User Manual Functional Description: Marflex Variable Speed Drive System

MarFlex Variable Speed Drive System
User manual
And
Functional Description
Disclaimer: Nothing of its contents may be published or distributed without the written approval of MarFlex BV
Rev 2.0 2.1 2.2
Modification / Remarks As build version Integration operating manual System design specifications Final changes
Author L.Sonneveld L.Sonneveld L.Sonneveld L.Sonneveld
Date 23-2-2011 24-3-2011 1-4-2011 7-4-2011
Author: Snijders Elektrotechniek B.V.
MarFlex VDSV functional description.doc
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1 Table of contents
1 2 3 4 Table of contents...................................................................................................................2 Introduction ...........................................................................................................................5 List of abbreviations .............................................................................................................5 SYSTEM OVERVIEW .............................................................................................................6
4.1 4.2 4.3 4.4 General ..................................................................................................................................................... 6 Basic system overview............................................................................................................................... 6 Power Conversion...................................................................................................................................... 7 Distribution Matrix ...................................................................................................................................... 7
SYSTEM FUNCTIONS ...........................................................................................................8

5.1 5.2 5.3 5.4 Selection operation mode........................................................................................................................... 8 Emergency stop......................................................................................................................................... 8 Thermal motor protection ........................................................................................................................... 9 Motor heating............................................................................................................................................. 9
5.5 Dry run ...................................................................................................................................................... 9 5.5.1 General................................................................................................................................................. 9 5.5.2 Ballast pumps ....................................................................................................................................... 9 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 Self Priming ............................................................................................................................................. 10 Motor Data Sets....................................................................................................................................... 12 Discharge Pressure High ......................................................................................................................... 12 Inert Gas Low .......................................................................................................................................... 13 3rd party cooling system failed .................................................................................................................. 13 Operating mode change failure................................................................................................................. 13 One or more Converters in operation........................................................................................................ 13 General alarm.......................................................................................................................................... 13
OPTIONAL FUNCTIONS ......................................................................................................14

6.1 Introduction.............................................................................................................................................. 14 6.2 Power Management System (PMS).......................................................................................................... 14 6.2.1 General description ............................................................................................................................. 14 6.2.2 PMS functionality for standard MarFlex configurations.......................................................................... 14 6.3 Water cooling........................................................................................................................................... 15
6.4 Cargo heating mode ................................................................................................................................ 15 6.4.1 General description ............................................................................................................................. 15 6.4.2 Cargo heating mode specifications....................................................................................................... 15
SYSTEM CONTROLS...........................................................................................................17
7.1 Introduction.............................................................................................................................................. 17 7.2 Local operation. ....................................................................................................................................... 17 7.2.1 General............................................................................................................................................... 17 7.2.2 The pump selection system ................................................................................................................. 17 7.2.3 The operation panels........................................................................................................................... 19 7.3 Remote modes ........................................................................................................................................ 28 7.3.1 Remote mode: Touch Panel ................................................................................................................ 28 7.3.2 Remote mode: Control Desk................................................................................................................ 28
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7.3.3
Remote mode: Cooperative with external systems................................................................................ 29
Remote Mode: TOUCH PANEL ...........................................................................................30

8.1 General ................................................................................................................................................... 30 8.2 Main Screens........................................................................................................................................... 31 8.2.1 Tree structure...................................................................................................................................... 31 8.2.2 Default screen ..................................................................................................................................... 32 8.2.3 Overview screen ................................................................................................................................. 33 8.2.4 Pump control screens .......................................................................................................................... 34 8.2.5 Cargo heating mode screen................................................................................................................. 35 8.2.6 Cargo heating control screens ............................................................................................................. 36 8.2.7................................................................................................................................................................. 38 8.2.8 Pump screen....................................................................................................................................... 38 8.2.9 Converter screen................................................................................................................................. 39 8.3 Auxilliary screens..................................................................................................................................... 41 8.3.1 Tree structure...................................................................................................................................... 41 8.3.2 Communication fault screen................................................................................................................. 41 8.3.3 Fault screen ........................................................................................................................................ 42 8.3.4 Login screen ....................................................................................................................................... 43 8.3.5 Maintenance screen ............................................................................................................................ 44 8.3.6 Diagnosis screen................................................................................................................................. 45 8.3.7 Settings screen ................................................................................................................................... 46 8.3.8 Operating hours screen ....................................................................................................................... 47 8.3.9 Info screen .......................................................................................................................................... 48 8.3.10 Help screen .................................................................................................................................... 49 8.4 User management ................................................................................................................................... 50
Remote mode: CONTROL DESK ........................................................................................51

9.1 Introduction.............................................................................................................................................. 51 9.2 General section ....................................................................................................................................... 52 9.2.1 Emergency stop button........................................................................................................................ 52 9.2.2 Emergency stop indication................................................................................................................... 52 9.2.3 Remote control indication .................................................................................................................... 52 9.2.4 External alarms ................................................................................................................................... 53 9.2.5 General alarm ..................................................................................................................................... 53 9.2.6 Buzzer ................................................................................................................................................ 53 9.2.7 Reset a converter-trip or emergency .................................................................................................... 53 9.2.8 Lamp test button ................................................................................................................................. 53 9.3 Converter sections ................................................................................................................................... 55 9.3.1 Visualization....................................................................................................................................... 55 9.3.2 Speed / Power indication .................................................................................................................... 55 9.3.3 Start Pump.......................................................................................................................................... 55 9.3.4 Stop Pump .......................................................................................................................................... 56 9.3.5 Speed Change buttons........................................................................................................................ 56 9.4 Dry Run settings ...................................................................................................................................... 56
10
10.1 10.2
General Converter Functionalities .................................................................................58

Introduction.............................................................................................................................................. 58 Frequency converters in non-grounded systems ....................................................................................... 58
10.3 Frequency converters as an electrical noise source .................................................................................. 59 10.3.1 High frequency harmonic distortion (load)........................................................................................ 59 10.3.2 Low frequency harmonic distortion (mains) ...................................................................................... 61 10.4 10.5 Frequency converters and earth fault detection. ........................................................................................ 62 Radio frequency interference suppression filters ....................................................................................... 62
11
11.1 11.2
Software design...............................................................................................................62
Standard control ...................................................................................................................................... 62 Dry run protection .................................................................................................................................... 63 MarFlex VDSV functional description.doc Page 3 of 67
11.3
External interfaces ................................................................................................................................... 63
12
12.1 12.2 12.3 12.4 12.5 12.6
VSDS system design specifications...............................................................................65

