more complicated and don t adequately represent the process (you must refer to the PLC program to understand how the process works).Secondly, the entire PLC program must be written beforehand and thoroughly tested before it can be implemented, and lastly, the sum of the costs with purchasing a PLC with all the required software may seem a bit exuberantat first. However,by looking at the bigger picture, it is easily observed that the advantages simply outweigh these mere initial inconveniences.
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Scope
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The topics covered in the report are: the sequence of operation of the batch fill and mix station, the long comments associated with all the networks of the PLC program, a detailed analysis of the schematic diagrams, the explanation of the Traffic Cop used for the PLC I/O cards, the interfacing with RSView32,using the Altivar Electronic Drive to control the mixer motor, and finally, the conclusion and recommendations.
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Sequence of Operation
The following paragraphs will detail the sequence of operation of the batch fill and mix station. All steps will have a link to the corresponding network in the PLC program where the action is being controlled. It is assumed that there are no faults on the system, as most faults encountered1turn off the process until it is remedied. Refer to the PLC program in Appendix C for the networks. 1. Press Cycle Start pushbutton in the field or in the RSView32 GUI, and the cycle on light comes on (network 6: Cycle Control and Drum Counter). 2. The Program detects where the drum is located with the help of the limit switches (network 15: Detect Drum Locations). If LS1 is actuated (drum ready), then the next step is step 3. If LS2 is actuated (drum in fill position), then the next step is step 4. If LS3 is actuated (drum in mixing position), then the next step is step 6(all of theinitial sequencing is controlled by network 16: Sequencer Step Initiator). 3. The conveyor starts and runs until the drum arrives to the fill station [until LS2 is actuated (network 17: ICMP and Sequencer)]. 4. SV3 opens and chemical #1 is dispensed until the fill weight reaches 30 lbs (transducer specs sheet in Appendix D). SV3 closesand SV4 opens, dispensing chemical #2 until the fill weight reaches 60 lbs. SV4 is then closed (network 5: Weight Comparators and Solenoid Valve Control).
Example: A PLC Card failure will not shut down the process, but will generate an alarm in RSView32 with high severity.
1
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5. The conveyor starts and runs until the drum arrives to the mix station [until LS3 is actuated (network 17: ICMP and Sequencer)]. 6. M2 energizes, making the mixer motor descend until LS4 (mixer in down position) is actuated (network 17: ICMP and Sequencer). 7. M4 energizes sending a start command to the drive controlling the mixer motor. The mixer motor has two speeds and is ramped up/ramped down, and for the full speed control sequence refer to Figures 13 and 14in Appendix A [networks 10 thru 12: Pulse Timer (N:10), Mixer Speed Control 1/2 (N:11), and finally, Mixer Speed Control 2/2 (N:12)]. 8. After the mixer motor is ramped down M3 energizes, making the mixer motor ascend until LS5 (mixer in up position) is actuated (network 17: ICMP and Sequencer). 9. The conveyor starts and runs until the drum arrives at its final destination and the next drum arrives at the ready position. (network 17: ICMP and Sequencer). 10. The count for the completed drums in the current cycle increments by one. After 10 completed drums, the system shuts down (network 6: Cycle Control and Drum Counter). 11. The total amount of drums in all cycles is stored in a separate register, and then the process proceeds back to step 3 (network 6: Cycle Control and Drum Counter).
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PLC Program Long Comments

Memory Mapping
PLC Coil Range Allocation 00001 00128 00129 00149 00150 00159 00700 00800 10001 10065 Real Discrete Outputs Internal Coils Sequencer Coils MMI Control Coils Real Discrete Inputs (Used to 00048) (Used to 00142) (Used to 00150) (Used to 00702) (Used to 10032)
PLC Register Assignments 30001 30032 40001 40009 40010 40399 40400 40500 40501 40699 40700 40799 Real Register Inputs Real Register Outputs Internal Registers Internal Registers for Masking Spare Registers STAT Block / Card Health (Used to 30009) (Used to 40004) (Used to 40354) (Used to 40500) (Not Used) (Used to 40712)
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Troubleshooting Aid
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This network visually displays the state of all the discrete inputs and outputs used in the program in order to help with the troubleshooting of a fault. The top portion consists of all the discrete inputs, and the bottom portion consists of the discrete outputs
Power-Up Delay
This network sets up a delay on power-up for 5 seconds in order to let the transmitters self-check and calibrate themselves and then energizes internal coil 00100.
Scaling
This network reads raw data (counts 0-4095) from a Load-cell transducer unit and converts it to an engineering unit (0 40205. 150 lbs) and stores that data into register
Weight Comparators and Solenoid Valve Control

