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HEX PUMP CONTROL DOC. 3AFE

Dept. Project

NatOil

Status Date

July 2, 2004

Author

Steve Boren

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Preliminary

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HEX PUMP CONTROL DESCRIPTION

The National Oilwell Hex Pump is controlled by a Siemens S7 Series PLC along with 2 ABBACS800 Multidrive Inverters. Each ABB ACS800 inverter is made of 3 R8i power modulesconnected in parallel, all being controlled simultaneously by one RDCU (Main Control Board)connected via a NDBU-42 branching unit. The new APBU-44 branching units will replace theNDBU-42. Each drive is operating an ABB motor, which are directly connected to an outer Bowlgear on the Hex Pump. Because of this rigid connection between both motors which will not allowslip between motors, the drives will operate in a Master and Torque Follower mode.

The over-riding Siemens S7 PLC is connected to both drives via a Profibus-DP communicationnetwork, where the drives utilize the RPBA-01 Profibus adapter module. There is also a DDCSFiber Optic network connected between Master Drive and Follower Drive, used when the Followeris operating as a Torque Follower for proper load sharing. The DDCS Fiber optic communicationlink is connected on Channel 2 of the RDCO-03 Fiber Optic Comm board, also directly connected

to the RDCU main control board. Both communication networks are active simultaneously.Depending upon the control mode the Follower is operating in which is controlled by the PLC, theFollower may be receiving control commands from either communication link. In normal loadsharing operation, the Follower drive will be receiving commands from the Master drive via DDCSFiber Optics, and the Profibus-DP will simply be used for monitoring status feedback of theFollower drive. If the Master drive were to Fault during operation, the Follower drive will becommanded to Coast to Stop. Then the PLC can send write to parameter 6001 and change theFollower drive to a Stand Alone controlled drive being commanded from the PLC instead of theMaster drive. This allows for operation of the pump by only the Follower Drive which is now beingcontrolled in a speed mode of operation. If Auxilliary equipment is lost on the Master drive duringnormal operation, then the PLC will shift the Follower drive from a Torque Follower to a stand aloneSpeed controlled drive on the fly, then shortly there after the Master drive will be commanded tostop. This is a bumpless transfer during operation from two drives load sharing, to the Followerdrive operating alone in a speed control mode. If the Follower drive were to fault during normaloperation of the pump, then the Master drive will continue operation without the Follower drive.Because the Master drive is always speed controlled by the PLC, by loosing the Follower drive thesystem transistions bumplessly to the Master operating in Stand alone mode.

Each drive has a different routine for Communication Loss Fault protection. The Master drive hasparameter 30.18 COMM FLT FUNC set to NOT SEL, which disables the drives watchdog oncommunications. To protect the system incase of a communication loss to the Master, the PLCsends a Heartbeat Bit which is a square wave to parameter 85.04. The drive is configured inGroup 51 to take this Heartbeat and return it to the PLC via Profibus. The PLC then monitors thesquarewave, if the signal stops toggling, then the Communication Loss is activated and theFollower drive will be transitioned to Stand Alone Speed Control as long as the communications

are still active to the drive. The Follower drive has parameter 30.18 set to FAULT. This allows theFollower to monitor the Master drives communications via the DDCS Fiber Link. If the Fiber Opticlink is lost between the drives, then the Follower drive will Fault so that the two drives do not fighteachother. When the Follower drive is transitioned to a stand alone Speed Controlled drive, thenthe Profibus Communication Loss Detection is monitored by the drive receiving commands intothe Control Word and the Heartbeat is monitored by the PLC in the same manor as the MasterDrive.

