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1. Figure 8 IO Manager 4 6 interface 19 Work on the bug when changing previously selected address was a significant problem It was then decided to work that section prior to any other changes However much of the code was overcomplicated causing uncertainties of when the controls were detected to adjust the I Os and would cause corruption in the Patchnames txt file this will be discussed in the patchnames txt section For the system to be a robust and efficient system which would still be able to both activate and deactivate the various I Os for each loop in the IO Manager it was decided that the system to use a different method of selecting addresses for activation and deactivation By having a table with a listing of addresses and an adjustable column which allows for the activation or deactivation of the addresses on each loop interface changes can be made by typing in a 1 for activation and a 0 for deactivation quickly and efficiently shown in figure 11 Loop 4 Activation Table Activate 1 Deactivate 0 Activation Figure 9 Activation Table interface As a result of the changes made to the interface the activation table brought on a new coding hence removing the issue of altering previous addresses The activation table of each loop was then be attached to the Activation Table vi which reads the activation table splits and adjusts the number of I
2. devs_3 cfg ij My Computer My Network Places Details es INSTALL P sixb GID A A A a AAR VDMCi tmp VDMC2tmp YDMC3 tmp VDMC4 tmp VDMCS tmp VDMC6 tmp VDMCB tmp sixb Application Date Modified Thursday 14 November 1996 5 46 PM Size 205 KB 72 6 After clicking the COM port you will be lead to a selection screen which stores previously searched devices as shown in below Select one of these devices and press OK 6B WIN SELECT DEVICE BER HELP 6B50 151 OK Type Adr Integ Range Baud Chksm Format Slew Rate Jmpr 6850 151 N A 40 N A 19200 NO N A N A NO 6B50 152 N A 40 N A 19200 NO N A Ma NO 6B11 160 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 161 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 162 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 163 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B21 172 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 173 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 175 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B11 180 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 181 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 182 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 183 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B21 192 N A 30 0 to 20 mA
3. 32 Figure 33 New 24VDC power Supp 33 Figure 34 Old 24VDC power suppl 33 Figure 35 Transformer 5 Primary Circuit Breaker eese 34 Figure 36 Conductor S P a CERE HH a Pa eR Uca Fe dene e CER EE des 35 Figure 37 Earth amp Neutral Bars rerserrrrnnnnnrnrrrrrrnsnrnnnnnnrsnnsnssnannnnnnrvnnsnssnsnnnnnnrsnnssssnnnnnnnnrsnnenen 35 Figure ade ideo 36 Figure 39 4 RS485 serial Card 37 Figure 40 6BP16 1 Analog backplane Devices 19071 39 Figure 41 Process Current Inputs Devices 19907 39 Figure 43 6B50 1 Digital Board Devices 1997 usse enne 41 Figure 44 Interconnection wiring Devices 19007 42 Figure 45 Other adjustments made to the I O control board rrrrrrnnvnnrnvvrrrvrrrrnrrnrnnvnrrnvenre 44 Figure 46 DP PA coupler in a system SIEMENS Bus links 2006 46 Figure 47 Profibus DP termination SAMSON 2007 sese 47 Figure 48 Profibus PA termination SAMSON 20071 47 Figure 57 Current Termination of Profibus PA network sssssssssessssssssensrsssssserensnssssssereene 47 Figure 49 Level sensor in PVC container ube 48 Figure 50 pressure sensor with resized fitting enne 48 Figure 51 RS485 2 board functional indicator sese enne 51 Figure 52 remapping progress state loop cccccccccssssssssececececeesesnsaececeescesseseuaeseesessessessnaees 52 Figure 53 Profibus remapping State cccessscccececsssessnsececeeecessesseaeseseescessesesaeeeesesseese
4. 4 2 3 Transformer 5 Primary Circuit Breaker Current Rating The circuit breaker used on the primary side of transformer 5 on the old power board uses a 16A current rating However a 10A current rating was documented for the transformer as shown in Figure 35 The 16A current rating circuit breaker might be due to the high inrush current However it was decided that a 10A current circuit breaker would be placed in the new power board This would allow future users to see if the circuit breaker trips when the power to the power board is switched on showing that the inrush current is 33 higher than 10A As there is no documentation on why this was done the change to a 16A circuit breaker in replacement of the originally designed 10A circuit breaker should be documented if the need for replacement arises TSLP CTS 10A ZE TSt10VAC 3 Maine T Figure 33 Transformer 5 Primary Circuit Breaker 4 3 Wiring Up the Power Board Prior to wiring the power board the wiring diagram was reviewed in consultation with John Boulton Technical Officer into the school Information for wiring such as conductor size and Protective device ratings were also checked based on the AS NZS 3000 NHP 2005 Based on these sources wiring sizes were chosen for the power box where conductor sizes from the main switch to the circuit breakers were sized at 2 5mm conductor sizes from the protective devices 8 16Amps to other components were 1 5mm and signal c
