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3 Engineering

Blocking Protection for Pumps with SIMOCODE pro V
Article ID: 109478058, V2.0, 09/2020

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3.4.2

Scenarios

The following 3 scenarios only represent a selection of possible sequences.

Scenario 1: Blockage is not cleared

1. Make sure that the blockage prevention logic is switched on.

2. Check whether Counter 1 has the value "0". In order to reset Counter 1 to the

value "0", perform a fault acknowledge operation (RESET), e.g. with the
"TEST/RESET" button on the SIMOCODE pro V PN basic unit.

3. Start the drive with "ON>" (conveying direction).

4. Wait for the Class 10 time to elapse until the start procedure is complete (10s).

5. Provoke or simulate a situation that causes one of the three limit monitors 2, 3

or 4 (fault situation).

CAUTION

Avoid overloading your motor.

Consider whether you can risk stalling your drive.

For testing purposes, you might parameterize a lower programmed current I

than appropriate for the motor, or lower critical limit values for the limit monitor.

Result:

1. The motor stops and runs in the opposite direction after the interlock time (2 s)

expires.

2. Counter 1 is incremented.

3. After Timer 1 expires (30 s), the motor stops again and turns in the conveying

direction after the interlock time has passed (2 s).

4. As the fault is still present, the motor only proceeds to turn in the conveying

direction until the start process finishes (i.e., until the Class 10 time of 10 s
expires). Items 1 to 3 are repeated three times.

5. If Counter 1 has the value "4", the drive stops with "External fault 1". This is

indexed as follows:

–

LED "GEN.FAULT" on the SIMOCODE device blinks red.

–

LED "GEN.FAULT" on the operator panel blinks red. If the operator panel
has a display, the fault "Blocked" will appear.

–

If using PROFINET communication, the fault will be transmitted to the PLC
via bit 1 of the interface "Cyclic send byte 1" with "true".

–

The "External fault 1" alarm will appear in TIA Portal in the online view
under "Commissioning > Faults".

Summary of Contents for SIMOCODE pro V

Page 1: ...Prevention of pump blockages by changing the direction of rotation SIMOCODE pro V https support industry siemens com cs ww en view 109478058 Siemens Industry Online Support ...

Page 2: ... Claims for damages arising from a breach of material contractual obligations shall however be limited to the foreseeable damage typical of the type of agreement unless liability arises from intent or gross negligence or is based on loss of life bodily injury or damage to health The foregoing provisions do not imply any change in the burden of proof to your detriment You shall indemnify Siemens ag...

Page 3: ...g the fault counter during operation 18 2 2 10 Blockage in the opposite direction 18 2 2 11 Cyclic communication with the controller 18 3 Engineering 20 3 1 Hardware configuration 20 3 1 1 Basic unit BU 21 3 1 2 Detecting irregularities in the conveying flow 21 3 1 3 Clearing blockages in the conveying flow 21 3 1 4 Digital module DM 21 3 1 5 Operator panel OP 21 3 1 6 Communication with a PLC 21 ...

Page 4: ...manually eliminate the blockages Figure 1 1 In many cases blockages in conveying flows can be broken up by briefly and sometimes repeatedly reversing the pump direction In order to initiate this operation an impending stall must be detected Plausible criteria for this can be derived from the electrical power supply to the pump drive SIMOCODE pro allows you to prevent interruptions and therefore ex...

Page 5: ...in a general description of the following hardware and software components The hardware and software listed in chapter 1 4 References are made to the pertinent manuals and system descriptions see chapter 5 2 TIA Portal SIMOCODE ES configuration software Basic knowledge of these topics is required 1 3 Required knowledge General knowledge in the areas of low voltage switchgear technology digital cir...

Page 6: ...g on version window type current transformer or bar connection also possible 3UF711x 1yA01 0 V2 depending on the required connection values of the motor y A B depending on version window type current transformer or bar connection 3UF711x 1yA00 0 depending on the required connection values of the motor y A B depending on version window type current transformer or bar connection SIMOCODE connection ...

Page 7: ... on the required connection values of the motor and the user s preferences for model version SIRIUS contactor 2 3RT2015 1BB42 or another contactor depending on the required connection values of the motor and the user s preferences for model version SIRIUS wiring module upper 1 3RA1913 3D For reversing starter for contactor combinations S00 SIRIUS wiring module lower 1 3RA1913 3E Motor 1 depends on...

Page 8: ... Siemens AG 2020 All rights reserved Components Quantity Item number Note SIMOCODE ES V16 Standard Floating License Download 1 3ZS1322 6CE14 0YB5 Driver for SIRIUS USB PC cable 3UF7941 0AA00 0 1 free download see 9 includes installation instructions Note Other minor materials have not been listed here ...