General ................................................................................................................................................... 65 Regulations ............................................................................................................................................. 65 Classification societies ............................................................................................................................. 65 Ambient conditions for panels................................................................................................................... 65 Power supply ........................................................................................................................................... 65 Cable and cable entry specifications......................................................................................................... 66
12.7 Cooling water specifications ..................................................................................................................... 66 12.7.1 Sinamics converters........................................................................................................................ 66 12.7.2 Vacon converters............................................................................................................................ 66
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2 Introduction
This document describes the and functional specifications of the MarFlex Variable Speed Drive System (VSDS) which is required for Cargo handling with the MarFlex Deepwell pumps. The MarFlex VSDS is an assembled system of electrical components, suitable to control the speed and torque of MarFlex Deepwell pumps, complete with presentation of operational situations and alarms for automatic or human interventions. Frequency Converters are the main components of the system. By controlling the voltage and frequency of the electric motor, the speed of the motor can be adjusted. With parameter settings in the converter, the maximum current and frequency of the motor is limited. This means limitation of torque and speed of the pump. Converters are assigned to electric pump motors by contactor matrices. Number of operational choices depends on the design of these matrices. In normal pump operation, only one pump is assigned to a converter. In the optional VSDS function called Cargo Heating Mode, a maximum of 2 pumps can be assigned to one converter. Output power of the motor reduces likewise. Changes in operation situations are only possible when the converters are shut off. Human control and operation takes place by means of Human Machine Interfaces (HMI). For emergency situations the most direct way is local mode: simple manipulations on the converter cabinets with a panel and pushbuttons. For normal operation more sophisticated HMIs are possible, such as Touch Panels, Control desks and Cargo Computers. Flexibility of operation depends on the number of HMIs. Selection of the mode of operation and which HMI is active takes place with a selection switch. All parts of the assembly are connected and controlled by a Programmable Logic Controller (PLC). Due to the described layout of the MarFlex VSDS, the configuration can be easily expanded with several options.
3 List of abbreviations
The abbreviations in the following list are used frequently in this document. Abbreviation AC PLC PTC element TP VSDS WCU HMI Meaning Alternating Current Programmable Logic Controller Positive Temperature Coefficient element Touch panel Variable Speed Drive System Water Cooling Unit Human Machine Interface Description 50 Hz or 60 Hz sinusoidal current Device for controlling processes using free programming Device for measuring temperature as resistance, also called thermistor Device for operation and monitoring using a touch sensitive screen Standard MarFlex system assembled as xx times 2-3 frequency converters to drive 2-8 pumps simultaneously. External unit to cool Frequency Converters with water Part of VSDS which converts human commands into automatic actions
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4 SYSTEM OVERVIEW
4.1
General
The MarFlex Cargo Handling System consists of pumps which are used to discharge cargo and slop tanks. The pumps are driven by AC motors which are speed controlled by the MarFlex Variable Speed Drive System. Sometimes discharge of Ballast tanks is as well part of the MarFlex System. Also these pumps can be controlled by the VSDS. Next to the tank pumps, some auxiliary pumps can be driven by the VSDS, such as residual, tank cleaning, skimming and bilge water pumps. In case variable speed is not requested, these pumps will be driven by soft starters.
4.2
Basic system overview
The configuration of the system is shown in figure below.
The basic configuration consist of a PLC, connected to the frequency converters by a Profibus-DP field bus. The PLC (Programmable Logic Controller) is the master controller of the system. The field bus carries out all interfacing between the PLC, frequency converters and HMIs. The PLC can be connected to the cargo computer, hard wired or by a field bus. A PLC is a Programmable Logic Controller which contains software. The operating system of the PLC is S7. This is highly stable industrial software, it can not be compared to PC operating systems like Windows. Windows only acts on events and actions from the outside, S7 is a real time operating system. This means that in cycles of milliseconds standard internal actions take place. For example: scanning inputs and storing measured values, scanning internal memory and activating outputs. The programmer decides with the project related software which specific actions are necessary.
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4.3
Power Conversion
To control pumps at variable speed, the electric power delivered by the generator, must be converted to a variable frequency (speed) and current (power) level. These frequency converters are placed in converter cabinets, together with basic local safety and control components, such as: - main power circuit breaker - local control panel and external hard wired safety signals such as: - emergency stop - overheating signal electromotor Variable speed control is standard supplied for cargo and slop pumps. For other pumps it is optional. Basic supply for ballast pumps as well as auxiliary pumps is control by soft starter. MarFlex advises against the use of Star-Delta starters, both for technical and commercial reasons. During cargo handling a converter is connected to one pump (single drive configuration). The number of converters, together with the capacity of the pumps, determines the total cargo discharge capacity and discharge time.
4.4
Distribution Matrix
To make efficient use of materials, the number of converters used for the pumps are as small as possible. All pumps can be connected dynamical to each CONVERTER by using contactors. This way of energy distribution is called a matrix. In local control the matrix is controlled by hardwired logic, in remote control the matrix is controlled by the PLC. The way of distribution determines the flexibility of the discharge operations and the time loss in case a converter is out of order. Classification rules state that each cargo, slop or ballast pump must be at least connectable to two converters. This is stated to be certain that, in case of malfunction of a converter, a tank can always be discharged. MarFlex advises to distribute in a way that always more then one converter can take over. Most practical distribution configuration for both construction and operation is at least three converters to all pumps on one side of the vessel. This configuration is called the portside-starboard-matrix. The energy distribution is as follows: 1 time 3on6 matrix
2 times 2on4 matrix
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5 SYSTEM FUNCTIONS
5.1
Selection operation mode.
One VSDS cabinet, the first matrix cabinet or the PLC cabinet, has a switch to select the control operation of the system. Several options are possible. Always present is: - LOCAL = Local operation One or more of the following options are present: - CARGO = Remote operation with the cargo computer - TOUCH = Remote operation with the touch panel - DESK = Remote operation with the control desk In local control the pumps are controlled using only an converter. The PLC is not essential in this mode. All necessary functionalities are built in the converter and therefore limited. By using the pushbuttons on the cabinet, a pump can be allocated to the converter. The pump can be operated on the keypad of the converter cabinet. Local control is only used in emergency situations, such as PLC failure. During local control without defects in the remote control, information is still presented to the operator as in remote mode. Remote operation is not possible. Only one mode is valid at a certain moment. When one converter is switched to local mode the complete system is in local mode. All pumps running during the transition are normally stopped. In remote control the pumps are controlled using the PLC which increases the functionality and therefore flexibility. Operation can take place in different ways depending on the customers wish. Remote control only becomes active again when all converters are switched back to remote control and all pumps are stopped. Remote control is the preferred and default way of operating the pumps. When the operating mode is changed from a remote mode to a other mode,with one or more drives running, a Operating mode change failure is generated, and the running drives will be stopped by a General stop. Changing the operating mode from local mode to another operating mode, with one or more drives running, only the Operating mode change failure is generated. In this situation the drives will stay running. The operating mode change will only take effect when all drives are stopped, and the Operating change failure has been reset.
5.2
Emergency stop.
The system is provided with an emergency stop safety relay which is situated in the PLC cabinet. All emergency stop buttons are connected to this relay. By activating an emergency stop button all pumps, except for ballast pumps, will be switched off immediately. Emergency stops are handled this way in both local and remote operating modes. The converter receives a hard wired signal to stop, which results in an OFF2 stop. With the OFF2 stop the converter stops pulsing, and the motor will coast down. The local control pad presents the emergency stop as an external fault. For extra safety the power supply of the contactors is switched off by hard wiring. To reset restart the system after an emergency stop, a reset command must be given. The button is mounted on the PLC cabinet door.
At least one emergency stop push button is present in the system. It is located on the PLC cabinet door. Inside terminal strokes are present to connect 3 extra pushbuttons and one is provided separately. 4 terminals are provided in the PLC cabinet for extending the number of emergency push buttons. Two Ex-barriers are in line (one per channel) with the safety circuit of all emergency stop push buttons.
Author: Snijders Elektrotechniek B.V. MarFlex VDSV functional description.doc Page 8 of 67
8 terminals are provided to connect emergency stop buttons in the Ex-zone on deck.
5.3
Thermal motor protection
All motors are equipped with one or more PTC-resistors for thermal protection. The motor PTC-elements are connected to a PTC-relay with one fault contact. In case of overheating the motor, the PTC-relay generates a failure. The fault contact of the relay is hard wired connected to the converter. The actions of the system are: - OFF2 stop (coasting down) of the motor connected. - Temperature fault displayed on the remote mode control panels - External fault message on the local display, in local and remote mode. - Activation PLC output General Alarm A thermal fault can only be cleared once the PTC-relay has been reset manually in the cabinet.
5.4
Motor heating
When a pump motor is not running and disconnected from a converter, the motor is heated by stand still heating. This heating prevents condensation in the motor. Activation of the motor heaters is hard wired. Therefore this function is also present in local mode. Note: optional it is possible to signal the operation of the standstill heating with a blue signal lamp on the contactor cabinets
5.5
Dry run
5.5.1
General
In normal operation the selected pump is pumping fluid, which results in a motor load. The motor load is represented in the converter by motor current, dependent on the speed of the pump (more speed means more flow, means more load). MarFlex pumps needs fluid to cool the pump seals. Running a pump without fluid will damage the pump and should be prevented. This is called dry run. To prevent a dry run situation, the converters are equipped with a safety function. If a pump is running above 50% of its maximum speed and the motor current drops below 30% of the nominal motor current, the dry run function is activated. If the value of the current does not rise within 30 seconds, the system will generate a dry run alarm signal. If the value of the current does not rise within 180 seconds, the system will generate a dry run trip, which results in a normal motor stop in local and remote mode. Dry run function is available in local and remote control. Alarm and trip situations are signalled on the remote control panels and on the local control screen. Local control alarm is presented as an external fault. Dryrun parameters can only be changed by authorised MarFlex engineers, and are therefore protected with a password. Since Simocode motor switches run at a fixed speed, dry run is detected when the motor current drops below 30% of the nominal motor current, independent of the motor speed.
5.5.2
Ballast pumps
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For ballast pumps running on a converter (Not on a Simocode) there is a different dryrun detection system. The dryrun-current is dependent on the actual speed. This dependency is set by 4 parameters: S1 , S2 , I1 and I2. The following diagram shows the calculation of the dryrun current:
The dry-run current (Idr) at speed (Sact) is calculated with the following formula:
Dry run detection for ballast pumps running on a Simocode is the same as dry run detection for normal pumps, as described in par. 5.5.1.
5.6
Self Priming
The MarFlex pumps are of the centrifugal type, a type of pump type which is not capable of self aspiration. Self priming is a function for non-self priming pumps, which are not always surrounded by fluid. In this case it is only applied to the ballast pumps. Non-self priming pumps need fluid in the pump before the pump is started to create a start flow. When a start flow is created, the flow will continue as long as the pump keeps running and fluid is available at the pump suction side. To create a start flow, the housing of the pump is filled with fluid by activating a fluid injector. This activation is called here the self priming function of the VSDS. After a start of a ballast pump, the priming valve is opened, and the motor current is monitored. If the current remains below a preset value ( Idr) of its nominal value for 30 seconds, it means that the start flow in the pump has been insufficient to create a continuous flow. A dry-run warning is generated. On this dry-run warning the pumpspeed will be set to zero.
The injector will inject liquid into the housing of the pump and after 30 seconds the pump will speedup to the previous setpoint automatically. If the current again remains below Idr for another 30 seconds the pumpspeed will be set to zero again. This sequence will be repeated until there is enough liquid in the pump to create a continuous flow, 4 times maximum. The priming valve remains active until one of the following events occur: 1. The pomp is stopped. ( By the operator or by a system-stop ) 2. There has not been a dry-run warning for more than 40 seconds. If a dry-run warning occurs after 4 restarts, the system will generate the dry run failure. The following diagrams show the different self-priming sequences: 1. Self-priming sequence, dry-run fault after 4 priming cycles
2. Self-priming sequence, no dryrun after second priming cycle
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5.7
Motor Data Sets
One converter can select different motors with different specifications. The specifications (protection) of 4 individual motors can be stored in the converter Motor Data Sets. The Motor Data Sets are: 1. Cargo pump. 2. Slop pump. 3. 2 Cargo pumps in heating mode. (*1) 4. Ballast pump. Data Sets are introduced and checked by MarFlex. They may not be altered during operation. Only after installation of a new motor or pump with other specifications, data sets may be changed by specialists. (*1) If in heating mode two different types of pumps are selected (e.g. cargo and slop), the motor data set for cargo pumps is selected. In this situation no guaranty is provided for each pump running at the correct speed! 5.8 Discharge Pressure High