5. dk IE UD v MURDOCH UNIVERSITY PERTH WESTERN AUSTRALIA Instrumentation and Control Laboratory Facility Upgrade Murdoch University School of Engineering and Energy A report submitted to the School of Engineering and Energy Murdoch University in partial fulfillment of the requirements for the degree of Bachelor of Engineering Supervisor Associate Professor Graeme Cole Daniel Lau 30499037 11 15 2010 Acknowledgements Associate Professor Graeme Cole John Boulton Will Stirling Abstract The Instrumentation and Control IC laboratory facility uses a Supervisory Control and Data Acquisition system to provide users with the flexibility in designing and implementation of control systems A new panel is being built and setup due to the growing demand of the IC laboratory facility the Labview server program must also be expanded to fulfil for this upgrade Additionally the current Labview server program has several problems within the system and requires some improvement to help student users to use it effectively The I O Control board within the new panel provides the necessary connections between the server and the field as well as controlling the power board This I O control board has been configured and will be prepared for the wiring into the patch panel The patch panel which is connected to both the I O control board and the power board provides the necessary connections and power to the instru
6. des 6g devs 7 dig devs _8 cfg Mj My Computer pe P rnc se I Bil grid INSTALL password cfg readme release sib sib Details A a a a m DH B BE Application sib sixb GID unstall VDMBD tmp VDMBEtmp VDMBF tmp YDMCO tmp Date Modified Thursday 14 November 1996 5 46 PM eee BH sg 8 8 Ff E VOMC1 tmp VDMCZ tmp VOMC3 tmp VDMC4 tmp VDMCS tmp VDMC6 tmp VDMCB tmp a 70 10 11 12 13 14 After clicking the COM port you will be lead to a selection screen which stores previously searched devices as shown below Select one of these devices and press OK 6B WIN SELECT DEVICE ot HELP 6B50 151 v OK Type Adr Integ Range Baud Chksm Format Slew Rate Jmpr 6B50 T51 N A 40 N A 19200 NO N A N A NO 6B50 152 N A 40 N A 19200 NO N A N A NO 6B11 160 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 161 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 162 60 ms 06 4 20 mA 19200 NO Eng Units N A NO 6B11 163 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B21 172 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 173 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 175 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B11 180 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 181 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B11 182 60 ms 06 4 20 mA 19200 NO Eng Units N A NO 6B11 183 60 ms 06 20 mA 19200 NO Eng Units N A NO 6B21 192 N A 30
7. e Digital board 6B50 1 11 4 Procedures This section will be split into three parts one each for analog devices digital board and inter device connections The connection used in the Murdoch Campus Instrumentation and Control Facility is a RS485 cable the 2 wires that are needed for configuration and connectivity to the server computer is in blue and white The blue wire will have to be connected to terminal 3 and the white wire to terminal 4 of the analog backplane or digital board in the red circles as shown in figures 1 amp 2 below ore PTILLAU APT TT Figure 55 6BP16 1 analog backplane Figure 56 6B50 1 digital board 68 11 5 Inter device connection 1 7 Implement one of the following connections between the devices ensure that the GNDs of the boards are connected to each other as they are not commoned within each board as shown in figure 5 Ensure that output signals go to inputs terminals board diagrams input and output terminals shown in figures 3 amp 4 To Host or Other Drops Figure 57 Interdevice connection Connect the Ethernet communication cable from the server computer Power the devices and ensure that there is sufficient power 5V at the power terminals of the board closest to the Ethernet cable Run Sixb 6B WIN software When the MAIN MENU will pop up click COMMS and use 19200 Baud rate and ensure that the max addresses includes the address the device is in Press OK DONE R
8. maybe included as a single RS 485 communication line The 6B analog modules and digital boards use non volatile memory to store configurations such as addresses calibrations and other parameters The 6B analog and digital systems have isolation devices that protect the devices from over currents or short circuits 5 1 1 1 Analog The 6B series analog field devices use two main components the backplane and the analog module The backplane acts as a rack for the analog modules and as a routing power and communications to all the modules to other boards or the server The analog backplane that is used in the IC laboratory facility is a GBP16 1 backplane shown in figure 40 It uses RS 485 to communicate with other 6B devices or the server including a RS 485 repeater to allow distances of up to 4000ft for later boards The 6BP16 1 Analog backplane also can houses up to 16 analog devices for either input or output power Devices 1997 A shunt diode is also present on the backplane providing polarity reversal protection to the backplane For the prevention of any short circuit or failure of other modules a fuse F1 in figure 40 is present and can be replaced The two LEDs CR3 and CR2 in figure 40 are status indicators providing information on data transmission board and module status The configuration jumper W1 in figure 40 allows for configuration for the analog module s parameters like address baud rate checksum status and integrat