Page 10: ... with a truth table For ease of understanding Figure 2 1 shows the truth tables as gates or a combination of gates Truth tables with the following input output quantity structures are available 3I 1O 2I 1O 5I 2O Detailed information is available in manual 3 Figure 2 2 1 TT4 1 2 3 Counters For every positive edge at one of the counter inputs the counter value is incremented or decremented The appli...

Page 11: ...true at the reset input R Negation Detailed information is available in manual 3 Figure 2 5 IN Q R Signal conditioning 2 1 IN Q R Signal conditioning 1 Limit monitor Using limit monitors the motor current in the example is monitored for its limit value being exceeded not met and the power factor is monitored for when its limit is not met When the respective limit value is met the digital output ch...

Page 12: ...l are interconnected by default as per Figure 2 7 Figure 2 7 To embed the logic for blockage prevention the interconnection of the ON commands has been separated The authorized control commands ON ON and OFF from Control station are fed into the logic as inputs marked in green in Figure 2 1 and Figure 2 8 The outputs of the logic are interconnected to the ON plugs of Protection Control marked in o...

Page 13: ...e SIMOCODE pro V PN basic unit detects a problem in the pumped flow if one of the following conditions is met The value of the motor current leaves a defined nominal range defined by limit monitors 2 value not met and 3 value exceeded inputs 1 and 2 of truth table TT9 The value of the power factor falls below a defined threshold which is defined by limit monitor 4 input 3 of truth table TT9 The th...

Page 14: ... the enabled control command ON provided by the Control station function block Although the ON commands maintain themselves with the default parameterization Non maintained command mode the ON command must also be stored with Signal conditioning 1 so that the fault logic can switch on the drive in forward flow direction again after an automatic reversal The ON command is passed to the function blo...

Page 15: ...tection Control are canceled when the motor is shut off Rescinding the ON command The ON command at Protection Control is rescinded in the logic by resetting signal conditioning 1 To achieve this the commands OFF and ON from the Control station function block and the general error from the general error function block are OR linked via the truth table TT1 and fed into signal conditioning 1 Rescind...

Page 16: ...on when the system is switched to run in the opposite direction For this purpose the ON command from the Control station function block is interconnected with the reset input of signal conditioning 1 via truth table TT1 Because the ON command is not saved separately in the logic direct reversal back to the direction of conveying flow is effected without any additional logical connections as long a...

Page 17: ...a TT2 A requirement for this logic to function is the parameterization of the operating mode Save change over command 2 2 7 Fault shutdown after defined number of reversals For every positive edge of the interference signal at output 1 of truth table TT9 Counter 1 is incremented It thus counts the times that the motor runs in the opposite direction If the counter reaches its programmed limit in th...

Page 18: ...iggered by the logic Timer 2 is reset so that it does not completely expire and the fault counter is also not cleared 2 2 10 Blockage in the opposite direction If the drive also blocks in the opposite direction which is detected by limit monitor 1 which reacts to a current maximum in reverse motion the logic initiates an immediate reversal back to the conveying direction For this purpose the perti...

Page 19: ...t possible to automatically clear a blockage in the conveying and the drive has stopped as a result see chapter 2 2 7 Fault counter Counter 1 The analog output from Counter 1 is interconnected with input 1 of the function block Cyclic send Byte 4 9 In this way the real number of reversals performed until fault shutdown see chapter 2 2 7 or until the value was reset see chapter 2 2 9 is transmitted...

Page 20: ...n This application example uses the flexible and modularly designed SIMOCODE motor management system for motors in the low voltage performance range Figure 3 1 PLC 1 SIMOCODE system wiring PROFINET IE 2 3 4 5 6 7 SIMOCODE pro V PN basic unit Digital module Operator panel SIRIUS circuit breaker Current voltage measuring module SIRIUS contactor combination PG PC 1 2 3 4 5 6 7 7 ...

Page 21: ...times if an irregularity is detected in the conveying flow in order to create a chance for successful smooth operation If this succeeds an impending forced shutdown can be avoided 3 1 4 Digital module DM The example allows status signals ON OFF and ON to be output at indicator lamps Because the SIMOCODE pro V PN basic unit can only provide a relay output for ON two relay outputs of the digital mod...

Page 22: ...ted 7 4 If as intended in the application example you want to display the ON OFF and ON states with indicator lights or illuminated pushbuttons for local control use the output OUT3 terminal 7 of the basic unit to signal left hand rotation ON Place the 24 V contact supply on terminal 6 5 If as intended in the application example you want to display the ON OFF and ON states with indicator lights or...

