Hydrogen-FC.com » admin http://www.hydrogen-fc.com Automation and Global Partnerships for Hydrogen Power Sat, 09 Jul 2011 19:02:40 +0000 en hourly 1 http://wordpress.org/?v=3.3.1 Review: PLC Panasonic FPX Series http://www.hydrogen-fc.com/2011/05/review-plc-panasonic-fpx-series/ http://www.hydrogen-fc.com/2011/05/review-plc-panasonic-fpx-series/#comments Mon, 23 May 2011 21:42:12 +0000 admin http://www.hydrogen-fc.com/?p=864 Panasonic Electric Works release new variant of PLC controller, FPX Series. Besides FPX Series there are other type PLC Panasonic that had release before, like FP0 Series, FP2 Series and FPΣ Series. On this article we only review PLC Panasonic FPX Series.

As a compact PLC, FPX Series offer 14 I/O or 30 I/O or 60 I/O built-in digital points. But the I/O capacity could expanded up tp 300 I/O digital points using the Expansion Unit. From that point, we could choosing Relay Output (Max. 2A/250VAC) or Transistor Output for digital output specified to our application. With the transistor output capability on PLC FPX Series, we could using this PLC for 4-axis position control application with pulse output up to 100kHz.

FPX Series offer only small I/O analog point, which is using add-on application cassette. Below are the application cassette type for analog point :

  • AFPX-AD2 : 2-points AI with 0-5VDC/0-10VDC/4-20mA
  • AFPX-DA2 : 2-points AO with 0-5VDC/0-10VDC/4-20mA
  • AFPX-A21 : 2-points AI with 0-5VDC/0-10VDC/4-20mA and 1-points AO with 0-5VDC/0-10VDC/4-20mA
  • AFPX-TC2 : 2-points AI with Thermocouple J/K type

On all PLC FPX Series doestn’t support float/decimal data (32-bit), so that all numerical data are saved on integer/word data (16-bit) which are Timer/Counter (SV & EV), External Input (WX), External Output (WY) and Data Register (DT).  PLC FPX Series offer capability holding last value of Timer/Counter (SV & EV) and Data Register (DT) before PLC turned off.

PLC FPX C14R and C14T/P

PLC FPX C30R, C30T/P, C60R and C60T/P

There are limited quantity on holding last value in PLC FPX Series, ie Counter/Timer (1008 – 1024) and Data Register (FPX C14 : 12230 – 12285, FPX C30/C60 : 32710 – 32765). We could increasing the quantity of holding last value in PLC FPX Series ie Counter/Timer (1008 – 1024) and Data Register (FPX C14 : 0 – 12285, FPX C30/C60 : 0 – 32765) by adding AFPX-BATT (backup battery).

By default, there is no RTC (Real Time Clock) capability on PLC FPX Series, we must adding AFPX-MRTC (master memory with a real-time clock).  AFPX-MRTC has calender accuracy at 0C: 119sec/month or less, 25C: 51sec/month or less, 55C: 148sec/month or less. When installing AFPX-MRTC on PLC FPX Series, the AFPX-BATT (backup battery) required.

PLC FPX Series with Communication Cassette AFPX-COM3 or AFPX-COM4 support to Modbus RTU/RS-485 protocol, both as Master or Slave device. As master device, PLC FPX Series could communicate to 127 slave devices with the max speed/baudrate 115.2kbps and total distance max 1200m. When programming using FPWIN GR software, we could using F145/P145 when PLC FPX Series becoming Master Device and F146/P146 when PLC FPX Series becoming Slave Device.

PLC FPX Modbus Configuration


]]> http://www.hydrogen-fc.com/2011/05/review-plc-panasonic-fpx-series/feed/ 1 Modbus RTU between PLC K120S and VSD Altivar-31 & iG5A http://www.hydrogen-fc.com/2010/03/modbus-rturs-485-plc-k120s-to-vsd-altivar-31-ig5a/ http://www.hydrogen-fc.com/2010/03/modbus-rturs-485-plc-k120s-to-vsd-altivar-31-ig5a/#comments Fri, 26 Mar 2010 17:05:06 +0000 admin http://www.hydrogen-fc.com/?p=621 On these case, we build system with PLC K120S from LS Industrial Systems as Master device and VSD (Variable Speed Drive) Altivar-31 from Schneider Electric as 1st Slave device and iG5A from LS Industrial Systems as 2nd Slave Device. All communication between Master and Slave device performed by Modbus RTU protocol.