9. pdf and tcw TurboCAD are readily available in the downloads section of the website The documents acquired in the process of this thesis will be available on the EngShared server under IC facility 2010 this will include various documents such as drawings references and software a list in shown in Appendix F This project has brought about numerous experiences in the different fields of Instrumentation and control Electrical power and industrial computer systems Through constant communication with the various experts in the respective fields the project has brought along much learning experiences The project still holds great purpose in both the present and the future developments in IC laboratory facility 56 9 Bibliography Devices 1997 6B Series User manual In A Devices Technical Manual Available on Timoshenko IC Facility 2010 NHP december 2005 NHP Retrieved 9 November 2010 from www nhp com http www nhp com au latest_news Technical 20news documents TNL46 pdf SAMSON 2007 Profibus PA In SAMSON Technical Information Technical Manual Available on Timoshenko IC_Facility_2010 Shimaden n d MPU Based single phase power regulator PAC16 Retrieved 2010 11 9 from www get point com http www get point com get point pdf pac16 NEW pdf SIEMENS 2006 Bus links In SIEMENS Technical Manual Available on Timoshenko IC Facility 2010 SIEMENS 2006 SIMATIC NET In SIEMENS S7 C
10. 1 Revamping Labview server program sesessesseeeeeenen eene enne nnns 50 7 1 1 Recording Previous Usability Listings esses 50 7 1 2 Alternation of Labview Coding esee enne 51 7 2 O Control Board Wiring Diagram c ccccsccccssecesscccssseecsseceessecesseeesseeeeaeeeeeeeees 54 7 3 Patch Panel and Power Board AAA 54 7 4 6B Series Settings on Older Panel 55 7 5 Proper Housing for the New PA Measuring Equipment snnrorrrnrrnnnrnnnnrrrrrnssrnnnnn 55 Conclusion amp Project Exvperiences eeerre a aa rian aa aa EEs OEL eias 56 Bibliography E 57 AP oae L EE 58 10 1 Academic Supervisor Endorsement 58 10 2 Appendix A autora ks 59 10 3 AppendbcBzu i ES 60 10 4 Appendix aonn et tet o ie tat bao dere e 61 10 5 Appendix D PE ve TR INE A 65 10 6 Appendix E ios orbi eti er iei i endi i 66 Table of Figures Figure 1 IC laboratory facility front panel cccccccssesssseceeccecessesseaecesececessesesaeceeeessesseseeaeens 14 Figure 2 IC laboratory facility back oanel enne 14 Figure 3 Master I O as part of the 2 networks 15 Figure 4 Old power board ssssssssssssssssesrnssssssrrerrnsnssssrrennnssssssrrennnssssssrrernnssssrsnrernnssssrerneenn 16 Figure 5 Patch panel power sockets soeisioessrtenunissedeeeetoniennaniieteenike kanes deteni kerniek kes 16 Figure 6 Patch panel connectors ee 17 Figure 7 I O control board essers tet ire etra eo aad aae or nk ka duse ocu al deo 17 Figure 8 IO Manage
11. 3 e a 2 1 amp 9 PrefsType S ctr Get ports gt Case S Si gt Read Datalog 3 E Feed patch PATCHNAMES TXT T d E Create Array lt Refnum Out Open Create Replace lt gt gt array of ports L Ed is Port string gt Port Int f Appanded Path lt F initialise Array Rebuild Array Send of Array of ports cti Shutdown gt Case m i Shutdown el T g Shutdown d 1s Ir 1 I F fe T v Error Code Fl 61 Sequence 3 ctri Configuration loop gt Case dALSJ M Port number PrefsType e Baud Rate AD6B SFP initialize Configure Screen Opens J QUNN 30d Case K Configure New Modules tt 4 gt AD6B SFP COnfig 5 W Jumper Reconfigure Modules Port Number AD6B SFP Config MEN 1 5 w o Jumper View Modules e 5 AD6B SFP Map LI e gt AD6B SFP view Mad LI D Reconfigure Port gt gt AD6B SF Initialised T T Finished Exits Configure Screen J8quinN Pod Sequence 3 ctri IO Manager 11 PrefsType Case T Initialisation g Original data gt Read Patch Lei dstp localhost master screen F r c Array 256x13 FFFF gt g global array g PrefsTpe TI Shutdown Array gt T PrefsType index 9 c blank 1 Shutdown Array a T c Not Used F index 5 c Array 257x6 blank Replace Array Subset index 0 5 1 Array gt Spreadsh
12. OFF Figure 30 Control modes and wave form of the Thyristors Shimaden 4 2 1 2 Technical Review Soft start slow rise fall The Soft start function is to delay an output against changes in a control input signal whenever power is supplied This produces an effect which helps to suppress rush current The slow rise function mode increases the rise time of output in the event of an abrupt change of control input signal For example when set data is changed during control 32 Shimaden The slow fall function slows the fall of the output in the event of sudden change to the input signal similar to the slow rise function Functions available in the new Thyristors it may not be desirable to use them as it may cause confusion amongst experimental users unless they are well aware of these functions 4 2 2 New 24VDC Power Supplies New 24VDC power supplies were purchased as the previous 24VDC power supplies were no longer manufactured Unfortunately there was no manual available on the old 24VDC power supplies Based on the label on the old power supply its function was 240VAC input and 5Amps 24VDC output as shown in figure 34 The new 24VDC power supplies Mean Well SP 150 24 have an 85 264VAC input and 6 3A 24VDC output as shown in figure 33 In addition the new power supply features protections for short circuit overload over voltage and over temperature Figure 32 Old 24VDC power supply Figure 31 New 24VDC power supply
13. been used in the past Connections T1 and T2 have yet to be commoned Connections to the power supplies T1 and T2 have been disconnection for configuration of the analog and digital devices shown as blue terminal blocks with separators in figure 45 The external power supplies are still in place as the patch panel is still not ready and the power box has not yet been grounded Hence the power board is not ready to supply the necessary power to the I O control board above 43 ER e Tas LI dE ET s i NC ng Figure 42 Other adjustments made to the I O control board 5 3 I O Control Board Conclusion Adjustments to the I O control board have brought the cabinet closer to the completion of the new panel Configuration of the new 6B series analog and digital modules and boards has been made including the connectivity to the Labview server program The I O control board is waiting for the patch panel which will be sent for construction with the help of John Boulton When the patch panel arrives the analog and digital I Os can be connected to it providing practical usage of the I O control board 44 6 Profibus The Profibus system is a new core network system within the IC laboratory facility It provides increased transmission rates of about 5096 from the previous 19 2K baud rate The following sub sections will provide information on how the Profibus system has been configured and setup It also introduces new technologies and