Page 23: ...MOCODE pro V PN basic unit 9 Establish the physical PROFINET connection to a controller PROFINET IO controller if one is present 3 2 2 Installing the software 1 To enable your source system PG PC to communicate with the SIMOCODE device via the USB PC cable you must first installed the associated drivers You can find the download and installation instructions in the SIEMENS Industry Online Support ...

Page 24: ...sic unit If the source system PG PC is connected to the PROFINET interface of the SIMOCODE pro V PN proceed according to the instructions below 1 Select the SIMOCODE device in the project tree 2 Click on the Download to device button in the function bar If downloading for the first time the Extended download to device dialog will open 3 Make the following settings Type of PG PC interface PN IE PG ...

Page 25: ...ll rights reserved 8 Follow the notes and instructions on the screen during the download process 9 A successful download will appear as follows Note The download process will be aborted with an error if the SIMOCODE device is in the Remote Automatic operating mode if an ON command is pending or if the motor is running ...

Page 26: ... Select the SIMOCODE device in the project tree 2 Click on the Download to device button in the function bar If downloading for the first time the Extended download to device dialog will open 3 Enter the interface type SIRIUS PtP and the number of the COM port used For the COM port number that the SIMOCODE device uses consult the installation information on the driver for the SIRIUS USB PC cable s...

Page 27: ...ocess will be aborted with an error if the SIMOCODE device is in the Remote Automatic operating mode if an ON command is pending or if the motor is running 3 2 4 Commissioning A specific commissioning sequence is not required If you have carried out the hardware and software installation described above you only have to connect the power circuit with the 3 phase mains or switch on the SIRIUS circu...

Page 28: ...terization Requirement The software components are installed on your source system in accordance with Table 1 1 You have created a new project in TIA Portal or opened a project to work on Default values If you add a device from the hardware catalog to the project in TIA Portal parameters will be assigned by default This will be used in the steps below Parameters and settings in this application ex...

Page 29: ...e click Devices networks in the project tree The hardware and network editor will open 2 Select the Network view 3 Drag and drop the SIMOCODE pro V PN in the version you are using from the Task Card Hardware catalog into the graphical area of the Network view Figure 3 2 The name of the SIMOCODE device which is now Control device_1 in the project tree and graphical area of the Network view can be m...

Page 30: ...OCODE device components 1 Select the SIMOCODE device in the graphical area and switch to the device view 2 Drag and drop the following components from the Hardware catalog Task Card to the respective slots in the graphical area of the device view Current voltage measuring module IUM V2 0 3 4A Digital module DM mono Operator panel BBD Figure 3 3 ...

Page 31: ...ghts reserved 3 3 2 Parameter assignment for the SIMOCODE pro V PN PROFINET parameters 1 Double click the Parameters command in the project tree 2 Go to PROFINET parameters and enter the following parameters IP parameters Select Basic type 3 so that you can transmit all of the send data described in 2 2 11 to the controller ...

Page 32: ...tion example Integrating and networking a controller is the user s responsibility in this project It should be noted here that the stall prevention logic can be used independently of the bus system that you use i e it can also be used with the PROFIBUS or MODBUS RTU variant of the SIMOCODE pro V Because the SIMOCODE device is not networked with a controller it also appears in the project tree unde...

Page 33: ... to Motor protection Overload unbalance stalled rotor 2 Set the motor calculation current of the connected motor Set current Is1 The setting in the application example is 0 5 A 3 The trigger Class affects the activation of the limit monitors 2 3 and 4 see chapter 2 2 2 They are parameterized such that they only become active after a motor start is complete For Class 10 the start procedure is defin...

Page 34: ... Engineering Blocking Protection for Pumps with SIMOCODE pro V Article ID 109478058 V2 0 09 2020 34 Siemens AG 2020 All rights reserved Figure 3 5 Motor control 1 Switch to Motor control Control station ...

Page 35: ...tricted PLC DCS Bits 0 0 0 2 of the cyclic communication Cyclic receive Byte 0 Operator panel Buttons 2 4 OP buttons Forward direction ON key 2 Reverse direction ON key 3 OFF key 4 3 Switch to Motor control Control function 4 Enable the operating mode Save change over command 5 Interconnect the control commands ON and ON with the outputs of the relevant truth tables ON TT 7 truth table 7 ON TT 2 t...

Page 37: ...ollowing plugs of the Protection Control function block BU output 1 Plug 1 QE1 BU output 2 Plug 2 QE2 BU output 3 Plug QLE ON Figure 3 6 Outputs for operator panel LEDs 1 Open Outputs Operator panel LEDs 2 Assign LED 1 of the operator panel to the binary connection block Status remote mode 3 Interconnect LEDs 2 4 of the operator panel with the following plugs of the Protection Control function blo...