PLC K120S with K7M-DR20U type is low price PLC with powerful built-in functions, like : PID function, Modbus RTU protocol, High Speed Counter (HSC), Pulse Output. Otherwise, the disadvantage of PLC K120S is could not processing floating data. All analog data will processed using integer format.

Goal target on this case is PLC K120S could set the reference frequency, acceleration, deceleration and monitor current value of output frequency, output current, output voltage and output power from each VSD.

There is a little trick when using modbus function on PLC K120S ladder programming. That is PLC K120S could not send/receive multiple parameter from/to slave device within same time. There will be occuring error communication. Error communication also occuring when PLC K120S request data to multiple slave devices within same time. We attach below the little trick to resolve that issue.

We also develop similar system using PLC Panasonic. Our system using PLC FPX Series from Panasonic as Master device and 2 units VSD iG5A from LS Industrial Systems as Slave device. There is no built-in RS-485 port on PLC FPX Series, so we need add-on communication cassette AFPX-COM3 to perform Modbus RTU communication. On these system, PLC FPX Series also needed similar ladder programming method like on PLC K120S.

We got last confirmation from the end-users that all above design are powerful system. Please fell free to develop your system by using our experiences.

]]> http://www.hydrogen-fc.com/2010/03/modbus-rturs-485-plc-k120s-to-vsd-altivar-31-ig5a/feed/ 2 Modbus TCP between HMI Ifix5.0 and Flow Computer OMNI6000 http://www.hydrogen-fc.com/2009/10/modbus-tcp-protocol-between-omni-6000-and-ifix-5-0/ http://www.hydrogen-fc.com/2009/10/modbus-tcp-protocol-between-omni-6000-and-ifix-5-0/#comments Thu, 01 Oct 2009 17:23:52 +0000 admin http://www.hydrogen-fc.com/?p=124 Our previous article had explained how to configuring Modbus TCP protocol between HMI Ifix5.0 and PLC VersaMax40. So that on these article we just explain how to create register blocks and few setup on Modbus Driver v.7.42 Ifix5.0 so that HMI Ifix5.0 as Client device could send/receive data from Flow Computer OMNI6000 as Server device.

OMNI6000 is latest Flow Computer from OMNIFLOW Inc. OMNI6000 suitable to be used as deterministic electronic flow/energy correction on metering measurement of crude oils, refined products, NGLs, LPGs, ethylene, propylene, natural gas, and specially gases, such as Oxygen, Nytrogen, Hydrogen, Water, and Carbon Dioxide. OMNI6000 suitable to be used for Orifice Plate or Turbin Meter metering system.