14. on the old wiring diagrams The power board is awaiting grounding of the power and I O control cabinets to be done by John Boulton as he has the proper equipment and expertise When black colour 2 5mm diameter cable becomes available wiring of the neutrals for cables that are orange and light blue attached to the neutral bars will have to be replaced with the specific black colour 2 5mm cables The isolation of the power cables should be done before any connections from the live lines are to be connected to the power board s main switch The metal pole which connects the main switch breaker and the switch on the box door is being cut by John Boulton When these things are completed the power board should again be cross referenced with the updated wiring diagram with a different set of eyes to check that everything is consistent and correct 54 The new patch panels which will be created will be placed in the locations highlighted in red in the figures 55 and 56 below Notice that in figure 55 that the patch panel has been located behind the power and I O control boards unlike previous panels this is to allow for more rack space for equipment Figure 53 New patch panel location back Figure 54 New patch panel location front 7 4 6BSeries Settings on Older Panels The 6B series modules and boards integration time settings on the old panels are all on 50hz 60ms these should all be altered to 60hz 50ms as discussed in the 6B s
15. pins A amp B as shown in figure 4 12 Attach the 50 pin ribbon cable which is connected to the 24 SSR rack 13 Power the board and ensure that there is sufficient power 5V at the power terminals of the board closest to the Ethernet cable 73 12 LabView configuration 12 1 Important notes e This section seeks to explain procedures required for the configuration of the Master I O Labview program whenever additional 6B analog or digital devices are added to the network e f the address being removed in not the largest address of its type Eg Removing analog output address 182 amongst analog outputs addresses 180 185 it would be advised not to be removed as it will likely be removed in the future e These procedures are made for the configuration in Murdoch University Campus Instrumentation and Control Laboratory Facility in 2010 11 16 12 2 Required information e Serial COM port number e Highest address used in the COM port e Maximum number of analog addresses e List of address to be added or removed 12 3 Procedures The following procedures will guide the user through the necessary adjustments in the Labview server sub vi program IO Manager Each section will have a picture of the location of the amendment s required some information on the configuration required and the steps that are taken for the adding or removal of I Os 12 3 1 Activation table configuration 3 Sept 2010 Allow all loops to be remapped P ing
16. program while remapping was incomplete shown in figure 19 Corruption has yet to occur since the placement of remapping indicator since the released for testing by the 2 and 3 year 2010 engineering students IO Manager 4 75 System Active Loop One E Loop Two Active Loop ni Active Loop Four hes Profibus Loop Active AIT al eons t5 ba recipe before STOP ing this VI Or else this will lead to corruption of the Figure 17 Remapping warning indicator 24 3 3 Read Write Previous I O Listings As previous programmers were unable to fix or even realise the corruption of patchnames txt file a temporary fix was used by sending data to rubbish txt file Figure 20 The temporary fix did not provide the desired aims of the original code Patchnames txt was still being read from for its previous usability settings and I O listings for which I O data to be displayed on IO Manager Patchnames txt had to be replaced as the path for I O listings to be written in when IO Manager was shut down in order to attain its originally designed purpose Figure 21 rubbish Ext PATCHNAMES txt Figure 18 Path to Rubbish txt Figure 19 Path to Patchnames txt 3 4 Setting up Loop 4 Prior to the IC laboratory facility being transferred from the Rockingham campus to the Murdoch Campus there were four loops but only 3 were used to run 6 of the 8 patch panels Certain Coding for loop 4 was already set up for p
17. v System map gt Shutdown Array fe T gt System Map Active Iv Stop System Map Active g Stop Profibus T System Map Active Stop System gt Loop Time ms Tick Count 1 gt Tick Count Loop Display v Loop Map 2 E ri amp morow 5 3 T Initialised Array S 8 S feireg 1 re e 1 Digital Cluster g V Status gt T F indicator Analog Cluster Error gt Error Out Tianalog port cluster L FISA Cluster Get date time s Convert Time Status iv Status Loop Active gt TLoop active Loop active 63 Profibus System Te dstp loca ESP ESP TS esst Connection id gt Connection H gt r s Write Error SIDE re Emo ss cose IT Current Time s Empty v Profibus Loop Active LD Current Time L Stop Profibus iv Status 5 F TiCurent Time 91St2P S Get Date Time s gt Convert to DB s Normal lv Stop cj E Wat for update Lv Profibus State A 1 gt g Status Profibus v Profibus g Stop Profibus Data Loop Time ms Status gt Stops Profibus Sm Fl pars Tick Count 7 Tick Count 2 T Data old c biank i s Fa e Profibus Devices Tags Size gt Initalise Array Replace Array Subset c 4 z I o4 ei m i Column Size 3 E HI 2 i Sub Array 2 D gt Concentrate S 3