MarFlex VSDS is equipped with the possibility to react on high pressure situations in the cargo discharge piping. Information of a pressure limit switch is necessary, connected with a potential free contact. When the potential free contact opens, all cargo and slop pumps will stop by an OFF2 stop, and an alarm is presented to the operator. Ballast pumps are not affected with this alarm. The discharge pressure high function is present only in remote modes. In local mode, the pumps will not stop.
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When an Discharge pressure high failure appears in local mode, the 3rd party will have to present an audible signal, in order to warn the operator for the situation. In case pressure switch information is not available, this function is deactivated
5.9
Inert Gas Low
MarFlex VSDS is equipped with the possibility to react on inert gas low situations in the cargo and slop tanks. Information of a pressure limit switch or gas analysis system is necessary, connected with a potential free contact. When the potential free contact opens, all cargo and slop pumps will stop by an OFF2 stop, and an alarm is presented to the operator. Ballast pumps are not affected with this alarm. The inert gas low function is present only in remote modes. In local mode, the pumps will not stop. When an Inert gas low failure appears in local mode, the 3rd party will have to present an audible signal, in order to warn the operator for the situation. In case pressure switch information is not available, this function is deactivated
5.10 3rd party cooling system failed If applied, the MarFlex VSDS system can detect a 3rd party cooling system failure. This detection is through a digital input of the PLC. When 3rd party cooling system failed is detected, in remote operation all pumps will stop. In local mode the pumps will not stop.
5.11 Operating mode change failure When the operating mode is attempted to be changed from one remote mode to another mode, and one or more pumps are running, an Operating mode change failure is generated, and presented on the remote control. When the Operating mode change failure occurs, all pumps will stop. When the operating mode is attempted to be changed from local mode to another mode, the pumps will keep running, and an Operating mode change failure is presented on the remote display.
5.12 One or more Converters in operation There may be circumstances on board that it is necessary to warn other systems that the MarFlex VSDS is active. For this the VSDS is equipped with an output signal containing that information. This signal is provided by the PLC to indicate that at least one CONVERTER is in operation. The signal is present for external use as a potential free contact. It is only available in remote control.
5.13 General alarm General alarm is provided by the PLC to indicate that there is a pending alarm. The alarm is presented as light indication on the contactor cabinet and on all remote control panels. The signal is present for external use as a potential free contact. It is only available in remote control.
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6 OPTIONAL FUNCTIONS
6.1
Introduction
The MarFlex VSDS can be equipped with several fully integrated optional functions. Functions can be added in the following ways: - Extra internal VSDS-function: extension of local or remote control application - Import or export of hard wired signals: the imported signals are potential free normally closed contacts. They are used to generate a normal or quick stop, or used only for signalling purposes. Actions can be done per pump or for the whole VSDS. - Import and export of information with data communication lines. In this way the amount of communicated information is unlimited. Also actions can be numerous. Extra thorough specifications are needed to execute the right actions. Extra functional specifications are needed to execute the wished actions in particular operation situations. Some common known optional functions are specified in the paragraphs hereafter.
6.2
Power Management System (PMS) General description
6.2.1
To prevent that the electrical grid will vary in voltage and frequency due to the start of too many consumers, a power management system decides if an electrical consumer may be started. When the operator chooses a pump to start, the VSDS generates a start request signal for this pump. The signal will be sent to the power management system, which checks if enough electrical power is available to start this pump. When there is enough power available the VSDS will receive a start permit signal (each pump needs a start permit signal). When the pump finally runs, the VSDS will activate a Pump Running signal. This function is managed by the PLC, therefore it only operates in remote mode. The VSDS is designed for standard MarFlex PMS systems.
6.2.2
PMS functionality for standard MarFlex configurations For standard MarFlex VSDS systems the PMS system has the following specifications: PMS is only functional for cargo and slop pumps. PMS is not functional in cargo heating mode. There is one PMS Request to Start Pump signal, a plc-output. There is one PMS Start Pump Permitted signal, a plc-input. For each pump [x] there is a Pump [x] running signal, a plc-output. .Only one PMS Request to Start Pump can be executed, other pumps have to wait until the request sequence for the active pump has finished. The sequence for starting a pump is: 1. A pump start request is generated by one of the operating systems (Touch panel (TP), control desk (CD) or cargo computer). 2. If there is no other PMS request pending, the PMS Request to Start Pump signal is set to 1. 3. On the operating system (TP or CD) a signal PMS start request pending is presented. 4. If the PMS responds with the signal PMS Start Pump Permitted, the pump will be started, and the PMS Request to Start Pump signal is set to 0.
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5. When the pump is running, for each pump the signal Pump [x] running ( where x is the name of the pump ) will be set to 1. 6. When the pump is stopped, for each pump the signal Pump [x] running ( where x is the name of the pump ) will be set to 0. 7. If the PMS does not respond with the signal PMS Start Pump Permitted within 90 seconds, the fault message PMS start prohibited is presented in the operating system (TP or CD). The signal PMS start request will be set to 0. On the touch panel the PMS status is presented in the following way: PMS start pending : blinking green led in pump section of matrix screen. PMS start permitted : green led in pump section of matrix screen. PMS start prohibited : red led in pump section of matrix screen. Other PMS request pending : blinking red led in pump section of matrix screen. On the control desk the PMS status is presented in the following way: PMS start pending : blinking 1 Hz green led in the pump start button. PMS start permitted : green led in the pump start button. PMS start prohibited : blinking 5 Hz green led in the pump start button, and general failure lamp on. Other PMS request pending : not presented on control desk. If a PMS start prohibited occurs, a fault message is generated, and presented in the fault screen of the touch panel.
6.3
Water cooling
Water is a better cooling medium than air. Normally the MarFlex VSDS is supplied with air cooled converters. High power systems can be delivered with water cooled converters. The heat loss of the converters must be removed by an external water cooling system. To guarantee the minimum water quality specifications MarFlex advises to use a separate cooling unit for the MarFlex VSDS. This unit is not standard included in the package of the MarFlex VSDS. The cooling unit has to comply to the specifications as described in chap Fout! Verwijzingsbron niet gevonden..
6.4
Cargo heating mode General description
6.4.1
Cargo heating mode is a optional function that provides a flow of cargo while keeping it at certain temperature by leading the cargo through heaters. In cargo heating mode it is possible to connect a maximum of two pumps to one converter. The maximum speed of the pumps is limited by the maximum power of the converters. The heaters are not controlled by the VSDS. Cargo Heating Mode is only possible when a touch panel is present as remote control unit.
6.4.2
Cargo heating mode specifications
Cargo heating mode has the following specifications: 1. A maximum of 2 pumps can be connected to one converter in cargo heating mode. 2. The maximum pump speed in cargo heating mode is 50%. 3. There is no guaranty that both pumps in cargo heating mode operate at the same speed. If for example one pump is in a less viscous media then the other pump, the first pump can still be at the correct speed, while the other pump runs at speed zero.
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4.
If two pumps with different specifications (e.g. a cargo and a slop pump) are connected to one converter, there is no guaranty that both pumps will operate at the same speed.
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7 SYSTEM CONTROLS
7.1
Introduction
The MarFlex VSDS can be operated in several ways. For normal operation there are more remote modes possible. In emergency situations local mode is always present. Only one mode of operation can be active at one time. The choice between the different modes is determined by using the selector switch on the PLC cabinet.
7.2
Local operation. General
7.2.1
In emergency situations or when the PLC is stopped (due to a failure), the converters can be operated in local mode. This mode is automatically active in case the PLC detects a data communication failure. To provide starting and stopping in local mode the converters are equipped with a pump selection system, and with an operation panel. For each brand of converter, a different type of operation panel is used. The pump selection system is the same for each brand of converter.
7.2.2
The pump selection system
To select a pump on a converter a number of illuminated pushbuttons are available on the converter cabinet. A pump can be selected by pushing the corresponding button. A red pushbutton is available to undo the selection. On a converter only one pump can be selected. The following drawing shows an example for the pump selection buttons :
Pump 1p
Pump 2p
Pump 3p
Deselect
Before a pump can be started by the operation panel on a converter, the following conditions have to be present: .The operating mode switch has to be in the position Local mode . The converter has to be available ( No other pump selected on this converter ) . The converter has to be ready ( No faults ) A pump can be selected in the following way:
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On the converter cabinet the pushbutton corresponding with the desired pump is pressed.
The light in the pushbutton will be lit. Now the pump can be controlled via the converter panel.
After the selected pump has come to a complete standstill, and the operating panel has given up control, the pump can be deselected by pressing the red deselect pushbutton. The light in the green pushbutton will be off.
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7.2.3
The operation panels The operation panel for Sinamics converters
7.2.3.1
Each Sinamics converter has an AOP30 (Advanced Operator Panel) mounted on the door which is connected to the corresponding converter. Using this panel a motor can be started and stopped. With this panel it is possible to increase or decrease the speed of the motor connected. On the display of the panel the motor speed and motor current is presented, as well as the actual status of the converter. If the key switch on the PLC cabinet is set in mode LOCAL, all running converters will be stopped automatically. AOP30 Layout
Before a pump can be started, the pump has to be selected ( par 7.2.2 ). First action to operate with the AOP30 panel is to place it into the local mode by pushing the Master Control Selector. The selector reacts with highlighting a yellow LED in the button, meaning that the converter is ready to operate in local mode. After the pump has come to a complete stop, the control can be given up by pushing the Master Control Selector. After that the yellow LED in the button will be off. Because remote control is deactivated, all AOP30 panels must be placed in local mode to make full operation possible. The following functions are available on the AOP30 panel: - Start pump: Choose pump with selection switch on front door and press the green ON key. - Stop pump: Press the red OFF key. - Increase pump speed: Press the Increase key until setpoint speed is reached. - Decrease pump speed: Press the Decrease key until setpoint speed is reached. - Change visualization LCD screen: Navigation with MENU, F2 , F3 and F5 OK Status information is displayed by three LEDs: - green flashing: converter is READY FOR OPERATION - green continuously: converter is RUNNING. - yellow continuously: an alarm is active. - red continuously: a fault is active
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After a pump is started, the pushbuttons on the matrix cabinet are de-activated. An important visualization to control the pumps is the status display of the AOP30 panel.
Status of drive Operating direction Operation time
Desired speed Actual speed Actual current Actual bus volt. Actual torque Text line
Actual speed % Actual power Actual current % Actual voltage Actual frequency
The following information is displayed: - Status of converter: Ready: Converter stand by, no fault present, ready to switch on. Operation: Converter is active. Fault: Converter has an actual fault. Reset with function key F5. - Operating direction: direction of the pump. : operation clockwise (not possible for MarFlex systems) : operating counter clockwise. - Operation time: System time. - NSET = Desired speed: Desired pump speed. (rpm) - 24001 = Actual speed. (%) - N_ACT = Actual speed. (rpm) - PACTV = Actual power consumption: Output power converter = Input power E-motor connected.(kW) - I_ACT = Actual current. (Aeff) - 24002 = Actual current. (%) - V_DC = Actual bus voltage: Voltage of the internal DC bus of the converter.(V) - V_OUT = Output voltage. (Veff) - M_ACT = Actual torque: Output torque of the E-motor connected.(Nm) - F_ACT = Actual frequency. (Hz) - Text line: Line of comment to be used for Functional description of the F-keys. Actual fault message. Actual alarm message. Information about faults and alarms can be found on the Active Alarms and Active Faults displays and in manual Sinamics S120 AOP30 2006-03 eng.pdf. Parameterization of dry run parameters for cargo, slop and residual pumps: 25000 threshold for start detection below the value, in rpms. Default value 50% 25001 threshold for decision dry run in Amps as percentage of the nominal value. Default value 30% Parameterization of dry run parameters for ballast pumps: 24525 - dry run speed limit 1, default value 50% 24526 - dry run current limit 1, default value 35% 24527 - dry run speed limit 2, default value 100% 24528 - dry run current limit 2, default value 67%
7.2.3.2
The operation panel for Vacon converters
Each Vacon converter has an Vacon Operator Panel mounted on the door which is connected to the corresponding converter. Using this panel a motor can be started and stopped.
With this panel it is possible to increase or decrease the speed of the motor connected. On the display of the panel the motor speed and motor current is presented, as well as the actual status of the converter. If the key switch on the PLC cabinet is set in mode LOCAL, all running converters will be stopped automatically. VACON Local Panel
On the panel the following buttons have the following meaning: Start button: When the converter is ready this button is used to start the pump
START
STOP
Stop button:
When the converter is running this button is used to stop the pump
Up button:
This button is used to increase the selected parameter or setpoint and to display the next menu This button is used to decrease the selected parameter or setpoint and to display the previous menu
Down button:
Right button:
This button is used to display the first submenu or parameter of the current menu or to start editing the current parameter
Left button:
This button is used to display the previous submenu or parameter
select
Select button: This button is used to toggle between the setpoint menu or other menus
reset
Reset button:
This button is used to reset converter faults during local mode