Both drives have Drive AP Programs present, both programs being different. Both Drives APPrograms are used for controlling the Precharge circuit. National Oilwell builds there own rectifiersto convert 600VAC to DC which is then fed to our ACS800 Multidrive modules. To control theinrush current to the DC capacitors, a precharge resistor is placed in series with the charging


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Dept. Project

NatOil

Status Date

July 2, 2004

Author

Steve Boren

Status

Preliminary

Revision

1.0

Page

2 / 12

circuit to limit the inrush current. The Drives AP program monitors the DC Bus Voltage andtriggers Relay Output 2 when 700VDC is met on the DC Link, this pulls in a contactor which shorts

the precharge resistor, thus taking it out of the circuit for normal drive operation. When the DC BusVoltage drops to 350VDC, a level below the drives undervoltage trip level, then the prechargecontactor is deactivated placing the precharge resistor back in the circuit.

Below is the Master Drives AP Program:


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Dept. Project

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Status Date

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Author

Steve Boren

Status

Preliminary

Revision

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The Follower Drives AP program also controls precharge, but it also performs another task.Because the drives are operating with no Encoder feedback from the motor and the Follower drive

is operating in Torque Mode during normal operation, the drive can occasionally loose properlmotor control when at zero speed. To prevent this from occurring, the Follower drives APProgram monitors the Master Drives Speed Reference via DDCS Fiber Optic link, and the actualmotor Torque requirement. The Follower drive will automatically shift from a Torque Follower to aSpeed Follower when the Master Drives speed reference is below approximately 7 rpm (100integer programmed in 85.05) and the Follower Motors actual Torque is below 1% (100 integerprogrammed in 85.08) for 2.5 seconds (85.09 = 2500 ms). The Follower drive will also shift toSpeed Mode when the PLC writes a value of 0 to 85.01.

The Follower Drives AP Program is below:

Control Enable Circuit

Both drives have a hardwired Run Enable connected to DI3. This input is controlled by Auxiliaryhardware so that the drive can not be operated unless all other auxiliary equipment is operational.If any of the auxiliary equipment drop out during normal operation, the PLC will drop the Run EnableCircuit causing the drive to coast to stop.


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Author

Steve Boren

Status

Preliminary

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AGPS-21C Board

The Inverters are each equipped with a AGPS-21C board which can be used to preventunexpected starts. These boards are accessed via a panel on the left-hand side of the invertermodule. On the board is a jumper that selects the voltage for the safety circuit, selection of either115VAC or 230VAC is available. National Oilwell has chosen to use 115VAC which is powered bya UPS inside the drive cabinet. This guarantees no unexpected control signal voltage drops whichwould cause the drives to shutdown.

The AGPS board is shown below:


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Steve Boren

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AINT-02 / 12 Board

The original ACS800 R8i inverters were shipped with AINT-01 boards, now the newer inverters areshipping with AINT-02 OR 12 boards. These newer INT boards have multiple sets of DDCS FiberOptic Transmitters and Receivers. The connection between the RDCU-01 (main control board)and the AINT boards to control the inverter are done via connections V1 and V2, shown below.

AINT-02 / 12 shown below:


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PLC CONTROL INTERFACE

Emergency stop hardwired to the Start Interlock input on the ACS800 I/O Terminal board. TheStart Interlock is a Safety Circuit that must be held closed (connection closed from Terminal X22:8to X22:11) before the drive will operate. Upon opening of this circuit, the drive will be forced to stopaccording to the Stopping Mode programmed in Parameter 21.09 START INTRL FUNC. Both theMaster and Follower drive are programmed to Ramp to a Stop (21.09 = OFF3 STOP) following theDecel time specified in parameter 22.07. See ACS800 Firmware Manual for alternative

definitions of Stopping Mode Selections.

Profibus DP PPO5 type is used.System is used in ABB Drives Profile (Not in Profidrive mode).