18. were the correct components fixed and labelled appropriately as well Another constraint was related to the time that the other people involved with this project had in which the project may or may not have been able to progress The constraint that areas such as the patch panel will not be able to be completed by the end of the project period due to the time consuming process of which the panel had to be sent to an external contractor for it to be cut hence the wires that lead towards the sockets will be incomplete 11 1 6 Definitions and Acronyms e vi Labview program e 6B 6B series Analog Devices hardware e AS NZS 3000 Australian New Zealand wiring rules e COM serial port e ECLB Earth Current Leakage Breaker e EEPROM Electrically Erasable Programmable Read Only Memory e ESB DO Experimental station Side B Digital Output e 1 0 Input or Output e C Instrumentation and Control e PLC process logic controller e PVC Poly vinyl chloride Plastic e RTD Resistor Thermal Detector e SCADA Supervisory control and data acquisition e SCR Silicon controlled rectifier e SSR Solid State Relay e VAC voltage alternating current e VDC voltage direct current e Vrms Voltage root mean squared e FMEA Failure mode and Effect Analysis 1 7 Structure of the Report The Instrumentation and control IC laboratory facility consists of various aspects from different fields of knowledge including power co
19. will be discussed in the Profibus section of the report 18 3 Labview Program Master I O The Master I O Labview program acts like a server for the whole IC laboratory facility dealing with the activation data manipulation and mapping of the I Os in the IC laboratory facility Prior to the start of the project there were several bugs and improvements that needed to be made The next few sections will discuss on the modifications and actions 3 1 Creation of the module known as the Activation Table vi Prior to the I O Activation table vi the IO Manager 4 6 program used a cumbersome method to activate and deactivate addresses Using the old programming code Add remove module vi users had to enter an address and hold down an activate or deactivate button shown in the bottom right corner of figure 8 for long periods of time 3 20 seconds for the adjustment of each address The old code was troublesome and had flaws in changing the previous address when another address was entered for activation or deactivation shown in the bottom right corner of figure 8 Due to having the Activate and Deactivate button in each main loop of IO Manager users were forced to hold the button till the loop was running again The old code also used multiple loops within loops which made the wait time for each change even longer and also caused the a bug when changing previously selected address Dig Patch Name
20. 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 193 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 195 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO The MAIN MENU will pop up Click COMMS and use 9600 Baud rate a new board will have a default Baud rate of 9600 and address of 00 and ensure that the max addresses includes the address the device is in Press OK DONE Back at the MAIN MENU click on SEARCH and select the appropriate device there should only be one if you followed the steps to enter Device Configuration or else you will automatically be brought to a Device Configuration where you can change the Address Baud Rate and Integration Period Some warnings on the changes in addresses and baud rate will pop up Ensure that the addresses are unique and the baud rate is 19200 for integrating with the Master I O Labview software Clicking on DONE will lead you to the MAIN MENU i BEE kJ pam 6B WIN Device Configuration BSB BROWSE 107119200 Disabled PROGRAM Disabled Unpowered and Repower the 6B series device to load the configuration into the module Repeat these procedures Step 1 8 if more modules are to be configured When all the devices are configured turn off the power supply Re install the Configuration jumper W1 n figure 3 place all the modules into their respective terminals Install the 50 Q
21. 000 resistor and a 1uF capacitor connected in series at the end of the PA branch line as shown in figure 48 below 46 VP 6 9 45V 390 2 3 1000 2200 8 3900 DGND 5 Figure 44 Profibus DP termination SAMSON Figure 45 Profibus PA termination SAMSON 2007 2007 The current termination of the Profibus PA network has been incorrectly terminated with an incorrect valued resistor and capacito as shown in figure 56 The recommended values for the resistor and capacitor in series should be a 1000 resistor and a 1pF capacitor connected in series at the end of the PA branch line This should be done to prevent any reflection of data in the Profibus PA line Figure 46 Current Termination of Profibus PA network 6 4 WinCC Explorer The WinCC explorer provides access to the components on the Profibus field and allowing the server to act as a central coordinating point for project management The program gives the user details of the loaded project and shows all related file associated to the project WinCC explorer allows for tag management server computer setup system 47 configurations and many other utilities WinCC explorer has to start up prior to the loading of the Labview server program as the program has not been set up to be able to reload new readings from the WinCC program into the Labview program The WinCC configuration location of the server had to be altered during this project as the previous configuratio