Page 38: ...8 Siemens AG 2020 All rights reserved Figure 3 7 Outputs of the digital module 1 Open Outputs Digital module 1 2 Interconnect outputs 1 and 2 of the digital module DM outputs with the following plugs of the Protection Control function block DM output 1 Plug QLA OFF DM output 2 Plug QLE ON Figure 3 8 ...

Page 39: ... the default interconnections of the reversing starter you will create the following signals to bits 0 and 1 of the interface Cyclic send byte 1 Bit 0 Signal Status device o k of the binary connection block Status device o k Bit 1 Output signal from the function block External fault 1 3 Interconnect the values of Counters 1 and 2 used in the logic to inputs 1 and 2 of the interface Cyclic send byt...

Page 40: ...rights reserved Standard functions 1 Go to Standard functions External fault External fault 1 2 Place the binary output of Counter 1 on the input of the function External fault 1 3 For response program trip 4 Create a label that will appear in the event of an error for example on an operator panel with display Figure 3 10 ...

Page 41: ...h tables 1 Under Logic modules Truth table 3I 1O Truth table 1 define the signals and logic of truth table 1 TT1 The logic corresponds to an OR junction with 3 inputs I1 I2 I3 1 2 Under Logic modules Truth table 3I 1O Truth table 2 define the signals and logic of truth table 2 TT2 The unused input 3 is set by default as false I1 I2 I3 false ...

Page 42: ...58 V2 0 09 2020 42 Siemens AG 2020 All rights reserved 3 Under Logic modules Truth table 3I 1O Truth table 3 define the signals and logic of truth table 3 TT3 I1 I2 I3 1 4 Under Logic modules Truth table 3I 1O Truth table 4 define the signals and logic of truth table 4 TT4 I1 I2 I3 1 ...

Page 43: ...58 V2 0 09 2020 43 Siemens AG 2020 All rights reserved 5 Under Logic modules Truth table 3I 1O Truth table 5 define the signals and logic of truth table 5 TT5 I1 I2 I3 1 6 Under Logic modules Truth table 3I 1O Truth table 6 define the signals and logic of truth table 6 TT6 I1 I2 I3 1 ...

Page 44: ...478058 V2 0 09 2020 44 Siemens AG 2020 All rights reserved 7 Under Logic modules Truth table 2I 1O Truth table 7 define the signals and logic of truth table 7 TT7 I1 I2 1 8 Under Logic modules Truth table 2I 1O Truth table 8 define the signals and logic of truth table 8 TT8 I1 I2 ...

Page 45: ...ction for Pumps with SIMOCODE pro V Article ID 109478058 V2 0 09 2020 45 Siemens AG 2020 All rights reserved 9 Under Logic modules Truth table 5I 2O Truth table 9 define the signals and logic of truth table 9 TT9 I1 I2 I3 1 I4 I5 ...

Page 46: ...hts reserved Counters 1 Define the following parameters under Logic modules Counter Counter 1 Limit value 4 Input increment Output TT 9 truth table 9 Reset Output TT 6 truth table 6 2 Define the following parameters under Logic modules Counter Counter 2 Limit value 65535 Input increment Output Timer 1 Reset Output Counter 2 ...

Page 47: ...r Pumps with SIMOCODE pro V Article ID 109478058 V2 0 09 2020 47 Siemens AG 2020 All rights reserved 3 Define the following parameters under Logic modules Counter Counter 3 Limit value 2 Input increment OP button 1 Reset Output Counter 3 ...

Page 48: ...r 1 Define the following parameters under Logic modules Timer Timer 1 Type with opening delay Limit value 30 0 Input Output 1 TT 9 truth table 9 Reset Output TT 8 truth table 8 2 Define the following parameters under Logic modules Timer Timer 2 Type with closing delay Limit value 3600 0 Input Output signal conditioning 2 Reset Output Timer 1 ...

Page 49: ... conditioning Signal conditioning 1 Type edge rising with memory Input Control command ON Reset Output TT 1 truth table 1 2 Define the following parameters under Logic modules Signal conditioning Signal conditioning 2 Type inverting Input Output Timer 2 3 Define the following parameters under Logic modules Signal conditioning Signal conditioning 3 Type edge rising with memory Input OP button 1 Res...

Page 50: ... reserved Limit monitor 1 Under Logic modules Limit monitor Limit monitor 1 parameterize the Limit monitor function block for the current upper limit in reverse direction The limit monitor should always be active always on The limit should be specified in based on the motor current at the input plug If necessary assign a label ...