This first function of this network is to detect two different weight values inside the drum when in the fill position. It detects when the weight reaches 30 lbs and is held at or above that weight for at least two seconds (anti-glitch feature) by energizing output coil 00005. It also does the same thing for 60 lbs, energizing output coil 00006. The other function of this network is to control and shutoff solenoid valves 3 and 4 when the weight reaches 30 lbs and 60 lbs respectively.
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Cycle Control and Drum Counter
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The first function of this network is to control when the cycle is ON or OFF with internal coil 00101. In order for the cycle to be started there must no stop commands and no overloads (faults). The second function of this network is to count the amount of drums per cycle, and store it in register 40101. Once register 40101 reaches 10, it initiates a system shut down via internal coil 00103. The third function of this network is to add the amount of completed drums per cycle to the total amount of drums completed and store it in register 40300. Registers 40101 and 40300 are added together whenever the cycle is stopped or completed.
Conversion to Internals for Bit Offset

This network converts output registers 00001 thru 00006 to internal coils. This offset is to allow the ICMP to read the values of inputs and outputs simultaneously.
Masked Inputs
This network copies the discrete inputs and real outputs, and applies a mask to them so that they can be conditioned and then used by the ICMP.
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Set Inputs of ICMP / Outputs of DRUM
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This network uses the masked inputs/outputs set up in network 8 and combines them into one common register (40500). This conditioning allows the ICMP to compare both the desired inputs and outputs simultaneously.
Pulse Timer
This network sets up a 1 second pulse timer that is used to ramp up/down and control the mixer motor speed. The pulse timer is stopped when we have a speed latch (at 50% speed and 100% speed) or when the mixer motor has finished ramping down.
Mixer Speed Control 1/2

This network controls the ramping up and ramping down of the mixer motor. The permissives for the mixer motor to run / change speeds are as follow: 1-The PLC must be sending a start command to the frequency drive (that means the cycle is ON) 2-There must not be a speed latch engaged (at 50% or 100% speed) and the motor cannot be fully ramped down 3-There must be a pulse from the pulse timer If there isn t a ramp down command (internal coil 00110 is not energized), the mixer motor s speed will be ramped up by 511 counts (or 12.5%) at every pulse from the pulse timer. If there is a ramp down command (internal coil 00110 is
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energized), the mixer motor s speed will be ramped down by 511 counts (12.5%) until it reaches 0%.
Mixer Speed Control 2/2

This network is only in operation when the cycle is ON. It detects when the mixer motor reaches 50% and 100% speeds and latches/un-latches the speed as necessary. When the motor reaches 50% speed during ramp up, coil 00106 is energized and it latches the mixer motor in at 50% speed for a total of 17 seconds. After the 17s have elapsed, a gear change allows the motor to ramp up to 100%, and then latches (coil 00108) the mixer motor at that speed for 26 seconds. After the 26s have elapsed, coil 00110 is energized and initiates a ramp down command.
Process E-Stops and Reset

This network deals with the emergency stops and the resets. When the cycle is OFF, the mixer speed is reset to 0%, sequencer step is returned to 0, and the outputs are reset. Input 10019 and MMI coil 00702 allow the total complete drums register 40300 to be reset to 0. The second function of this network is to detect if any of the motors have an overload and engage internal coil 00112.
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Set Read from Drum Location Limit Switches
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This network reads the limit switches that determine the drum location on the conveyor (discrete inputs 10005 thru 10007). It then sets up a mask, and applies it the aforementioned limit switches, and then stores it in register 40213.
Detect Drum Locations