Modbus Register of Current Datetime Data Block - Datetime
Current – Hour : 403868
Current – Minute : 403869
Current – Second : 403870
Current – Month : 403871
Current – Day of Month : 403872
Current – Year : 403873
Current – Day of Week : 403874
Advanced Data Block Settings
Size of Registers : 2 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : FALSE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of AGA 8 – 1994/1992 Components Override Value Data Block - AGA8
Product #1 – Mol % – Methane : 417231
Product #1 – Mol % – Nitrogen : 417232
Product #1 – Mol % – Carbon Dioxide : 417233
Product #1 – Mol % – Ethane : 417234
Product #1 – Mol % – Propane : 417235
Product #1 – Mol % – Water : 417236
Product #1 – Mol % – Hydrogen Sulfide : 417237
Product #1 – Mol % – Hydrogen : 417238
Product #1 – Mol % – Carbon Monoxide : 417239
Product #1 – Mol % – Oxygen : 417240
Product #1 – Mol % – i-Butane : 417241
Product #1 – Mol % – n-Butane : 417242
Product #1 – Mol % – i-Pentane : 417243
Product #1 – Mol % – n-Pentane : 417244
Product #1 – Mol % – n-Hexane : 417245
Product #1 – Mol % – n-Heptane : 417246
Product #1 – Mol % – n-Octane : 417247
Product #1 – Mol % – n-Nonane : 417248
Product #1 – Mol % – n-Decane : 417249
Product #1 – Mol % – Helium : 417250
Product #1 – Mol % – Argon : 417251
Product #1 – Viscosity : 417252
Product #1 – Isentropic Exponent K : 417253
Product #1 – Heating Value : 417254
Product #1 – Reference Specific Gravity : 417255
Product #1 – Reference Density : 417256
Product #1 – Water Content : 417257
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Gas Chromatograph Data & Auxilliary Parameter Data Block - GC_AUX
Analyzer Component #1 : 417351
Analyzer Component #2 : 417352
Analyzer Component #3 : 417353
Analyzer Component #4 : 417354
Analyzer Component #5 : 417355
Analyzer Component #6 : 417356
Analyzer Component #7 : 417357
Analyzer Component #8 : 417358
Analyzer Component #9 : 417359
Analyzer Component #10 : 417360
Analyzer Component #11 : 417361
Analyzer Component #12 : 417362
Analyzer Component #13 : 417363
Analyzer Component #14 : 417364
Analyzer Component #15 : 417365
Analyzer Component #16 : 417366
Analyzer Component #17 : 417367
Analyzer Component #18 : 417368
Analyzer Component #19 : 417369
Analyzer Component #20 : 417370
Analyzer Component #21 : 417371
Analyzer Component #22 : 417372
Analyzer Component #23 : 417373
Analyzer Component #24 : 417374
Analyzer Component #25 (Actual BTU) : 417375
Analyzer Component #26 (Dry BTU) : 417376
Analyzer Component #27 (Specific Gravity) : 417377
Analyzer Component #28 : 417378
Analyzer Component #29 : 417379
Analyzer Component #30 : 417380
Auxilliary Input #1 – Low Limit : 417381
Auxilliary Input #1 – High Limit : 417382
Auxilliary Input #1 – Override Value : 417383
Auxilliary Input #1 – @ 4mA : 417384
Auxilliary Input #1 – @ 20 mA : 417385
Auxilliary Input #2 – Low Limit : 417386
Auxilliary Input #2 – High Limit : 417387
Auxilliary Input #2 – Override Value : 417388
Auxilliary Input #2 – @ 4mA : 417389
Auxilliary Input #2 – @ 20 mA : 417390
Auxilliary Input #3 – Low Limit : 417391
Auxilliary Input #3 – High Limit : 417392
Auxilliary Input #3 – Override Value : 417393
Auxilliary Input #3 – @ 4mA : 417394
Auxilliary Input #3 – @ 20 mA : 417395
Auxilliary Input #4 – Low Limit : 417396
Auxilliary Input #4 – High Limit : 417397
Auxilliary Input #4 – Override Value : 417398
Auxilliary Input #4 – @ 4mA : 417399
Auxilliary Input #4 – @ 20 mA : 417400
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Auxilliary Live Value Data Block - AUX
Auxilliary Input #1 : 407810
Auxilliary Input #2 : 407811
Auxilliary Input #3 : 407812
Auxilliary Input #4 : 407813
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Stream A Live Value Data Block - Stream A
Flow Rate – Gross (MACF/hr or m3/hr) : 407102
Flow Rate – Net (MSCF/hr or m3/hr) : 407103
Flow Rate – Mass (Klb/hr or ton/hr) : 407104
Flow Rate – Energy (MMBTU/hr or GJ/hr) : 407105
Temperature : 407106
Pressure : 407107
Orifice – Diameter : 407113
Meter Tube Diameter : 407118
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Stream B Live Value Data Block - Stream B
Flow Rate – Gross (MACF/hr or m3/hr) : 407202
Flow Rate – Net (MSCF/hr or m3/hr) : 407203
Flow Rate – Mass (Klb/hr or ton/hr) : 407204
Flow Rate – Energy (MMBTU/hr or GJ/hr) : 407205
Temperature : 407206
Pressure : 407207
Orifice – Diameter : 407213
Meter Tube Diameter : 407218
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Transmitter Stream A Parameter Data Block - FT TT PT Stream A
Orifice Plate – Reference Temperature : 407148
Meter Tube – Reference Temperature : 407151
Differential Pressure – Low Limit : 407153
Differential Pressure – High Limit : 407154
Differential Pressure – Override Value : 407155
Low Range – Differential Pressure – @ 4mA : 407156
Low Range – Differential Pressure – @ 20mA : 407157
Meter Temperature – Low Limit : 407164
Meter Temperature – High Limit : 407165
Meter Temperature – Override : 407166
Meter Temperature – @ 4mA : 407167
Meter Temperature – @ 20mA : 407168
Meter Pressure – Low Limit : 407169
Meter Pressure – High Limit : 407170
Meter Pressure – Override : 407171
Meter Pressure – @ 4mA : 407172
Meter Pressure – @ 20mA : 407173