MarFlex VDSV functional description.doc Page 21 of 67
enter
Enter button:
This button is used to accept a changed parameter
The following LEDs have the following meaning:

ready
Ready LED:
When this LED lights green the converter is ready for operation
run
Run LED:
When this LED light green the converter (and the pump) is running
fault
Fault LED:
When this LED lights red the converter has a fault
The following display indicators have the following meaning:

RUN STOP READY ALARM FAULT
Run indicator: Stop indicator: Ready indicator: Alarm indicator: Fault indicator: Forward indicator: Reverse indicator:
This indicator indicates the convertor (and the pump) is running This indicator indicates the converter (and the pump) is stopped This indicator indicates the converter is ready for operation This indicator indicates that an alarm is present This indicator indicates that a fault is present This indicator indicates the forward direction of the pump This indicator indicates the reverse direction of the pump (n/a) This indicator indicates the converter is controlled via the I/O terminal (n/a) This indicator indicates the converter is controlled via the display (local mode)
I/O term
I/O indicator:
keypad
Keypad indicator:
Bus/Comm
Bus/Comm indicator: Parameter number:
This indicator indicates the converter is controlled via the profibus (remote mode) This text shows the number of the current parameter or menu
V 1.5.5
Actual speed
Parameter name: Parameter value:
This text shows the name of the current parameter or menu This text shows the value and unit of the current parameter or value
89 %
Before a pump can be started, the pump has to be selected ( par 7.2.2 ). The Ready LED on the panel lights and on the display the Keypad indicator and the Ready indicator will be visible.
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STOP READY
V 1.5.8
keypad
MarFlex VSDS
ready
run fault
START
reset STOP
select
enter
After pressing the Start button the converter will start. The Run LED lights and the Run indicator becomes visible in the display.
RUN
READY
keypad
R 1.5.4
Speed setpoint
0%
ready run fault
START
reset STOP
select
enter
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The panel automatically selects reference parameter R 1.5.4 which is the speed setpoint. The Up and Down buttons can be used to increase and decrease the speed setpoint.
RUN
READY
keypad
R 1.5.4
Speed setpoint
54 %
ready run fault
START
reset STOP
select
enter
To view other menus or parameters while the pump runs the Select button can be pressed. After accepting the setpoint value with the Enter button, the Up, Down, Left and Right buttons can be used to navigate through the menus and parameters.
RUN
READY
keypad
V 1.5.5
Actual current
36 %
ready run fault
START
reset STOP
select
enter
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When the select button is pressed again the display will return to the setpoint reference which can be adapted immediately using the Up and Down buttons.
RUN
READY
keypad
R 1.5.4
Speed setpoint
54 %
ready run fault
START
reset STOP
select
enter
To stop the pump the Stop button can be used. The Run LED will start blinking to indicate the down ramping of the speed.
RUN
READY
keypad
R 1.5.4
Speed setpoint
0%
ready run fault
START
reset STOP
select
enter
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When the converter has stopped the pump the display remains in the setpoint menu for a period of five minutes. After these five minutes the display returns to the default menu.
STOP READY
V 1.5.8
keypad
MarFlex VSDS
ready
run fault
START
reset STOP
select
enter
When a fault occurs the pump will be stopped by the converter and display will show the fault text. The Fault LED will be lit and the Fault indicator will be shown. The Reset button can be used to reset the converter.
After the selected pump has come to a complete standstill the pump can be deselected, as described in par 7.2.2.
After deselecting the pump the Ready LED will go off and the pump can no longer be started. Depending on the state of other converters and the selection switch on the PLC cabinet, the system remains local or transits to remote mode.
STOP
V 1.5.8
keypad
MarFlex VSDS
ready
run fault
START
reset STOP
select
enter
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7.3
Remote modes
If the key switch on the PLC cabinet is set from local mode to a remote mode the system can be controlled by one of the remote operating options. To activate the remote control chosen, all converters have to be stopped on the converter cabinets and AOP30 panels. After the last converter is stopped, the remote indicator light on the PLC cabinet indicates remote operation. If the key-switch on the PLC cabinet is set from remote mode to another remote mode or local mode, while there are still converters running, all converters stop automatically, and a general fault is generated. After the last converter is stopped, and the general fault is reset, the operating mode change will take effect. For remote control the following modes are possible: - Touch panel - Control Desk - Cooperation with external systems In case of remote mode with a touch panel or an external system, the operator starts and stops pumps. Which converter will be used is determined by the PLC. If more than one converter is available, the PLC chooses the one with the smallest amount of operation hours. In case of remote mode with a control desk, the operator starts and stops pumps, connected to a specific converter.
7.3.1
Remote mode: Touch Panel TFT panel with a Windows CE very easy to understand
The MP377 touch panel is a 15 operating system. It is a most flexible for operation and Human Machine Interface (HMI). The panel has a Profibus-DP the PLC. The panel will report if the lost or the PLC has stopped. Detailed information about this panel and maintenance application in
interface to communicate with communication to the PLC is together with the operators chapter 8.
7.3.2
Remote mode: Control Desk
A more conventional HMI, but not less adequate to use, is the control desk. Operation takes place with switches, buttons, lamp and meter indications. With a control desk the function cargo heating mode is not possible.
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A control desk consist of a number of operating devices such as switches, pushbuttons and visualization devices such as lamps and meters. A pump can be started by pushing a start button. The PLC allocates the pump to a converter and the pump can be operated using pushbuttons to alter the speed or to stop the pump. Indication lamps inform the operator about faults and statuses. Meters inform the operator about motor speed and currents. Detailed information about the operation with the desk in chapter 9.
7.3.3
Remote mode: Cooperative with external systems
With interconnection of more than one intelligent system present on the vessel, it is possible to create a centralized operation station. For example the cooperation of the operation stations of the MarFlex VSDS and the Cargo Computer. Cooperation takes place through data communication. For this the standard used protocol is MODbus.
Communication during engineering takes place with common data tables. Standard the VSDS is designed to work with the standard MarFlex data model.
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8 Remote Mode: TOUCH PANEL