This network uses the value in register 40213 to detect where the drum is located. Additionally, it provides the program with the means to expand and work for more than one drum at a time per cycle if it ever were required. When the drum location is detected, the associated internal output is energized.
Sequencer Step Initiator

This network sets the correct step to the sequencer. When the cycle is switched ON, the program allows the sequencer 1/10th of a second to set itself up. If the drum is in the fill position, register 40140 (the current step register for the sequencer/ICMP) is set to 3. If the drum is in the mix position, register 40140 is set to 5. If the drum is neither in the fill or mix positions, register 40140 remains at 0.
ICMP and Sequencer

This network deals with the sequence of the cycle. When the cycle is switched on, there is a 1/10th of a second delay to allow the initial step to be setup (network 16). This network has two SCIF blocks, one being a sequencer and the other an ICMP.
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The ICMP compares the state of inputs/outputs conditioned in the previous networks to the data of the current step. If there is a match, the ICMP energizes internal coil 00150. This means that the step is complete. When coil 00150 is energized it sends a pulse to the sequencer. This allows the sequencer to change the current step and control certain outputs. When all the steps are complete, the sequencer energizes internal coil 00102, which is the cycle complete command. That coil then restarts the sequencer, which in turn restarts the ICMP.
PLC Card Health 1/2

This network is the first of two that detects the health of the PLC cards. The STAT block sets up register 40712 to be the word with the state of all the cards in the PLC rack. Output 00137 is de-energized if the power supply card fails, output 00138 is de-energized if the analog input card fails, and finally, output 00139 is de-energized if the analog output card fails.
PLC Card Health 2/2

This network is the second of two that detects the health of the PLC cards. Output 00140 is de-energized if the first discrete input card fails, output 00141 is de-energized if the second discrete input card fails, and finally, output 00142 is de-energized if the relay output card fails.
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Workstation and Schematic Diagrams

Actual PLC Rack and Workstation
As mentioned in the Purpose section of the introduction, there are theoretical limitations to the project. The entire the project is done in the PLC lab class at a computer workstation (Figure 1).
Figure 1: PLC Workstation
Additionally, the discrete and analog inputs are simulated using switches and a potentiometer respectively they are mounted directly on the PLC rack (Figure 2). The switches are on the input cards, and the potentiometer (and indicator, for the analog output) is on the simulation card XSM 010 00.
Figure 2: Actual PLC Rack
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Main Schematic Diagrams
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The main schematic diagram is found onFigures 15and 16in Appendix B. It consists of 3 x 575V motors: the conveyor motor, the mixer up/down motor (which operates in forward and reverse), and the mixer motor (which is controlled by a frequency drive the reasoning behind this will be explained in great detail later
in this report). The control circuit stems off of the conveyor motor power circuit, and feeds all of the components/inputs/outputs required to control the process. In essence, a single 575V, 3-phase supply is required for the entire process (none of the motors are on at the same time).
PLC Input Cards