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Transmitter Stream B Parameter Data Block - FT TT PT Stream B
Orifice Plate – Reference Temperature : 407248
Meter Tube – Reference Temperature : 407251
Differential Pressure – Low Limit : 407253
Differential Pressure – High Limit : 407254
Differential Pressure – Override Value : 407255
Low Range – Differential Pressure – @ 4mA : 407256
Low Range – Differential Pressure – @ 20mA : 407257
Meter Temperature – Low Limit : 407264
Meter Temperature – High Limit : 407265
Meter Temperature – Override : 407266
Meter Temperature – @ 4mA : 407267
Meter Temperature – @ 20mA : 407268
Meter Pressure – Low Limit : 407269
Meter Pressure – High Limit : 407270
Meter Pressure – Override : 407271
Meter Pressure – @ 4mA : 407272
Meter Pressure – @ 20mA : 407273
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of In Progress Batch, Cumm, Daily Live Value Stream A Data Block - In Batch Day Stream A
Batch in Progress – Gross Totalizer : 405102
Batch in Progress – Net Totalizer : 405103
Batch in Progress – Mass Totalizer : 405104
Batch in Progress – Energy Totalizer : 405105
Cummulative in Progress – Gross Totalizer : 405106
Cummulative in Progress – Net Totalizer : 405107
Cummulative in Progress – Mass Totalizer : 405108
Cummulative in Progress – Energy Totalizer : 405109
Today In Progress – Gross Totalizer : 405110
Today In Progress – Net Totalizer : 405111
Today In Progress – Mass Totalizer : 405112
Today In Progress – Energy Totalizer : 405113
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of In Progress Batch, Cumm, Daily Live Value Stream B Data Block - In Batch Day Stream B
Batch in Progress – Gross Totalizer : 405202
Batch in Progress – Net Totalizer : 405203
Batch in Progress – Mass Totalizer : 405204
Batch in Progress – Energy Totalizer : 405205
Cummulative in Progress – Gross Totalizer : 405206
Cummulative in Progress – Net Totalizer : 405207
Cummulative in Progress – Mass Totalizer : 405208
Cummulative in Progress – Energy Totalizer : 405209
Today In Progress – Gross Totalizer : 405210
Today In Progress – Net Totalizer : 405211
Today In Progress – Mass Totalizer : 405212
Today In Progress – Energy Totalizer : 405213
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of In Progress Hourly Live Value Stream A Data Block - In Hourly Stream A
In Progress – Gross Total for Hour : 405145
In Progress – Net Total for Hour : 405146
In Progess – Mas Total for Hour : 405147
IN Progress – Energy Total for Hour : 405148
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of In Progress Hourly Live Value Stream B Data Block - In Hourly Stream B
In Progress – Gross Total for Hour : 405245
In Progress – Net Total for Hour : 405246
In Progess – Mas Total for Hour : 402247
IN Progress – Energy Total for Hour : 405248
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Previous, Hour, Cumm Live Value Stream A Data Block - Pr Hour Cumm Stream A
Increment – Gross Totalizer : 405171
Increment – Net Totalizer : 405172
Increment – Mass Totalizer : 405173
Increment – Energy Totalizer : 405174
Previous Hourly – Gross Total : 405175
Previous Hourly – Net Total : 405176
Previous Hourly – Mass Total : 405177
Previous Hourly – Energy Total : 405178
Previous Batch – Opening Gross : 405179
Previous Batch – Opening Net : 405180
Previous Batch – Opening Mass : 405181
Previous Batch – Opening Energy : 405182
Previous Day’s – Opening Gross : 405183
Previous Day’s – Opening Net : 405184
Previous Day’s – Opening Mass : 405185
Previous Day’s – Opening Energy : 405186
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
Modbus Register of Previous, Hour, Cumm Live Value Stream B Data Block - Pr Hour Cumm Stream B
Increment – Gross Totalizer : 405271
Increment – Net Totalizer : 405272
Increment – Mass Totalizer : 405273
Increment – Energy Totalizer : 405274
Previous Hourly – Gross Total : 405275
Previous Hourly – Net Total : 405276
Previous Hourly – Mass Total : 405277
Previous Hourly – Energy Total : 405278
Previous Batch – Opening Gross : 405279
Previous Batch – Opening Net : 405280
Previous Batch – Opening Mass : 405281
Previous Batch – Opening Energy : 405282
Previous Day’s – Opening Gross : 405283
Previous Day’s – Opening Net : 405284
Previous Day’s – Opening Mass : 405285
Previous Day’s – Opening Energy : 405286
Advanced Data Block Settings
Size of Registers : 4 Bytes
Swap Bytes : TRUE
Swap Long Words : FALSE
Swap Words : TRUE
Accept Unsolited Messages : TRUE
Disable Output : FALSE
Enable Block Writes : FALSE
Enable Latch Data : FALSE
]]> http://www.hydrogen-fc.com/2009/10/modbus-tcp-protocol-between-omni-6000-and-ifix-5-0/feed/ 1 PID & Alternate Control System http://www.hydrogen-fc.com/2009/09/pid-close-loop-controller/ http://www.hydrogen-fc.com/2009/09/pid-close-loop-controller/#comments Sun, 13 Sep 2009 13:05:19 +0000 admin http://www.hydrogen-fc.com/?p=450 PID (Proportional-Integral-Derivative) controller is control loop feedback mechanism that widely used in control system. PID calculating the error value that generated by difference between feedback Process Value (PV) and Set Point (SP) PID. When error value generating, PID controller adjusting output Measurement Value (MV) to minimize error near to zero value.