8.1 General
This chapter describes the functional design of the touch panel (TP) which is used for operation of the VSDS during remote control. The following screens are present: - Default screen Screensaver with picture, any touch will open the Overview screen - Overview screen Overview of the system including pump control - Pump control screen Pump control and status, 1 screen per distribution matrix - Cargo heating mode screen Similar as the Pump Control screen of activating cargo heating mode - Pump screen Pump status - Converter screen Converter status - Fault screen Fault message table including reset and accept possibilities - Login screen For access to Maintenance and System screen by changing the user - Maintenance screen To adapt date and time, calibration of touch screen (accessible for clients technician). - System screen Reset operation times, view logs and exit the runtime environment (necessary to load new software, accessible for MarFlex technician) - Information screen MarFlex contact information, with software version and project number - Communication fault screen Appears when the connection with the PLC is lost - Help screen per screen Information on the use of the screen including explanation of colors Every screen has the standard view configuration: General information line
Screen navigation buttons
Screen hierarchy
Active alarms
Command buttons
The following items are visible on each screen: - Name of the screen with pump or converter identification where applicable - Current date and time - Status of operation mode (local or remote), - Current user Touch: navigate to login screen - Help area Touch: navigate to help screen - Current, most recent faults, maximum of five Touch: navigate to fault screen
Current position in the screen hierarchy. Logo of MarFlex
Touch: navigate to overview screen Touch: navigate to MarFlex contact information
8.2
Main Screens
8.2.1
Tree structure
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8.2.2
Default screen
This screen is shown when the touch panel (TP) is (re)started. It shows a representative picture or animation and facultative information. The following interaction with other screens is present: Origin Action
Operating system TP Overview screen Cargo heating screen Restart of Touch Panel No touch activity for 8 hours and no converter active No touch activity for 8 hours and no converter active Any touch Fault occurs Communication fault occurs
Destination
Overview screen Overview screen Communication fault screen
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8.2.3
Overview screen
This screen shows all tanks with MarFlex pumps in the shape of the vessel. It contains the following information: - operation status (running, standby, not active, warning, fault) using tank colours - actual speed pumps in operation, using bargraphs and numerical visualization outside vessel contours. The screen has no control functions, it is only meant as general status overview. Navigation links with other screens: Origin
Default screen Pump Control screen Cargo heating mode screen
Action
Any touch Navigation tree touched Overview button touched No touch activity for 8 hours Navigation tree touched Tank button touched
Destination
Fault area touched User area touched MarFlex logo touched Communication fault occurs
Default screen Default screen Pump Control screen (default) or Cargo Heating Mode screen, depending on previous chosen way of operation. Fault screen Login screen Info screen Communication fault screen
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8.2.4
Pump control screens
The screen shows all pumps and converters in a distribution matrix with following information: Pump and converter connection status.(using colours: green=running, red=fault, grey=connected, yellow=dry run) Actual speed (%) Actual current (%) Pump operation status (using colours: green=running, red=fault, white=not active, yellow=dry run) Converter operation status(using colours: green=running, red=fault , grey/white text=not active, grey/green text= first drive to start) Cargo heating mode status (if applicable) PMS status (if applicable) Motor temperature fault status Speed deviation warning status Dry run warning and fault status Converter fault status Actual speed setpoint (%)
The following functions will be activated by touching: - a pump: selects the pump for operation and navigation - a converter: selects the converter for navigation - Start / stop button: starts or stops the selected pump - Speed up / down button: raises / lowers the setpoint of the selected pump Navigation links with other screens:
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Origin
Overview screen
Action
Tank touch No touch activity for 5 minutes Navigation tree touched Pump status button touched Converter status button touched Fault area touched User area touched MarFlex logo touched Communication fault occurs
Destination
Overview screen Overview screen Pump screen Converter screen Fault screen Login screen Info screen Communication fault screen
8.2.5
Cargo heating mode screen
This screen shows all tanks with MarFlex pumps in the shape of the vessel. It contains the following information: - operation status (running, standby, not active, warning, fault) using tank colours - actual speed pumps in operation, using bargraphs and numerical visualization outside vessel contours. The screen has no control functions, it is only meant as general status overview.
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Origin
Default screen Pump Control screen Cargo heating mode screen
Action
Any touch Navigation tree touched Overview button touched No touch activity for 8 hours Navigation tree touched Tank button touched
Destination
Fault area touched User area touched MarFlex logo touched Communication fault occurs
Default screen Default screen Pump Control screen (default) or Cargo Heating Mode screen, depending on previous chosen way of operation. Fault screen Login screen Info screen Communication fault screen
Cargo Heating Mode contains also control screens, 1 per distribution matrix:
8.2.6
Cargo heating control screens
These screen are similar to the pump control screens, with the exception that a maximum of 2 pumps can be selected for operation. A Clear selection button clears the selection of the pumps. Starting a pump will start it in cargo heating mode. Only pumps in cargo heating mode can be stopped. The cargo heating control screen shows the following information: Pump and converter connection status.(using colours: orange=running, red=fault, grey=connected, yellow=dry run) Actual speed (%) Actual current (%)
MarFlex VDSV functional description.doc Page 36 of 67
- Pump operation status (using colours: orange=running, red=fault, white=not active, yellow=dry run) Converter operation status(using colours: orange=running, red=fault , grey/white text=not active, grey/green text= first drive to start) Cargo heating mode status (if applicable) Motor temperature fault status Speed deviation warning status Dry run warning and fault status Converter fault status Actual speed setpoint (%)
The following functions will be activated by touching: - a pump: selects the pump for operation and navigation - a converter: selects the converter for navigation - Start / stop button: starts or stops the selected pump(s) - Speed up / down button: raises / lowers the setpoint of the selected pump(s)
Navigation links with other screens: Origin Action