DAI 540 00 115V Discrete Input The first set of schematics for the PLC input cards are the 115V discreet inputs, which are found on Figure 17 in Appendix B. The use of two separate cards was to facilitate the ICMP function in the PLC program, and I had two cards at my disposal. ACI 030-00 4-20 Analog Input The second schematic for the PLC input cards is the analog input, which is found on Figure 18 in Appendix B. A weight is received by the load cell sensor and interpreted by the transducer, and then converted to a 4-20 mA signal. This analog signal then goes to the analog input, where it is converted to counts (04095) to be used by ProWorx.
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PLC Output Cards
DRA 840-00 Relay Output Card
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The first schematic for the PLC output cards is the relay out, which is found on Figure 19 in Appendix B. As its name implies, this card does not provide power to its outputs, it is simply comprised of 16 normally opened contacts that are controlled within the PLC program (like a relay). ACO 020-00 Analog Output Card The second schematic for the PLC output cards is the analog output, which is found on Figure 20 in Appendix B. As previously mentioned (for the analog input), ProWorx does not directly work with the 4-20 mA, it must first convert it to counts (0-4095). The Analog output card acts as a transducer by converting the count value back to a 4-20 mA signal. This signal is then sent to the frequency drive analog input AI3 and used to control the mixer motor speed.
Traffic Cop
Traffic Cop is what ProWorx utilizes to determine which PLC cards are being used and where they are physically located in the PLC rack. Additionally, it is used to set up the addressing, and therefore generally sets up the memory mapping (refer to the PLC Long Comments section of this report for a complete list of the
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memory mapping) to be used within the PLC program. Figure 3 visually displays the Traffic Cop used for the Batch Fill and Mix Station.
Figure 3: Traffic Cop in ProWorx
A quick comparison between Figures 2 and 3 will show which cards are being used in respect to what is actually in the PLC rack. The Traffic Copped PLC rack is composed of the following cards (in order from left to right in Traffic Cop): one CPS 114-20 power supply card, one CPU 454 12A controller card, one ACI 030-00 analog input card, one ACO 020-00 analog output card, two DAI 540-00 discrete inputs cards, and one DRA 840-00 relay output card.
Interfacing with RSView32

RSView32 is an integrated human-machine interaction (HMI) software program that enables us to obtain data from the field (in this case, acquired from the PLC)
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and display it in an easy to follow graphical interface. The program greatly facilitates the troubleshooting of a fault, and keeps the user up to date on the entire process at all times. A mediator program, known as KEPServer, does the communications between the PLC and RSView32. In laymen s terms, KEPServer allows the data collected in ProWorx to be seamlessly shared with RSView32. Another great feature of RSView32 is its versatility it can be used in conjunction
with other programs (such as ANIMATE) to create animations without doing any additional programming in ProWorx.
Using ANIMATE with RSView32

ANIMATE is a DDE (Dynamic Data Exchange) server that is used with RSView32 to create animations. The advantage of using ANIMATE is that no additional it has values of constantly changing numbers (as seen
programming is required
in Figure 4), which can be used to create rotations and other simple types of animations without the slightest bit of change to the PLC program. This proves itself as being advantageous because it keeps the PLC program de-cluttered, simple, and easier to read. The only inconvenience of ANIMATE is that it must constantly be operating in the background, and if it is closed, RSView32 will not operate correctly.
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Figure 4: The ANIMATE Software Program
Interacting with ProWorx via KEPServer