22. 09 ES DO COMS Used 152 21 E57 DO 10 Es DO COM6 Used 152 22 E57 DO 11 ES DO COM6 used 152 23 E57 DO 12 E57 DO COM6 used al 19200 v 160 E58 AI 01 E58 AI COM6 used 161 E58 AI 02 E58 AI COM6 used 162 E58 AI 03 E58 AI COM6 used 200 163 E58 AI 04 E58 AI com used 172 E58 AO 01 E58 AO COMS used 173 ESB AO 02 E58 AO COMS used 174 ESB AO 03 E58 AO COM6 Used 175 ESB8 AO 04 ES8 AO COM6 used 180 ES7 AI 01 ES AI COM6 used 181 ES AI 02 ES AI COM6 Not Used 182 ES AI 03 ES AI COM6 used 183 ES7 AI 04 ES AI COM6 used 192 ES7 AO 01 ES AO COM6 Not Used 193 ES AO 02 ES AO COM6 used 194 E57 AO 03 ES AO COM6 used 195 E57 AO 04 ES AO CoM6 Used Ej ESl TS ES1 TS COM3 ES2 TS ES2 TS COM3 1 ESS TS ES3 TS com4 Figure 23 Maximum number of Addresses Figure 24 loop 4 configured patchnames txt Lastly the Patchnames txt file had to be configured to allow the displaying of I Os being read by IO Manager Addresses and configuration data had been added to the Patchnames txt file where 6B boards and modules had been configured and placed into the loop4 system as shown in figure 26 3 5 Labview Conclusion The Labview server program has now been debugged solving previously known issues and improved in a few different areas These improvements will provide greater usability of the Master I O program and reactivation of its broken hardware debugging software The Labview program still has room for improvement but in particular it needs to be complete
23. 19200 NO Eng Units Immediate NO 6B21 193 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 6B21 195 N A 30 0 to 20 mA 19200 NO Eng Units Immediate NO 7 The MAIN MENU will pop up click COMMS and use 9600 Baud rate and ensure that the max addresses includes the address the device is in Press OK DONE 8 Back at the MAIN MENU click on SEARCH and select the appropriate device there should only be one if you followed the steps to enter Device Configuration or else you will automatically be brought to a Device Configuration where you can change the Address Baud Rate and Integration Period Some warnings on the changes in addresses and baud rate will pop up Ensure that the addresses are unique and the baud rate is 19200 for integrating with the Master I O Labview software Clicking on DONE will lead you to the MAIN MENU jelx KL 6B WIN Device Configuration Let HELP ategration Pariu Fou CANCEL BEAD DEV CALIBRATE 150 WRITE DEV EN DONE 6B50 READ ALL 107 19200 HELP QUIT PASSWORD E CONFIGURE READ Disabled PROGRAM Disabled 9 Unpowered and Repower the 6B series device to load the configuration into the module Repeat these procedures Step 1 8 if more modules are to be configured 10 When all digital boards have been configure remove power from the board 11 Rre install the configuration jumper to
24. 3 phase power supply sockets will use a red power socket cap Signal for the coils come from the SSR connections DB 05A to DB 11A for panel A and DB 17A to DB 23A for panel B Required connections to the earth and neutral bars have been listed on the right of the bar symbols Dotted line areas represent section that will be connected to outside of the power box Emergency stop buttons are connected before the mains enters the power box and are not indicated in the wiring diagram Labels 1 10A and 1 10B are numbered in accordance to the patch panel where 1A and 1B are at the top of the patch panel and 10A and 10B are at the bottom of the patch panel 30 These important notes have been placed in the wiring diagram s legend to provide further details on the information that cannot be shown clearly on the wiring diagram shown in Appendix B The legend also includes a listing of components which can be cross referenced to the power board layout diagram and short description on the component 4 2 Component Changes Certain changes to the hardware components have been made as compared to the previous older set ups due to components not being in production or questionable implementations These changes in components have been discussed with Graeme Cole and John Boulton before any implementations had been made on the actual power board 4 2 1 New Thyristors One of the changes is the Thyristors which are no longer in production The old Thy
25. C laboratory facility 1 4 Related Work One major part of the project was the testing of the program and different components within the IC laboratory facility Simple gadgets where made to accommodate the various 10 sensors which were Profibus networked as these sensors were slightly different in physical size or had different attachments which did not allow for connectivity with the existing instruments in the IC laboratory facility Another important aspect to the project was the planning and communication with various people involved with the project in order for the project to flow smoothly 1 5 Assumptions Constraints and Risks Several assumptions were made before and during the progress of the project These assumptions would help constrain the various factors involved in the process of upgrading the IC laboratory facility The current Labview software was assumed to be sufficient for the desired upgrade for the IC laboratory facility This was done so as to have the users of the IC laboratory facility be able to easily use or manipulate the functionality of the facility The wiring of the power control board will be checked by John Boulton and information on wiring standards were informed through him with some guidance from the AS NZS 3000 2007 Wiring rules Risk of incorrect wiring may occur even after triple checking with the redrawn wiring diagram It was also assumed that the previously components fixed onto the control board
26. D d ig Z c OPC localhost OPCserver wincc 1 2 Pe Not ton I H ic 0 S Connection id 4 T gt o gt Error T gt Concentrate s Read SIPS Error Rend 1 Jl ESP AI 4 gt ae Type c dstp localhostyESP 7 T c 2000ms Time Out 1 gt Concentrate Ic not wait for update value ata Connection id Connection id x 3 DS Open lt DS write lt DS Close E D geg eso des m 4 os cose 2 Concentrate Connection id Connection id d T c PLC HB read Ope mE SLOS Read JS cose ctrl Clear Error s Error ZAR Error Tei TI Type gt Time Stamp Data v Profibus loop error 64 10 5 Appendix D Master I O VI Hierachy Available Electronically S a A veg e e E dd EE OE 1 ARE 65 Daniel Lau USER GUIDE 2010 10 6 Appendix E E 3 T MURDOCH UNIVERSITY PERTH WESTERN AUSTRALIA Instrumentation and Control Laboratory Facility Upgrade Murdoch University School of Engineering and Energy Daniel Lau 2010 66 Table of Contents 1 Installation amp Configuration of 6B series devices ceceesesseceeececessesssaeceeeeesessessnaeees 68 1 1 lu eege 68 1 2 Required Information Software cccccccsscesssecesseecsseeccsseeecseecesseeesseeeesaecesseeeees 68 1 3 Assumed devices Used ue ierat ree Cites ere epa de bade Sa eee 68 1 4 ProcedU ES uieii alerede 68 1 4 1 Analog d