Let us give some example PID Controller on Booster Pump application like on the left picture. Feedback Process Value (PV) is Actual Pressure (Bar), Set Point (SP) PID is Set Pressure (Bar), and output Measurement Value (MV) is VSD Reference Frequency (Hz).  This is the mechanism. Whenever the difference between PV & SP negative, PID Controller increasing output MV. Otherwise when the difference between PV & SP positive, PID Controller decreasing output MV. How fast the PID Controller could execute error calculation are depend on cycle speed on each controller and type of PID function.  There are several PID function base on control actions, which are P, I, PI, PD. PI function is widely used for Booster Pump application.

This is the PID & Alternate control system on Booster Pump application. There are 1 unit Pressure Transmitter,  1 unit PLC and 2 units Booster Pump that controlled by 1 unit VSD. Because of most VSD have PID Controller, we design the PI controller in the VSD. These are the several case :

  • At the first time start PID in VSD with Pump A. VSD adjusting output frequency (Hz) into Pump A so that Actual Pressure (Bar) close to Set Pressure (Bar).
  • Case 1 : Pump A couldn’t reach the target of Set Pressure (Bar), then PLC set 50Hz into Pump A and start PID in VSD with Pump B.
  • Case 2 : Actual Pressure (Bar) is too high so that VSD set 0Hz into Pump B. This case make PLC to stop Pump B and start PID in VSD with Pump A.
  • Case 3 : Actual Pressure (Bar) still on high pressure so that VSD set 0Hz into Pump A. This case make PLC to stop Pump A. That mean booster Pump A and B on the sleep condition.
  • Case 4 : Suddenly Actual Pressure (Bar) drop to below Set Pressure (Bar). This case make PLC start PID in VSD with Pump B because of the last running pump before sleep is Pump A. This mechanism important to make sure all pumps have same running hour.

With the PID & Alternate control system, we could just add booster pump without add more VSD  to increase efficiency and capacity on Booster Pump Station. Mostly, Booster Pump Stations are using PID & Alternate control system because it could saving more cost for electrical energy consuption.

All of animation and graphical developed by Wonderware ArchestrA 3.0.

]]> http://www.hydrogen-fc.com/2009/09/pid-close-loop-controller/feed/ 4