As mentioned above, in order for the PLC and RSView32 to communicate and exchange information, we need a mediator . KEPServer (Figure 5) sets up these communications (in this case, in Modbus Plus) and interactions between the PLC and RSView32. Like ANIMATE, it must be operating in the background at all times, or else RSView32 will not be able to communicate with the PLC.
Figure 5: KEPServer Software
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The Graphical User Interface
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The RSView32 GUI (Graphical User Interface) for the Batch Fill and Mix Station is composed of 5 screens: the Login screen, The Process Display screen, the Monitor Screen, the Alarms Screen, and finally, the PLC Card Health Screen. The navigation between menus (see Figure 6) is achieved with the Navigation button (1), which opens up a submenu (2), allowing the user to navigate through the menus without interfering with any pertinent visual aspects of the process.
Figure 6: Navigating Menus in the RSView32 GUI
The Login Screen The Login screen (Figure 7) does exactly what it implies: it allows the user to login to the GUI, and provides the security to prevent unauthorized access. The correct password must be entered before the rest of the buttons become visible.
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Figure 7: The Login Screen
The Process Display Screen The Process Display (Figure 8) screen gives the user a visual representation of what is happening in the field. It displays whether the cycle is on or off, the drum s location on the conveyor, the limit switches (along with their current state), the SVs and the fill weight of the drum, the position of the mixer motor along with its current speed, the amount of drums completed, and finally, the most recent alarm encountered. The Progress Display screen also allows the user to start and stop the current cycle, and even reset the count of total completed drums with the software pushbuttons incorporated in the top left portion of the screen.
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Figure 8: The Process Display Screen
The Monitor Screen The Monitor screen (Figure 9) is very similar,yet different to the Process Display screen. It differs by showing the actual state of every input and output connected to the PLC in an easy to read, structured setting. In addition, it provides the user with the information on the current step being performed. It also displays (as text) the position of the drum and mixer. Just like the Process Display screen, The Monitor screen displays the most recent alarm encountered.
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Figure 9: The Monitor Screen
The Alarms Screen The Alarms screen(Figure 10) is a popup window that displays the alarms received, at what time the event occurred, the severity of the alarm (1 being the most severe), and the time the alarm was acknowledged.
Figure 10: The Alarm Screen
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The alarm screen also allows the user open the alarm log viewer (Figure 11), which is the log of all the alarms that occurred, with all the same information provided on the alarm screen.
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Figure 11: The Alarm Log Viewer
The PLC Card Health Screen The PLC Card Health screen(Figure 12) is a popup window that displays the health of each individual PLC card Traffic Copped in ProWorx.
Figure 12: The PLC Card Health Screen
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Batch Fill and Mix Station Using the Altivar31 Electronic Drive
April, 2011
Electronic drives, or frequency drives, are becoming increasingly popular in modern processes due to their versatility and ease of use. The drives offer optimal control of motor speeds without the need of additional components in the motor circuit, like extra contactors, timers, resistors or autotransformers. The Altivar 31 electronic drive used in this project uses pulse width modulation (PWM) to control the output voltage and output frequency going to the motor. It essentially receives a sinusoidal 3-phase 575V input, rectifies it into a DC voltage, and then inverts it back into a square wave pulsating AC voltage. The pulses of the AC voltage are then varied according to the desired speed of the motor, and this results in a change of output frequency to the motor (which is where the name frequency drive is derived from).This method of speed control is
mathematically proven by (1.1), where RPM is the actual motor speed in rotations per minute, Hz is the frequency applied to the motor, and #poles(constant) is the amount of poles the motor has (typically 4). 120 v Hz # poles
RPM !
(1.1)
To get a list of all the specifications/characteristics of the Altivar 31 electronic drive, please refer to Appendix E. The Altivar 31 must first be setup properly in order to control the speed of the mixer motor consulting the manufacturer s manual is always a good idea before
the first power up. As mentioned previously, the drive receives a 4-20 mA input in
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its analog input AI3 and uses that as a reference, where 4 mA is minimum speed (0% or 0Hz), and 20 mA is maximum speed (100% or 60Hz). However, without a start command, the drive will not operate this is where logic input LI1 comes
into play. When +24 Vdc is applied and held to LI1, the drive receives a start command, and the speed of the mixer motor is now controlled depending on the amount of current applied to AI3 (refer to Figure 20 and Figure 16 in Appendix B for a visual representation of terminals AI3and LI1respectively). Getting the drive to operate this way is very simple, and is set with the aid of parameter settings, which will be discussed shortly. Before talking about the settings of the drive, I will begin by explaining the advantages of using an electronic drive to control the mixer motor.
Advantages of Using an Electronic Drive