Page 51: ...mplete if motor is running except TPF with startup override run The limit should be specified in based on the motor current at the input plug If necessary assign a label 3 Under Logic modules Limit monitor Limit monitor 3 parameterize the Limit monitor function block for the current upper limit in forward flow direction The limit monitor should only be active when the motor is running and after th...

Page 52: ...mit monitor 4 parameterize the limit value function block for the cos φ lower limit in forward flow direction The limit monitor should only be active when the motor is running and after the start procedure is complete if motor is running except TPF with startup override run The limit should be specified in based on the motor current at the input plug Add a label is necessary ...

Page 53: ...le the device Control device_1 to detect any errors then save its parameterization Figure 3 11 2 3 1 4 Note If necessary complete your configuration by networking the SIMOCODE pro V PN as a PROFINET IO device with a controller PROFINET IO controller that is also configured in TIA Portal You thus have read and write access to the interconnected cyclic receive and send data ...

Page 54: ...n On Off button 1 Conveying direction ON button 2 Reverse direction ON button 3 Off button 4 Message External fault 1 Reset External fault 1 The blockage prevention can only be disabled or enabled with button 1 on the operator panel in the operating mode Local 2 see Control stations Selection However regardless of the operating mode Local 2 or Remote the LED in button 1 will always show the correc...

Page 55: ... 5 of the interface Cyclic receive Byte 0 If bit 5 has the value true the mode Remote is selected Local 2 The drive can be operated as desired either locally by pushbutton or via the operator panel If no PLC is connected bit 5 of the interface Cyclic receive Byte 0 is always false The Local 2 operating mode is thus selected automatically Remote The drive can be operated as desired either through a...

Page 56: ...DE pro V Article ID 109478058 V2 0 09 2020 56 Siemens AG 2020 All rights reserved Figure 3 12 The following menus are relevant for these scenarios Faults If a blockage can t be cleared the parameterized External fault 1 will be displayed in the menu Faults ...

Page 57: ... pro V Article ID 109478058 V2 0 09 2020 57 Siemens AG 2020 All rights reserved Measured values In the Measured values menu you can monitor the live values for current and power factor in order to compare them with the programmed limits of the limit monitors ...

Page 58: ... SIMOCODE pro V Article ID 109478058 V2 0 09 2020 58 Siemens AG 2020 All rights reserved Service data statistical data In the Service data statistical data menu you can monitor the live values of the timers and counters in the stall prevention logic ...

Page 59: ...parameterize a lower programmed current Ie1 than appropriate for the motor or lower critical limit values for the limit monitor Result 1 The motor stops and runs in the opposite direction after the interlock time 2 s expires 2 Counter 1 is incremented 3 After Timer 1 expires 30 s the motor stops again and turns in the conveying direction after the interlock time has passed 2 s 4 As the fault is st...

Page 60: ...the conveying direction after the interlock time has passed 2 s 5 Counter 1 keeps the value of 1 for the time being 6 After Timer 2 runs out 1 hour Timer 1 is reset to the value 0 if no further blockage occurs during this time If there are more blockages within that one hour there are still two more reversals available to clear the blockage before the drive stops with External fault 1 Scenario 3 B...

Page 61: ...External fault 1 alarm will appear in TIA Portal in the online view under Commissioning Faults 7 Acknowledge the fault in one of the following ways Press the TEST RESET button on the SIMOCODE pro V PN basic unit Press the right hand softkey on the operator panel Transmit the value true via PROFINET at bit 6 of the interface Cyclic receive byte 0 Once acknowledged Counter 1 will be reset again 8 El...

Page 62: ... output of limit monitor 2 Current upper limit in conveying direction reached output of limit monitor 3 Cos φ lower limit in conveying direction reached output of limit monitor 4 The example project does not receive a time stamp for the aforementioned signals because Time stamping is not part of the core contents of this application example Time stamping is only available with the PROFIBUS variant...

Page 63: ...pport contracts Please send queries to Technical Support via Web form www siemens com industry supportrequest SITRAIN Training for Industry We support you with our globally available training courses for industry with practical experience innovative learning methods and a concept that s tailored to the customer s specific needs For more information on our offered trainings and courses as well as t...

Page 64: ... com cs ww en view 109743957 5 Function Manual SIMOCODE pro Communication https support industry siemens com cs ww en view 109743960 6 Application Manual SIMOCODE pro Application examples https support industry siemens com cs ww en view 109743959 7 Getting Started SIMOCODE pro https support industry siemens com cs de en view 109743956 8 Manual Collection SIMOCODE pro 3UF7 https support industry si...

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