27. ES2 TS ES2 TS COM3 ES3 TS E53 TS COM4 0 E56 DI 01 E56 DI COMS Used dress PatchName Topic Type Port Usability 2 ES6 DI 03 ES6 DI COMS Used 1ES6 DI 02 E56 DI COMS Used 3ES6 DI 04 ES6 DI COMS Used 2 ES6 DI 03 ES6 DI COMS Used 1 4 ES6 DI 05 E56 DI COMS Used 1 5 E56 DI 06 E56 DI COMS Used 1 6 ES6 DI 07 E56 DI COMS Used 1 5 E56 DI 06 E56 DI COMS Used 1 7 ES6 DI 08 E56 DI COMS Used 1 6 E56 DI 07 ES6 DI COMS Used 1 1 1 ES6 DI 02 ES6 DI COMS Used 0 ES6 DI 01 ES6 DI COMS Used 2 1 Figure 11 Test point readings When the program was ran following the normal procedures corruption of the usability data were found to be overflowing into the Timestamp data section shown in Figure 14 One of the main causing issue was that there were missing I O addresses in the patchnames txt file which lead to an unequal number of usability data This issue was solved with the introduction of a new sub program known as the Activation Table vi as it continued to write data on I O addresses which were not found during the remapping procedure Activation Table vi kept the I O addresses for the finishing vi to use and to prevent usability data corruption in the Patchnames txt file og EDL AL LU EDL AL Lures LIEU ER ESl AI 08 ESL AI COM3 used 88 ESL AI 09 ESL AI COM3 used 89 ESl AI 10 ESL AI COM3 used 92 ESL AO 01 ESL AO COM3 used 93 ESl AO 02 ESL AO COM Used 94 ES1 AO 03 EST 95 ESl AO 04 EST x ES1 TS ESL TS AL ES2 TS ES2 TS Not used ab ES TS
28. ESL TS a ES2 TS E52 TS at ES3 TS E53 TS 2L Es4_TS ES4 TS L ESS TS ES5 TS ai ES6_TS ES6 TS al ES7 TS ES TS SS ESS8 TS E58 TS Figure 12 Normal procedure corruption Unfortunately this was not the only corruption source Reviewing the original patchnames txt with the corrupted txt file the addresses were being altered and jumbled data all over the place This was due to the wrong sequence of combining data in the 22 IO Manager vi Data was being combined in the sequence of loop2 loop1 loop 3 loop4 Figure 15 This jumbling of sequence might have been due the shifting of loops and addresses when the IC laboratory facility was brought from the Rockingham Campus to the Murdoch campus Hence adjustments were made to suit the Murdoch Campus IC laboratory facility address and loop sequencing to prevent further corruption of the Patchnames txt file this code is shown in Figure 16 Loop One hd HIN B si D 0 8 Loop Three Map m Loop Four Map Figure 13 Jumbled sequence of combining data Loop Three Map System Map Default v Loop Two Map Loop One Map Eat D stem maj fbe ag Loop Four Map Figure 14 Murdoch Campus Adjusted Sequence However still there was more corruption was occurring Data in the patchnames txt file started loading Timestamp data in sections where I O address data was being written as shown in figure 17 This problem was due t
29. O that should be present in the system and corrects usability states accordingly this new code is shown in figure 12 Activation Table vi still used parts of the old coding for the activation and deactivation of I Os but adjusted to fit 20 the new table system and capable of selecting appropriate data to increase its robustness Activation Table vi handles all I Os in each loop splitting and manipulating data for the various required formats of other Vis in the IO Manager Compared to the old coding system Add remove modules vi the Activation Table method is simple easy to use and significantly improves the usability The program was released for testing engineering student users 274 and 3 year who have found the new method much more convenient and efficient Loop 1 Activation Table EE ER B hanna loop 1 nannannana 2 Figure 10 Activation Table connected to Activation Table vi in loop system 3 2 Patchnames txt Corruption The Patchnames txt corruption was known prior to start of this project Previous programmers were unable or did not have to solve this problem Patchnames txt allowed users to retain information across the session In order to find out what was actually happening to the Patchnames txt file several test points were added to the program particularly within finishing vi this included picking up readings of different types of data and formats as shown in figure 13 21 1 TSES1 TS COM3
30. O1 30 CBO2 31 RAO6 32 RAO7 33 RAOB 34 RAOS 35 RA10 36 RA11 37 RBO6 38 RBO7 39 RB08 40 RB09 41 RB10 42 RB11 43 RA12 44 RB12 45 T1 5VDC 46 T2 5VDC 47 T3 24VDC 48 T4 24VDC 49 T5 110VAC 2 THYRISTOR A THYRISTOR B 52 main Earth Bar 53 ELCB N Bar 54 Main N Bar 55 110V N Bar Item Description Main Switch Earth Leakage Circuit Breaker Circuit Breaker Power Supply 1 3A Circuit Breaker Power Supply 2 3A Circuit Breaker Power Supply 3 6A Circuit Breaker Power Supply 3 secondary 6A Circuit Breaker Power Supply 4 6A Circuit Breaker Power Supply 4 secondary 6A Circuit Breaker Transformer 10A Circuit Breaker 3 Phase Side A Circuit Breaker 3 Phase Side B Circuit Breaker ESA DO 06 Circuit Breaker ESA DO 07 Circuit Breaker ESA DO 08 Circuit Breaker ESA DO 09 Circuit Breaker ESA DO 10 Circuit Breaker ESA DO 11 Circuit Breaker ESB DO 06 Circuit Breaker ESB DO 07 Circuit Breaker ESB DO 08 Circuit Breaker ESB DO 09 Circuit Breaker ESB DO 10 Circuit Breaker ESB DO 11 Circuit Breaker Thyristor A Circuit Breaker Thyristor B SPARE Circuit Breaker 110V outlet AO1 Circuit Breaker 110V outlet A02 Circuit Breaker 110V outlet BO Circuit Breaker 110V outlet BO2 Relay ESA DO 06 Relay ESA DO 07 Relay ESA DO 08 Relay ESA DO 09 Relay ESA DO 10 Relay ESA DO 11 Relay ESB DO 06 Relay ESB DO 07 Relay ESB DO 08 Relay ESB DO 09 Relay ESB DO 10 Relay ESB DO 11 Relay ESA DO 12