Overview screen Tank touch No touch activity for 5 minutes Navigation tree touched Pump control screen button touched Pump status button touched Converter status button touched Fault area touched User area touched MarFlex logo touched Communication fault occurs
Destination
Overview screen Overview screen Pump control screen Pump screen last selected pump Converter screen Fault screen Login screen Info screen Communication fault screen
MarFlex VDSV User Manual Concept.doc
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8.2.7
8.2.8
Pump screen
This screen shows the status of the selected pump: - Actual speed (%) - Actual current (%) - Dry run speed limit (%) - Dry run current limit (%) - Operating hours (h) - Connected converter - Cargo heating mode status (if applicable) - PMS status (if applicable) - Motor temperature fault status - Speed deviation warning status - Dry run warning and fault status - Converter fault status - Actual speed setpoint (%) The following functions functions will be activated by touching : - Start/ stop button: starts or stops the selected pump - Speed up / down button: raises / lowers the setpoint of the selected pump(s) The following navigation links with other screens exist:
MarFlex VDSV User Manual Concept.doc
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Origin Pump control screen
Action Pump status button touched No touch activity for 5 minutes or Navigation tree touched Fault area touched User area touched MarFlex logo touched Communication fault occurs
Destination Pump control screen or Cargo heating mode screen Fault screen Login screen Info screen Communication fault screen
8.2.9
Converter screen
This screen shows the status of the selected frequency converter: - Operation status (running, standby, not active, fault) - Actual selected parameter set - Operation time of the converter - Speed deviation warning status - Converter fault status and converter fault number - Connected pump - Actual speed (%) - Actual current (%) - Cargo heating mode status (if applicable) - Actual setpoint (%) No control functions present. Navigation links with other screens:
Author : L.Sonneveld
Functional Description rev22 2011-04-11.doc
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Origin
Pump control screen Cargo heating mode screen
Action
Converter status button touched No touch activity for 5 minutes Navigation tree touched Pump status button touched Fault area touched User area touched MarFlex logo touched Communication fault occurs
Destination
Pump control screen Cargo heating mode screen Pump status screen Fault screen Login screen Info screen Communication fault screen
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8.3
Auxilliary screens
8.3.1
Tree structure
8.3.2
Communication fault screen
This screen appears when there is no connection with the PLC. No operation or navigation is possible. When the connection is (re)established an accept button appears to acknowledge the fault.
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8.3.3
Fault screen
The screen shows all current faults and warnings. The colors represent the following fault status: Yellow : Warning Red/Blinking : Fault active and not accepted Red : Fault active Blue : Fault not active and not accepted The following control functions will be activated by touching : - Reset button: resets all faults and accept all faults and warnings - Accept button: accepts all visible faults and warnings Navigation links with other screens: Origin Action
Any screen Fault area touched No touch activity for 5 minutes Navigation tree touched User area touched Communication fault occurs
Destination
Previous screen Login screen Communication fault screen
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8.3.4
Login screen
In this screen the user can log in as dedicated user, which changes the presentation and control possibilities according the authorisations granted to this user. The following control functions are present: - Log in with a code by choice of code en acknowledgement with the Enter button. Navigation links with other screens: Origin Action
Any screen User area touched No touch activity for 5 minutes Navigation tree touched Fault area touched Communication fault occurs
Destination
Overview Screen Fault screen Communication fault screen
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8.3.5
Maintenance screen
The following control functions will be activated by touching : - Change of the current date and time, by choice of time zone with acknowledgement of the choice by touching the Set button. - Calibration the touch screen, by touching precisely the symbols which are visualized one by one. - Temporarily deactivation of the screen for cleaning purpose The following navigation links with other screens are present: Origin Action Destination
Login screen User area touched Navigation tree touched No touch activity for 5 minutes Fault area touched Communication fault occurs Overview screen Overview screen with deactivation user code Fault screen Communication fault screen
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8.3.6
Diagnosis screen
In this screen the user can scoll through the fault history where up to 500 previous faults are stored. In the logging part of the screen, changes to important parameters like dry run settings are stored. In the bottom part of the screen, below Profibus slaves, the active profibus stations are shown. The following navigation links with other screens are present: Origin Action Destination
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8.3.7
Settings screen
The Settings screen is only accessible in engineer mode. In this screen dry run settings for each pump can be adjusted. The following engineer functions are available : Initialize all plc data - Erase all diagnosis data - Exit runtime ( to operating system) - Alter contactor switch off delay - Adjust the engineer logout time The following navigation links with other screens are present: Origin Action Destination
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8.3.8
Operating hours screen
This screen shows the operating hours for all pumps and converters. By pressing the reset button, the operating hours of a pump/converter are being reset. The following navigation links with other screens are present: Origin Action Destination
Login screen Operating hours button touched Navigation tree touched No touch activity for 5 minutes Fault area touched Communication fault occurs Overview screen Overview screen with deactivation user code Fault screen Communication fault screen
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8.3.9
Info screen
This screen shows general information of MarFlex and the Variable Speed Drive System. The following navigation links with other screens exist: Origin Action
Any main screen MarFlex logo touched No touch activity for 5 minutes Navigation tree touched Fault area touched Communication fault occurs
Destination
Previous screen Fault screen Communication fault screen
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8.3.10
Help screen
Every screen has a separate help screen, which displays information on the functions and indications on the present screen. The following navigation links with other screens exist: Origin Action
Any screen Question mark area touched No touch activity for 5 minutes Navigation tree touched Fault area touched Communication fault occurs
Destination
Previous screen Fault screen Communication fault screen
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8.4
User management
To manage the accessibility of screens or functions three different user levels are present: Operator Granted to all functions except the Maintenance screen and Settings screen Maintenance Granted to all functions except for Settings screen. Engineer (available for MarFlex engineers only) Granted to all functions
Passwords consist of 4 decimal digits which can be selected with a numeric key pad:
User Operator has no password. User Maintenance has a password which is provided to the client, e.g. 1397 (square on the panel) User Engineer has a password which is provided to MarFlex engineers only. Passwords or other special application changes can only be changed by MarFlex. One of these changes is for example management of dry run parameters. The system automatically deactivates the user Maintenance or Engineer after 5 minutes of no touch activity.
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9
9.1
Remote mode: CONTROL DESK