The first advantage of using the Altivar 31 isthe torque-speed characteristics it brings to the mixer motor; other across the line methods of speed control (generally varying the voltage to the motor) for motors offer low torque at lower speeds. With the electronic drive, nearly 100% torque is maintained at all speeds. This is due to varying the frequency instead of the voltage applied to the motor, thus positively affecting the interaction of the stator and rotor magnetic fields. By lowering the output frequency to the motor, the inductive reactance (which is a type of resistance obtained in magnetism) in the motor coils is also lowered,which is proved by (1.2), where XLis the inductive reactance (in ohms), F is the frequency
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(Hz), and L is the inductance of the coil (stays constant, and is expressed in Henries). X L ! 2TFL (1.2)
This will, in turn, cause a smaller difference between the phase angle in the stator and rotor magnetic flux, as proved by (1.3), where TanJis the phase angle in the stator or rotor, XLis the inductive reactance (in ohms), and R is the actual resistance in the coil (is constant, and expressed in ohms).
tan J !
XL R
(1.3)
This causes increased torque at lower speeds, increased efficiency, and improves the power factor of the motor. All these advantages will result in a longer motor life and improved performance. Another advantage of using the Altivar 31 is that we no longer need thermal or magnetic overloads to monitor the mixer motor for thermal damage. The drive can be programmed to monitor the temperature of the mixer motor and engage a contact if an overload condition exists. This brings me to the next advantage: the drive constantly monitors the mixer motor for over current, incorrect voltages, and other faults. Additionally, it also filters and snubs transients, and has a plethora of different settings that can be used to control the motor.
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Parameter Settings
April, 2011
Most of the advantages listed above cannot come to fruition without the proper programming of the parameter settings to the drive. Consult Appendix F for all the available parameter settings only the prominent settings are programmed to the drive. The following table lists the parameter settings used, the setting at which they are set, and the reason for that particular setting. Settings Menu (SEt) Parameter Setting What is does This setting sets the low speed of the motor. When the speed 0 Hz reference is at its minimum value, the motor will operate at a speed of 0 Hz. This setting sets the high speed of the motor. When the speed 60 Hz reference is at its maximum value, the motor will operate at a speed of 60 Hz. This setting sets the motor thermal state threshold, above which the relay contact (R1) will change state. It is used to set the 115% overload, in this case set at 115%; the motor will have an overload if its temperature reaches 115% its rated temperature. Drive Control Menu (drC) Parameter Setting What is does bFr UnS 60 Hz This setting is the motor frequency 575 V This setting is the nominal motor voltage (as indicated on the motor nameplate) This setting is the nominal motor frequency (as indicated on the motor nameplate)
LSP
HSP
ttd
FrS
60 Hz
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This setting is the nominal motor current (as indicated on the motor nameplate) This setting is the nominal motor speed (as indicated on the motor nameplate) This setting is the motor power factor (as indicated on the nameplate) I/O Menu (I-O)
nCr
varies
nSP
varies
COS
varies
Parameter Setting What is does tCC 2C This setting is to set the type of control, in this case set to 2-wire control
tCt
This setting is to set the type of 2-wire control. It is set so that a trn transition from low to high on the logic input must occur before a start command is received. 4 mA This setting sets the minimum reference value for AI3. When this value is reached, the motor will go at its lowest speed (LSP) This setting sets the maximum reference value for AI3. When this value is reached, the motor will go at its highest speed (HSP)
CrL3
CrH3
20 mA
r1
This sets what relay R1 will engage to. In this case it is set to motor tSA thermal threshold reached - when the setting (ttd) is reached, the R1 contacts will change state. Control Menu (Ctl)
Parameter Setting What is does Fr1 rFC rOT AI3 This setting configures the speed reference, in this case set to AI3, which is the 0 - 20 mA current input.
Fr1 This setting assures that the reference set cannot change from Fr1. dFr This setting sets the direction of rotation of the motor, in this case, forward. Application Functions Menu (FUn)
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Parameter Setting What is does
April, 2011
Stt
This setting sets the normal stop type of the motor. When the run rNP command disappears from the logic input the motor will follow the ramp to stop. Fault Menu (FLt)
Parameter Setting What is does OPL YES This setting assures that the drive will trigger an OPF fault if there is a motor phase loss. This setting assures that the drive will trigger a fault if there is a line phase loss. This setting allows the motor to come to a freewheel stop in the event of a drive overheating fault.
IPL
YES
OHL
YES
OLL
This setting allows the motor to come to a freewheel stop in the YES event of a motor overload fault. This setting allows the motor to come to a freewheel stop in the YES event of a loss of the 4 - 20 mA current signal.
Table 1: Parameter Settings for the Altivar31
LFL
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Conclusion
In conclusion, the implementation of a PLC system to control and monitor a batch fill and mix station was successful. A programmable logic controller is the best option for total automation of a process, and with the integration of RSView32 as an HMI, the process is not only visually displayed at all times, it also logs any fault that occurs at any given time. This greatly enhances the troubleshooting efficiency and results in a proactive reduction of down time. By looking at the big picture, I strongly believe that the overall process improvements (with regards to time for troubleshooting, constantly monitoring, etcetera) attained by using a PLC to control a batch fill and mix station make it the most viable option for total costs. The upsides of using the PLC will result in quickly repaying the large initial costs of the system. To sum it all up, the powerful combination of ProWorx, RSView32 (and its associated programs: KEPServer and ANIMATE), Modbus Plus, the Modicon Quantum Series Automation PLC, a personal computer (with Windows XP), and a knowledgeable user make a great team for any industrial process. The use of an electronic drive to control the speed of the mixer motor was also a key point in this report: the drive provides the motor with more torque at all speeds, better speed control, better power factor (and efficiency), and more monitoring capabilities.
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Batch Fill and Mix Station Recommendations
April, 2011
The only good recommendation I can make is to have the project tested in the field prior to the first startup. Although I am confident of its functionality, testing is always the safest option testing capabilities. Another recommendation (not as feasible as the first) would be to upgrade the outdated ProWorx NxT to ProWorx 32. This newer version of ProWorx can import programs from its older NxTcounterpartand convert it to a 32-bit format (currently at 16-bit) without changing the initial program, and this would result in the PLC program being useable on newer operating systems. All communications (through Modbus Plus) would remain the same, and RSView32 would still work the same way. With the constant innovations in computer technology, older software programs (like ProWorx NxT) tend to become obsolete faster, and keeping the PLC program up to date could help solve compatibility issues down the road. This would be particularly advantageous on a new installation. the theoretical limitations of the project limit my
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References
Drury, B. (2009). Control Techniques Drives and Controls Handbook (Second ed.). London, England: Institution of Engineering and Technology. Ellis-Christensen, T. (2010, March 30). What is Batch Production? Retrieved April 5, 2011, from WiseGeek: http://www.wisegeek.com/what-is-batchproduction.htm
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Appendix A Mixer Motor Speed Control