Profibus DP (PPO-5) message frame is following:

Parameter Field Process Data Field

CW REF PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10

ID INDValu

e SW ACT PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10

Signals from Master (PLC) to the Drive:

CW Control WordREF Speed Reference, +/- 20000 = +/- EXT REF1 MAXIMUM (Parameter 11.05, RPM)

PZD3 Reference 2, (Scaling Depends upon the use of the signal; not used for National Oil Well)

PZD4 Max Motor Torque (Parameter 20.04), Scale: 10000 = 100% of Motor Nominal Torque

PZD5 Min Motor Torque (Parameter 20.15), Scale: 10000 = 100% of Motor Nominal TorquePZD6 Max Motor Power (Parameter 20.11), Scale: 10000 = 100% of Motor Nominal Power

PZD7 Follower Drive Control Mode (3=DDCS Follower; 4=PLC Controlled Drive) Slave Only

PZD8 Selects between Torque and Speed Control Mode (Slave Drive Only)

PZD9 Communication Heartbeat Square wavePZD10Not used

CW Control Word

Control Word is used to Start/Stop, issue Fault Resets, and other various binary bits forcontrol of the drive. Control word utilizes the Profibus Drive Profile which has a statemachine present inside the drive, thus requiring certain bits to be active in a given sequence

before the drive will run. Profibus always has access to the Master drive control word.However, the Profibus does not always control the Control Word of the slave drive. If PZD7is writing a 3 for DDCS communications, then the data displayed in parameter 9.06representing the Communicated Control Word will be controlled by the Control being sentfrom the Master drive via the DDCS Fiber optic communications on Channel 2. If PZD7 iswriting a value of 4 to parameter 60.01, then the Slave Control Word will be following the datafrom the Profibus Comm Link, and thus displayed in 9.06 for diagnostics. See Control Wordbit description on page 4 for further bit descriptions and State Machine logic.


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Author

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Preliminary

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REF Reference for Speed

The speed reference is scaled so that 20000 = setting for Parameter 11.05 (rpm). If PZD7 is

writing a 3 to parameter 60.01, then the speed reference will come from the Master drive viaDDCS Fiber optic communications on Channel 2. If PZD7 is writing a value of 4 toparameter 60.01, then the speed reference will be coming from the Profibus Comm Link. Ineither case, the respective communicated speed reference will be displayed for diagnosticsat parameter 9.07.

PZD3 Reference 2

Reference 2 is unused by the Master drive and the Slave drive via the Profibus Link whenPZD7 is writing a value of 4 to parameter 60.01 (Speed Mode active). When PZD7 is writinga value of 3 for DDCS communications and PZD8 is writing a 1 for Torque Mode, then theSlave drive is torque controlled via the Master drive torque reference and the Communicatedreference is displayed in Parameter 9.08. Profibus continues to have no effect on thisreference and continually writes a zero.

PZD4 Max Motor Torque

Torque limit in the motors forward direction (normally same as hoisting direction in adrawworks application)

PZD5 Min Motor Torque

Torque limit in the motors reverse direction (normally same as lowering direction in adrawworks)

PZD6 Max Motor Power

Power limit in motoring direction (normally same as hoisting direction)

PZD7 Follower Drive Control ModePLC writes to this parameter to switch the control location of the slave drive. Normaloperation the Slave drive will be a Torque Follower to the Master Drive (Drive A) receiving itscommands from the DDCS Fiber Optic link connected to Channel 2. This control is done bywriting a value of 3 to parameter 60.01. If the Master drive is Disabled (no Run Enable) orFaults, then a value of 4 is written to parameter 60.01 to change it to Standby Mode. Thisallows the PLC to now write all commands and references to control the drive independentlyof the Master drive.

PZD8 Torque or Speed Mode Selection

Along with writing to parameter 60.01, the PLC also writes to parameter 85.01 to switch theSlave Drive from Torque Mode (Value of 1) to Speed Mode (Value of 0). The drive has a

Adaptive Program written inside the slave drive that automatically switches the slave drive

from a torque follower to a speed follower following the Master Drive via the DDCS FiberOptic Channel 2 connection. This automatic switch from Torque to Speed occurs when theMaster drive speed reference is below 5 rpm, so that when both drives are active at zerospeed they will both be in speed mode (displaying rpm in upper right-hand corner). As thespeed increases, the slave drive will switch to Torque Mode and load share with the Master.