Introduction
The control desk displays the pump-controls divided into several vertical sections: - per converter one section - a general section at the right side of the desk. The control desk is actived for operation by switching the key switch on the PLC cabinet to remote mode control desk. In all other cases, the desk only presents the results of other operation equipment if possible. The control desk is connected to the VSDS through data communication, protocol Profibus-DP. In case of data communication error, all signalisations on the desk will be off, read outs will be zero. Emergency stop remains active in all cases, established by its hard wired connections.
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9.2
General section
For common use several buttons and indications are available at the right side of the desk, From the top to bottom side: Emergency stop-button Emergency stop indication Remote-control indication Inert gas indication High pressure indication General failure indication Buzzer Buzzer reset-button Lamp test-button
9.2.1
Emergency stop button On top of the desk at the right side, the emergency stop button is situated. This button is active in all operation situation. After activation, no motors can be started and all motors in operation are switched-off immediately (motor-contactors are powered down).
To reset the emergency situation, first the push button activated must be released by tearing it upwards, then the reset button must be pushed to acknowledge the safe situation
9.2.2
Emergency stop indication
The emergency stop indication is available for displaying the status of the emergency stop relay in the PLC cabinet of the VSDS.
9.2.3
Remote control indication With the key switch on the PLC cabinet, the operation mode is selected: local or remote. In case of the choice remote mode control desk, the green signalization on the desk will be active.
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9.2.4
External alarms It is possible to show external alarms on the control desk. Standard MarFlex supply is the signalisation of the external alarms Inert gas pressure level to low and high pressure alarm at the output side of the MarFlex pumps. and possibility to stop the VSDS for external reasons. are the
9.2.5
General alarm When there is a general alarm in the system, a signalisation is present at the control desk to indicate there is a general failure. This indication only works if the control desk operation is selected.
9.2.6
Buzzer The buzzer on the control desk is used to indicate an error or emergency situation. After detecting an error or emergency, the sound of this buzzer can be switched off by pressing the reset button. The sound will be activated again, when a new error or emergency is detected.
9.2.7
Reset a converter-trip or emergency To de-activate the buzzer, push the reset buzzer button. The buzzer reset button is also used to reset any emergency, alarm or converter trip situation.
9.2.8
Lamp test button Lamp test button is used for checking the LEDs, buzzer and analogue panel-meters on the control desk.
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After pressing this button at first, all analogue signals are activated to the full-scale (20mA). After a few seconds, the analogue-signals are changed to 4mA and all digital signals are on for one second (the LEDs and the buzzer on the control desk).
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9.3
Converter sections Each converter has its own section on the desk, all sections are identical. For each panel the following controls are available for running the connected pumps: Selection indication/start-buttons for the pumps Dry-run indication/stop-button for the pumps Panel meter for RPM Panel meter for current Error indication Power indication Run indication/motor-pot buttons
9.3.1
Visualization
The following indications are present on each converter section: Stand by Converter is powered on, no faults are present and it is ready for use. In operation Converter in operation in cooperation with the pump of which the visualization is active. Motor fail Converter stopped, due to external motor failure, mostly thermal alarm. Dry Run Dry Run alarm. Blinking in warning phase, continuous at motor stop. Trip Converter stopped, due to internal malfunction. Detailed information on the local control panel on the converter cabinet.
9.3.2
Speed / Power indication Two panel-meters are used for the motor-speed and motor-current indication. The meters are displaying the actual measured processvalue, read from the converter. The signals from PLC to the meters are 4-20mA values and correspond to the full-range of the meter.
The 20mA signal corresponds to the maximum speed setting from the parameters in the converter.
9.3.3
Start Pump Pumps can be started by pressing the push button concerning. After activation of the pump (motor), the signalization in the button will be activated continuous during pump operation. If pump start does not succeed, it is possible that this pump already operates with another converter.
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9.3.4
Stop Pump To stop a pump, the stop button must be pressed. The motor is decelerated to 0 RPM after which its contactor is switched off and the frequency-converter is stopped.
9.3.5
Speed Change buttons To change the speed of the selected motor, two buttons are used on the lower part of the controls-section. At start 0 RPM is send to the converter for speed-reference. Changing the speed reference from 0 to 100% is possible by pressing the up and down buttons.
Pressing the UP button will increase the speed, pressing DOWN will decrease the motor speed. Change of the speed can be verified at the analogue speed indications.
9.4
Dry Run settings
The settings for the dry run protection can be changed individually for each pump on the control desk. This function is only available when the control desk is the only available remote control (when no touch panel is available ). The analogue panel meters are used to display the settings for the maximum speed and the minimum current at dry run protection. Warning: The dry-run settings should only be changed by MarFlex-personal and is accessible when all motors are switched off and remote control is selected on the control desk with the key switch. Conditions for entering set-up-mode: Before the dry-run parameters on the control desk are changed, make sure that all pumps are off and remote control on the control desk is selected. + To enter dry run set up mode: To prevent accidental changes of the dry-run settings, you can only enter the set-up-mode after pressing the reset-button for more than 20 sec. As soon as the reset-button is released the set-up-mode is closed and the system is ready for running a pump.
20sec.
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Dry-run selection is active: Keeping the reset button pressed will provide the option of changing the minimum speed-, or the maximum current-settings for the dry run detection on all pumps individually. The setup mode is displayed in the control desk by blinking motor start buttons. When all pump start buttons are blinking, a pump selection can be made.
Pump selection for dry run: Keeping the reset button pressed simultaneously with a pump start button, the dry run settings for the selected pump are activated. All other pump-indications in this section will stop blinking exept for the selected one.
Changing the dry-run settings: At first the setting for the minimum speed is set displayed on the RPM panel-meter. Dry run is detected when the measured speed is higher than the value, now displayed on the panel meter. +
Increase the minimum speed setting: The minimum speed setting is increased in steps after pressing the up on the speed reference buttons, while the reset button is still pressed. + + Decrease the minimum speed setting: The minimum speed setting will be decreased in steps after pressing the down on the speed reference buttons, while the reset-button is still pressed. + +
Switch between speed and current setting: Switching between the selection for the minimum speed or the maximum current setting for dry-run detection is done by pressing the stop-button, while the reset-button is still pressed. + + The maximum current setting can be changed the same way as the minimum speed settingby reading the current value and also increasing and decreasing with the UP and DOWN buttons. Allways with the Buzzer button pressed down
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10 General Converter Functionalities
10.1 Introduction This chapter is a brief overview of frequency converter systems with respect to the following subjects: - Frequency converters in non-grounded systems - Frequency converters as a electrical noise source - Frequency converters and the earth fault detection system - Radio interference suppression filters
10.2 Frequency converters in non-grounded systems In many industrial sectors, non-grounded supplies (IT supplies) are used to increase the availability of the plant/installation. In the event of a ground fault, no fault current flows, and the plant remains in operation and therewith in production.
Earthed (TN) system
Unearthed (IT) system
When an earth fault occurs in an earthed system, a high current via this earth fault will flow back to the energy source, here a transformer. Because of this, the over current protection (and directly the differential protection) will respond. In an unearthed system there is just a small capacitive coupling between the system and earth. This is caused by cabling. The cable lengths and the cable quality determine the size of the couplings. According to EMC-directives, these couplings must be as small as possible. Small capacitive currents can and may be neglected by insulation monitor devices (IMD). When an earth fault occurs in an unearthed system, the short circuit current from the earth point back to the energy source will be small. Over current protection will not respond, situation remains safe. Only the IMD detects the earth fault and warns the environment that the system is earthed.
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Unearthed system, Second earth fault Only when a second earth fault occurs, in an unearthed system, a fault current, causing a danger to both man and installation, can flow (see figure 9.3). A phase-to-phase fault will always result in a current flow and will always activate the protective systems. Therefore, correctly configured and maintained, non-grounded systems offer a reduced danger for both man and installation and also provide a higher reliability and availability because protection systems do not switch off the power in case of an earth fault. To maintain this unearthed, safe, situation, the resistance value between the system and earth has to be monitored continuously with an insulation-monitoring relay. The unearthed, IT-system provides the following advantages in comparison with earthed systems (TT, TN): - High continuity of the system (no switching off) - Higher level of electrical protection for man - Better protection against damage when earth faults emerge - Higher level of fire protection
10.3 Frequency converters as an electrical noise source
10.3.1
High frequency harmonic distortion (load)
Sinamics frequency converters operate with a voltage-source DC link.
Built-up frequency converter In order to keep the power losses as low as possible, the inverter switches the DC link voltage to the motor winding in the form of voltage blocks. The properties of the electric circuit at the output side of the converter change the voltage block commands into an almost sinusoidal current, which flows through the motor.
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Block diagram output voltage (V) and motor current (I) of a converter This mode of operation, in conjunction with high-performance semiconductor switching elements, have made it possible to develop compact frequency drives which now play a vital role in drive technology. As well as having many advantages, the fast semiconductor switches also have one disadvantage. A pulse-type noise current flows to ground through parasitic capacitances CP at each switching edge. Parasitic capacitances exist between the motor cable and ground, and also within the motor.
Block diagram output voltage (V) and fault current The source of the noise current IS of the inverter and therefore the noise current must also flow back to the inverter. Impedance ZN and ground impedance ZE act in the return flow path of the noise current. Impedance ZN is from parasitic capacitances between the supply cable and ground in parallel with the impedance (between phase and ground) of the supply transformer. The noise current itself and the voltage drops across ZN and ZE caused by the noise current, can also affect other electrical units. The high-frequency noise emission can only be reduced if the generated noise current is correctly routed. Using non-shielded motor cables, the noise current flows in an undefined fashion back to the frequency
Author : L.Sonneveld Functional Description rev22 2011-04-11.doc Page 60 of 67
drive, e.g. via foundation, base frame grounders, cable ducts, cabinet frames. These current paths have a very low resistance for currents with a frequency of 50 or 60 Hz. However, the noise current induces a highfrequency component, which can result in problematical voltage drops. A shielded motor cable is absolutely essential to enable the noise current to flow back to the frequency drive in a defined fashion. The shield must be connected to the housing of the frequency drive and to the motor housing through a large surface area. The shield now forms the easiest path for the noise current to take when returning to the frequency converter.
Flow of the noise current with shielded motor cable A shielded motor cable with a shield connected at both sides causes the noise current to flow back to the frequency converter through the shield. Although (almost) no voltage drop arises across impedance ZE for shielded motor cables, the voltage drop across impedance ZN can affect other electrical units. For detailed information, see the Sinamics drives manual Sinamics Engineering Manual V3.1 eng.pdf
10.3.2
Low frequency harmonic distortion (mains)
Besides the high-frequency noise currents generated by frequency drives, as previously described, lowfrequency harmonics should also be taken into account. As a result of rectification of the line supply, a nonsinusoidal line current is drawn, which causes a distortion of the line supply voltage. Power Systems have been designed to generate, transform, transport and distribute power at a frequency 50 or 60 Hertz. The presence of voltages and/or currents at any other frequencies can cause problems. Traditionally, typical loads consisted of lights, motors, heaters etc., are based on inductive, capacitive and resistive elements. All of which are linear in nature. This means that when fed with a sinusoidal voltage they will create a sinusoidal current of the same frequency. Since the development of rectifiers and power semiconductor technology, the term "typical loads" has broadened to include personal computers, fax machines, photocopiers, variable speed drives, etc. This new generation of power consumers is based on very sophisticated electronics that create power in a nonlinear fashion. In other words, when powered by a sinusoidal voltage they do not create a sinusoidal current. The degree by which this current deviates from a perfect sine wave is known as Harmonic Current Distortion. By the same token the degree by which a voltage deviates from a perfect sine wave is referred to as Harmonic Voltage Distortion. Although there is no such thing as a perfect voltage or current, there are maximum distortion limits deemed as acceptable. When the harmonic distortion exceeds these limits, problems can be expected. Traditional analysis no longer applies to systems with harmonic problems. It is important to approach them with the right tools and philosophy in order to obtain meaningful results.
Many articles and papers have been written regarding harmonics in power systems. They explain the phenomenon as the result of nonlinear loads drawing non sinusoidal currents. Terms such as Total Harmonic Distortion, Zero sequence harmonics, etc. are often utilized to further define their behaviour. Although these explanations are accurate in every respect, often, some of the terms used, end up being confusing rather than informative. Harmonic oscillations are not a recent discovery. Physicists and mathematicians identified them quite a long time ago. They postulated the laws that explain the movement of pendulums, springs, the planets, and other oscillatory phenomena including alternating currents. In fact, the very foundation of Power Systems Analysis revolves around harmonic theory. Low-frequency harmonics are reduced using line reactors, such as coils, sinusoidal filters or transformers.
10.4 Frequency converters and earth fault detection. The SINAMICS S120 converter features electronic voltage sensing using high value resistors to provide an electrical connection between the power unit and the grounded converter electronics. This circuit design provides for a certain inevitable insulation resistance. The insulation resistance of a SINAMICS S120 is approx. 800 Mega Ohm. If a large number of electronic devices with lower insulation resistances operate together parallel in one IT supply system, the insulation value to earth of the supply system can drop to a low value. If classification or other involved survey and inspection societies subscribe a minimum insulation value of an IT supply-system in operation, the supply system must be monitored continuously. Siemens recommends the use of an earth fault protection device / insulation monitor with two fault contacts. Each contact should react to a different insulation level. Low level when the drives are not switched on and high level when the drives are switched off. The insulation monitoring device made by BENDER, type IRDH 275 for example, is an established and safe solution for monitoring for insulation faults and has the two level contacts. The frequency converters for the Siemens-MarFlex installations are equipped as standard with a connection for the insulation monitoring device.
10.5 Radio frequency interference suppression filters RFI filters are not used in Siemens-MarFlex installations. A radio interference suppression filter needs grounding to earth. When a radio interference suppression filter is used in an unearthed system, a fault current will flow when a ground fault occurs. This earth fault may cause shutdown of the drives or even the destruction of the radio interference suppression filter. Radio interference suppression filters additionally affect the concept of non-grounded supply networks and can result in a safety risk when used with these networks (see Product Standard EN 61800-3: 1996).
11 Software design
11.1 Standard control The Converter is controlled in speed control without feedback (steering). The direction of the motor is fixed, the reverse signal of the converter is not used.
Two ways of stopping exist: - OFF2 stop (coasting down) - Normal stop A OFF2 stop is engaged in fault situations: - An emergency stop button is pressed - Converter fault - motor temperature fault - dry run fault - communication fault A OFF2 stop is a direct disconnection of the motor with the converter, followed by a free coast down. Coast down time depends on physical specifications at the driven pump. A normal stop is engaged when the operator issues the stop command. A normal stop results in a fixed ramping down the speed, following the preset ramp down time. The ramp up and ramp down time for a normal stop are fixed values, default 30 seconds.
11.2 Dry run protection When the motor speed is above a preset value and the motor current is below a certain a preset value the pump is probably running dry. An output signal of the converter called Dry Run is set.
Dry Run function
11.3 External interfaces The PLC software design consists of a number of control classes and interfaces:
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An interface is an implementation of signal enhancement. One side of the interface provides and accepts standard signals, the other side expects signals implementing functionality that can be converted into the standard signals. Interfaces are non-standard implementations, but provide and accept standard signals to and from control classes. For VSDS operation with human machine Interfaces connected through Profibus-DP, the operation interface provides and accepts standard signals necessary to operate the VSDS. Per pump and per converter an interface like table 11-1 is necessary to communicate with the HMIs. Standard HMIs like touch screens are internal MarFlex supply. Creation of the interface on both PLC and HMI side is done under responsibility of MarFlex. In case an external HMI is used, creation of these tables must be done in cooperation with the supplier of the HMI.
Table 11-2: Example of an external operation interface Signal name StartRequest ResetRequest HeatingMode Setpoint Ready Running SpeedDeviationWarning DryRunWarning DryRunFault MotorTemperatureFault DriveFault ActualSpeed ActualCurrent DriveNr Description Request to start the converter Request to reset the converter Combine more than one pump on a converter Setpoint to the converter The connected converter is ready The connected converter is running Actual speed is deviating from setpoint Dry run warning Dry run fault Motor temperature is high Number of the pending converter fault The speed of the connected converter The current of the connected converter The number of the connected converter Type Logical Logical Logical Numerical Logical Logical Logical Logical Logical Logical Numerical Numerical Numerical Numerical Range [0-1] [0-1] [0-1] [0-100%] [0-1] [0-1] [0-1] [0-1] [0-1] [0-1] [0-9999] [0-100%] [0-100%] [0-99]
Accepts
Provides
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12 VSDS system design specifications