The following flowcharts describe the decision tree process used for the speed control of the mixer motor.
LEGEND
TERMINAL POINT SYMBOL
PROCESS SYMBOL
DECISION SYMBOL YES ONPAGE CONNECTOR
NO
OFFPAGE CONNECTOR SYMBOL
BATCH PROCESSING MIXER SPEED FLOWCHART
DATE: 24/03/2011
DRAWN BY: JOEY MERCIER
Figure 13: Flowchart Legend
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LOAD AT LC PROGRAM MANUALLY START CYCLE NO STOP AND ALARM
YES
WAIT OR MI ER TO BE DOWN NO NO YES
YES
NO WAIT OR DRUM TO BE IN MI POSITION
IS PLC SENDING A START COMMAND TO MI ER?
NO
STOP AND ALARM
YES
HAS MOTOR BEEN RUNNING AT 5 % OR 17s?
YES NO READ ROM REGISTER "40002"
NO
HAS MOTOR BEEN RUNNING AT 100% OR 26s?
YES READ ROM REGISTER "40002"
NO
YES
SEE NETWORK IS MOTOR SPEED AT 0%? YES MI ER MOTOR SPEED CONTROL OK

IS THERE A PULSE ROM THE TIMER ?
WAIT OR PULSE (1s)
BATCH PROCESSING MI ER SPEED LOWCHART
Figure 14: Batch Processing Mixer Speed Flowchart
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NO
YES
RAMP DOWN MOTOR SPEED BY 511 COUNTS (12.5%)
RAMP UP MOTOR SPEED BY 511 COUNTS (12.5%)
NO
DATE: 24/03/2011
DRAWN BY: JOEY MERCIER
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WAIT OR PULSE (1s)
NO
IS THERE A PULSE ROM THE TIMER ?
YES
I ITIAT RAMP DOWN COMMAND
IS T ERE A RAMP DOWN CMD?
IS MOTOR RUNNING YES AT 100%?