PZD9 Profibus Communication HeartbeatProfibus continually sends a square wave to parameter 85.04 which is then returned to thePLC via Profibus. If this signal becomes static, then the PLC will flag a Profibuscommunications loss to the drive and remove the Run Enable from Digital Input 3.


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Author

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Signals from the Drive to the Master (PLC)

SW Status Word

ACT Actual Speed, Scale: +/-20000 = +/- Maximum Speed (Parameter 20.02, Rpm)PZD3 Auxiliary Status Word 3 (Parameter 3.13)PZD4 Motor Current, Scale: 10 = 1 A (Parameter 1.04)

PZD5 Motor Torque, Scale: +/-10000 = +/- 100% Motor Nom Torque (Parameter 1.05)

PZD6 Motor Power, Scale: 1000 = 100% Motor Nom Power (Parameter 1.06)

PZD7 DC Bus Voltage, Scale: 1 = 1V (Parameter 1.07)

PZD8 Profibus Com Heartbeat (Parameter 85.04)

PZD9 Fault Word 1 (Parameter 3.05)

PZD10 Fault Word 2 (Parameter 3.06)

Drive Profibus Communication Configuration Parameters

Param

#Value Parameter Description

51.01 RPBA-01 Vx.x Fieldbus Module Type used

51.02(# for Profibus Node

Address)Node Address specified by rotary dials onRPBA (Read Only)

51.03 1500 (= 1.5Mbit) Baud Rate of network, set by PLC (Read Only)

51.04 5PPO-Type configured in the PLC Networkconfig for this Node Address (Read Only)

51.05 3 PZD3 Output from PLC to Drive (Ref 2)

51.06 313 PZD3 Input from Drive to PLC (Aux Status 3)

51.07 2004 PZD4 Output from PLC to Drive (Max Torque)

51.08 104 PZD4 Input from Drive to PLC (Current)

51.09 2015 PZD5 Output from PLC to Drive (Min Torque)

51.10 105 PZD5 Input from Drive to PLC (Torque)51.11 2011 PZD6 Output from PLC to Drive (Max Power)51.12 106 PZD6 Input from Drive to PLC (Power)

51.13 6001 PZD7 Output from PLC to Drive (Follow Mode)

51.14 107 PZD7 Input from Drive to PLC (DC Bus Volt)

51.15 8501 PZD8 Output from PLC to Drive (Spd/Torq)

51.16 8504 PZD8 Input from Drive to PLC (Heartbeat)

51.17 8504 PZD9 Output from PLC to Drive (Heartbeat)

51.18 305 PZD9 Input from Drive to PLC (Fault Word 1)

51.19 0 PZD10 Output from PLC to Drive (Unused)51.20 306 PZD10 Input from Drive to PLC (Fault Word2)

Note: After making changes to the Group 51 Profibus Configuration parameters, power must becycled on the ACS800, or a Refresh must be triggered at parameter 51.27 before the parameterstake effect.

GSD Notes: When configuring the Profibus network in the PLC Scanner, the Drive must be

configured so that the Operation Mode of the RPBA-01 module on the network is configured forVendor Specific. This allows for the ABB Drives Profile communication structure as described inthis document to control the ACS800 Drive.