12.1 General The MarFlex VSDS systems are designed to operate under the specifications as described in the following paragraphs of this chapter.
12.2 Regulations The MarFlex VSDS systems are designed and manufactured according to the following regulations: Standards for low voltage directive : NEN-EN-60439-1 Standards for the machinery directive : NEN-EN-IEC-60204-1 Standards for the safety of machinery : NEN-EN-954-1 Standards for the electromagnetic : EN-50081,EN-50082 and EN-61800-3 compatibility directive (EMC) Standards for equipment intended for : ATEX95 use in potentially explosive atmospheres (only for connections to field equipment where needed) Standards for symbols in electric documents :IEC 60617, symbols related to IEC 60617
12.3 Classification societies MarFlex VSDS systems are designed and manufactured according to the regulations of the following classification societies: - ABS (American Bureau of Shipping) - Bureau Veritas - CCS (China Classification Society) - DNV ( Det Norske Veritas) - Lloyds Register - RMRS (Russian Maritime Register of Shipping)
12.4 Ambient conditions for panels Ambient conditions for the panels have to comply with the following specifications: - Location : Indoors - Panels should be mounted in a conditioned area, free of dust and dirt - The mounting base should be stable - There must be free area around opened doors (escape route), according to classification rules - Altitude : < 1000m - Temperature : 0-40C - Relative humidity (min-max) : 30-95% (without condensation) - Mechanical forces/impact : 1. Vibration frequency range 5 to 50 Hz with vibration velocity amplitude 20 mm/s 2. Peak accelerations 0.6 g for vessels of length exceeding 90 m (duration 5 to 10 s) or 1 g for vessels of length less than 90 m (duration 5 to 10 s)
12.5 Power supply The MarFlex VSDS systems are designed to operate with main switch board power supply complying with the following specifications: - Mains configuration : IT with insulation protection in switch board (provided by others) - Line voltage main supply : Steady +/- 2,5% and transient +20%/-15%, 400-690VAC
Number of supplies (cables) Nominal Current (per supply) Frequency Max. short-circuit strength Auxiliary voltage supply Number of supplies (cables) Nominal current (per supply) Frequency Max. short-circuit strength Simultaneous power
: Each converter or each matrix : 435A : 50/60Hz +/-5% : 50kA : 230VAC +/-10% : Each converter or each matrix : 4A : 50/60Hz +/-5% : 10kA : 1994kVA
12.6 Cable and cable entry specifications Cables and cable entries have to comply with the following specifications: - Cables must enter the panels from the bottom side - Cables must be tightened on the pull relief - Cable shields must be connected to the EMC screen rail properly
12.7 Cooling water specifications Sinamics converters
12.7.1
The cooling system for Sinamics water cooled converters has to comply with the following specifications: - Coolant : Filtered drinking water with specifications as follows: - Chloride : <200 mg/l - Sulfate Ions : <240 mg/l - Nitrate Ions : <50 mg/l - pH value : 6,5-9,0 - Conductivity : <2000 S/cm - Total hardness : <1,7 mmol/l - Dissolved solids : <340 mg/l - Size of entrained particles : <100 m - Max. system pressure : 6 bar - Max. differential pressure : 2 bar - Max. coolant temperature : 38C - Rated volumetric flow for water : 12 l/min At 7 kPa pressure drop - Power loss max. : on request (depending on converter) - Closed cooling circuit is the recommended standard solution - Connection flange : Only for stainless steel heat sink (Frame size FL/GL) Note : Drinking water may contain more than 200 mg/l chloride. Values higher than 200 mg/l may damage the heat sinks if no inhibitors are added.
12.7.2
Vacon converters
The cooling system for Vacon water cooled converters has to comply with the following specifications: - Coolant : Filtered drinking water with specifications as follows: - Non corrosive - Cortec corrosion inhibitor is required - Chloride : <200 mg/l - Sulfate Ions : <240 mg/l - Nitrate Ions : <50 mg/l
pH value : 6,5-9,0 Conductivity : <2000 S/cm Total hardness : <1,7 mmol/l Dissolved solids : <340 mg/l Size of entrained particles : <100 m Max. system pressure : 6 bar Recomm. system pressure : 1,5 bar Max. differential pressure : 2 bar Max. coolant temperature : 38-40C Rated volumetric flow for water : 12 l/min At 7 kPa pressure drop Power loss max. : on request (depending on converter) Closed cooling circuit is the recommended standard solution Connection flange : Only for stainless steel heat sink (Frame size FL/GL)
Note : Drinking water may contain more than 200 mg/l chloride. Values higher than 200 mg/l may damage the heat sinks if no inhibitors are added.
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User Manual Functional Description: Marflex Variable Speed Drive System

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User Manual Functional Description: Marflex Variable Speed Drive System

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MarFlex Variable Speed Drive System

Rev 2.0 2.1 2.2

Author L.Sonneveld L.Sonneveld L.Sonneveld L.Sonneveld

Date 23-2-2011 24-3-2011 1-4-2011 7-4-2011

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

SYSTEM FUNCTIONS ...........................................................................................................8

OPTIONAL FUNCTIONS ......................................................................................................14

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Remote mode: Cooperative with external systems................................................................................ 29

Remote Mode: TOUCH PANEL ...........................................................................................30

Remote mode: CONTROL DESK ........................................................................................51

General Converter Functionalities .................................................................................58

Author: Snijders Elektrotechniek B.V.

MarFlex Variable Speed Drive System

External interfaces ................................................................................................................................... 63

VSDS system design specifications...............................................................................65

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Basic system overview

The configuration of the system is shown in figure below.

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

2 times 2on4 matrix

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Selection operation mode.

MarFlex Variable Speed Drive System

Thermal motor protection

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

MarFlex Variable Speed Drive System

2. Self-priming sequence, no dryrun after second priming cycle

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Motor Data Sets

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Inert Gas Low

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Power Management System (PMS) General description

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System

Cargo heating mode General description

Cargo heating mode specifications

Author: Snijders Elektrotechniek B.V.

MarFlex VDSV functional description.doc

MarFlex Variable Speed Drive System