YES
NO
ALLOW MOTOR TO RUN AT 100% OR 26s
NO
IS MOTOR RUNNING AT 5 %?
IS SEQUENCER AT STEP 6?
IS DRUM IN MI POSITION?
IS MI ER MOTOR DOWN?

READ ROM REGISTER "
"
IS T E CYCLE ON?
NO
ARE T ERE ANY AULTS?
YES
STOP AND ALARM YES
NO ARE ONLY LS3 AND LS4 ACTIVATED?
YES
ALLOW MOTOR TO RUN AT 5 % OR 17s
Batch Fill and Mix Station Appendix B Batch Processing PLC Schematics
April, 2011
3% LINE REACTOR AS REQUIRED PER ALTIVAR 31 INSTALLATION MANUAL LOAD FILTER AS RECOMMENDED PER ALTIVAR 31 INSTALLATION MANUAL
DRAWN BY: JOEY MERCIER BATCH PROCESSING PROGRAMMABLE LOGIC DATE: PRINT 1 OF 2 NTS CONTROLLER SCHEMATIC DIAGRAM 24/03/2011 Figure 15: Batch Processing PLC Schematic Diagram 1 of 2
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115VAC CONTROL POWER CONTINUED FROM PRINT 1
BATCH PROCESSING PROGRAMMABLE LOGIC CONTROLLER SCHEMATIC DIAGRAM
DATE: 24/03/2011
DRAWN BY: JOEY MERCIER PRINT 2 OF 2 NTS
Figure 16: Batch Processing PLC Schematic Diagram 2 of 2
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Figure 17:PLC 115V Discrete Input Card Schematic
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BATCH PROCESSING PROGRAMMABLE LOGIC CONTROLLER CARD SCHEMATICS
April, 2011
Figure 18: PLC Analog Input Card Schematic
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Figure 19: PLC Relay Out Card Schematic
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Figure 20: PLC Analog Output Card Schematic
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Batch Fill and Mix Station Appendix C PLC Program
April, 2011
The following pages include the entire PLC Program as printed from ProWorx. It contains the ladder logic, short comments, long comments, and all component addresses.
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Appendix D Omega DMD-466 Specifications

The following pages contain the specifications sheet for the load cell transducer used in this process: the Omega DMD-466.
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Appendix E
Altivar 31 Electronic Speed Drive Characteristics
and Specifications
The following pages include the characteristics of the Altivar 31 Electronic Speed Drive. It also consists of the applications of the drive, as well as the electrical specifications.
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Appendix F Drive
Parameter Settings for the Altivar 31 Electronic
The following pages include the parameter settings used for the drive to optimally control the mixer motor. The pages were taken from the drive s programming manual, which is copyrighted by Schneider Electric.
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Batch Fill and Mix Station

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Batch Fill and Mix Station List of Equations

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anything from cakes to computer chips, have numerous ways of organizing

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PLC Program Long Comments

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Weight Comparators and Solenoid Valve Control

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Conversion to Internals for Bit Offset

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Mixer Speed Control 1/2

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Mixer Speed Control 2/2

Process E-Stops and Reset

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Detect Drum Locations

Sequencer Step Initiator

ICMP and Sequencer

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PLC Card Health 1/2

PLC Card Health 2/2

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Workstation and Schematic Diagrams

Figure 1: PLC Workstation

Figure 2: Actual PLC Rack

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PLC Input Cards

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Batch Fill and Mix Station

Figure 3: Traffic Cop in ProWorx

Interfacing with RSView32

Batch Fill and Mix Station

Using ANIMATE with RSView32

Batch Fill and Mix Station

Figure 4: The ANIMATE Software Program

Interacting with ProWorx via KEPServer

Figure 5: KEPServer Software

Batch Fill and Mix Station

Figure 6: Navigating Menus in the RSView32 GUI

Batch Fill and Mix Station

Figure 7: The Login Screen

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Figure 8: The Process Display Screen

Batch Fill and Mix Station

Figure 9: The Monitor Screen

Figure 10: The Alarm Screen

Batch Fill and Mix Station