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CONTROL WORD. CW to be used with ABB Drive Profile:

BIT DESCRIPTION

Value = 0 Value = 1

0STOP (by ramp, Decel TimePar 22.03)

START (0->1 transition)

1 STOP (by coast) Active to Run Drive

2 STOP (by ramp, time Par 22.07) Active to Run Drive3 Drive Disabled Drive Enabled for operation

4Ramp Generator Output forcedto Zero, Stop by Torque Limit

Active to Run Drive

5Ramp Generator is held notallowing speed to change

Active to Allow Speed Reference to Ramp

6

Ramp Generator Input forced to

Zero, Stop by Decel Time(22.03)

Active to Allow Speed Reference to Ramp up tocommanded speed

7 No Reset FAULT RESET (0->1)

8 No Action No Action9 No Action No Action

10 Disable Fieldbus Control Allows Fieldbus (Profibus) to control the drive

11External Control Location isEXT1

External Control Location is EXT 2, ifParameter 11.02 = COMM. CW(11)

12 No Action No Action




CONTROL WORD DESCRIPTION. The Control Word for the ACS800 has a built in State

machine when the ABB Drives Profile format is utilized. The state machine is derived from theProfibus Profidrive Control Word. The table above describes the bits of the Control Word. Anothersimpler way of understanding the State machine of the Control Word is as follows: If Bits 1-6, and10 are held high (logical 1) the drive may be started and stopped according to the status of Bit 0. Itmay be useful to Start the drive, however, holding the speed at zero speed reference instead ofRamping the speed. In this scenario the Control Word would have Bits 1-5, and 10 held high(logical 1). Start the drive by setting Bit 0 high, which activates the drive at zero speed, thenrelease the speed reference ramp by setting Bit 6 high.


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STATUS WORD. Status Word used with ABB Drive Profile:

BIT DESCRIPTION

Value = 0 Value = 1

0 Not ready Ready (no drive system faults are present)

1 Not ready to operateReady to begin operation (No faults active,Drive is Enabled, Start Interlock is closed, anddrive is ready to be started)

2 Stopped Running (Modulating the output)

3 No Fault Fault Active, drive operation is halted

4Off 2 Active, drive operation ishalted

Off 2 Inactive, drive operation is normal

5Off 3 Active, drive operation ishalted

Off 3 Inactive, drive operation is normal

6 Normal Operation Switch on Inhibit7 No Warning Warning Active, will not cause drive shutdown

8Not at Speed ReferenceSetpoint

Actual Motor Speed is at Reference Setpoint

9 Keypad is in Local Mode Drive is in Remote Control Mode

10Actual Motor Speed is withinSupervisory Limit

Actual Motor Speed is above the SupervisoryLimit (Parameter 32.02)

11 EXT1 control Location is active EXT2 control Location is active

12No External Run Enablecommand has been received

External Run Enable command received



15 No Profibus comm. errorNPBA module has detected a Profibus Commerror with the fiber optic link to CH0 (Not validfor RPBA module)

STATUS WORD DESCRIPTION. The Status Word can also be simply defined as having

Bits 0-2, 4-5, 8-9, 12 active when the drive is running the motor at the command speed. Whensitting idle waiting for a run command Bits 0-1, 4-5, 9, 12 should be active.


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AUXILIARY STATUS WORD3

BIT DESCRIPTION

Value = 0 Value = 1

0Motor is Running in ForwardRotation

Motor is Running in Reverse Rotation

1Drive Control comes fromkeypad

Drive Control comes from External Signals

2 Reference 1 is active Reference 2 is active

3Drive is following analoguespeed reference

Drive is operating with a Constant Speedselected by a Digital Input

4No Start command issued todrive

Drive has received a Start Command

5 User 1 Macro or other Macro isactive

User 2 Macro is active

6 Brake is active holding the motorRelease Brake Command has been issued,Brake Control Logic has been satisfied

7 Reference is operational Controlling Reference has been lost

8Start Interlock on terminalX22:11 has been removed, driveis blocked from operation

Start Interlock on terminal X22:11 is active anddrive may operate





13 No Action No Action14 No Action No Action15 No Action No Action

FAULT WORD 1 AND FAULT WORD 2. All Fault Words, Alarm Words, Status Words, and Limit

Words are described in the Fieldbus Control Section of the ACS800 Firmware manual (back ofthe manual)..

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