31. P for profibus Technical Manual Available on Timoshenko IC Facility 2010 57 10 Appendix 10 1 Academic Supervisor Endorsement ENG460 Engineering Thesis Academic Supervisor endorsement performance am satisfied with the progress of this thesis project and that the attached report is an accurate reflection of the work undertaken Signed Date 58 10 2 Appendix A Power Board Wiring Diagram Available Electronically ICE LAB ELECTRICAL PANEL WIRING MURDOCH UNIVERSITY INSTRUMENTATION AND DRAWING NUMBEF 70133939E DANIEL LAU DATE 7 SEPTEMBER 2010 EE VOL we pe X v1 1089 yog o I VOL F YD mei ysl vol Lovo H YT M var AHLYD Ha St ee VOL 5060 5087 Deel n vol 2089 cu vo ae Sov o 5 vol zovo aw LLL voi AHLSO AUS D E d v01 9089 9087 A s vor e080 6087 DANZ EL OUAYC EL OAK PL 00AVZ HL SCALE N T amp 59 10 3 Appendix B Power Board Wiring Diagram Legend Available Electronically LAYOUT item Name 1 Main Switch 2 C Earth Leakage 3 CT A CT2 5 CT3 6 CT3S 7 CT4 8 CT4S 9 CT5 10 C3PA 11 C3PB 12 CAO01 13 CA02 14 CA03 15 CA04 16 CA05 17 CA06 18 CBO1 19 C802 20 CBO3 21 CBO4 22 CB05 23 CBO6 24 CATHY 25 CBTHY 26 SPARE 27 CAO01 28 CAO2 29 CB
32. Relay ESB DO 12 Power Supply 1 SVDC Power Supply 2 5vDC Power Supply 3 24VDC Power Supply 4 24VDC Transformer 5 110VAC THYRISTOR A THYRISTOR B Main Earth Bar ELCB N Bar Main N Bar 110V N Bar IMPORTANT NOTES SYMBOL TABLE 5444 2 we mult ore wires that re used to oonmned the power supply bound with the Symbol Symbol description I p dr panel s power eine dien there wil be anisolatcn witch betwesntiwse wires and a hw actual power supplysecket Figure EIL emm 3 phase Circuit Breaker x meme Une tet ras Eeer I se 2 phase Circuit Breaker o 1 Phase Circuit Breaker iana 5 Relay Coil dra relay 4 Labo x a te A RX so four 240W AC En e ne w patch panels 2020 22 049 inte ad SS Relay Terminal ur i waishi from ther mann kr Thyristersusedin the power a d Eartning Line 1 Zar sagt the me se of ERR being alie ES rm bi i cdtry which idealy 9o occur eadi time she Thyriste at 16 a di Mare gl B Power Supply trolled by the ESA DO 04 and Tis risters amp is controlled by ESS00 04 E m ae named CAL 4 or the patch panel ard vil use a yelow powa S El Transformer chute wil ine ablue power der cas and wil be lakelled ESAA O 06 DO 06to SB 00 12 Ipha e power uppiy sodenn wil use red o xxxxxx Bar Earth Neutral Bar Sera io coil come from the SSA oon necs ons OIB 05 to O8 11A for panel Aart OG 174 10 08234 ei r fa qui rw di corte ct
33. S Loop Three state he map count is used to get the system ap progress Map count us flap progress Loop Four Mapping Progress Loop One Mapping Progress Loop Two Mapping Progress Got JS Loop Three Mapping Progress E REMAPPING IN Figure 50 remapping progress state loop 7 1 2 3 Profibus remapping state Currently Profibus remapping state servers no real purpose however when the WinCC program has not been started up before the Labview program tags cannot be picked up by IO Manager This blank state will serve a purposeful location for code on remapping tags from WinCC shown in figure 53 Figure 51 Profibus remapping state 52 7 1 2 4 Profibus logging Currently there no logging system for the Profibus network unlike the other 6B network which has patchnames txt file which logs data from the previous session This will help with the debugging of new devices which will most likely be added onto the Profibus PA network or when device failure occurs The profibus system should preferably not use the existing PATCHNAMES txt file to log the data as this may cause confusion when the 6B loops are drawing information unlike the Profibus system which does not read off these previous logged data 7 1 2 5 COM port numbers The COM port constant numbers have not entirely been changed to fit the actual COM port being used within the program For example COM6 used fro
34. ared server A VI hierarchy has been included in the appendix D and will be available in the EngShared server This will help users locate the various sub programs and to understand the structure of the server program A few thoughts into the revamping of the Labview server program will be discussed in the sub sections below 7 1 1 Recording Previous Usability Listings Previously the usability listings used a basic method of gathering data and writing over all of the previous data With the use of the activation table data on usability has been made more robust However it is not entirely failure proof After much work on the master I O program it has been found to be very troublesome to adjust multiple parts of the master I O program to prevent corruption of the patchnames txt file As the system is being revamped the user should look into a method which alters the usability column of the patchnames txt file alone The addresses tag name station number I O type and port number should never be over written in the first place The user should create a system 50 which retains all possible addresses data but only have the usability overwritten The updating of the patchnames txt file should happen after a number of loops eg every hour or when there is a change this will help prevent the patchnames txt file from getting corrupted from premature shut down procedures This will help the patchnames txt updating system being more robust an
35. art of this project improvements were made to the wiring diagram Providing a bit more information on how major components had to be wired up as shown in Figure 28 However not all the required information on how all components were to be wired was included in the diagram 28 E54 00 09 26 ESADO 10 not in mew situm 07 ESADO 11 nat in mew system 1 8 20 8598 00 08 21 S8 00 09 22 ESE DO 10 not in new system 23 ESB DO 11 nat in new system 24 Tnpistor ESA DO 25 zen ES8 00 12 26 SPARE Zeie 7A 110VAC k 28 0 78 1104 29 00 BA ILOVAC 30 Outlet 88 110VAC DA Relay ESO i nat in mew ttm nei in mew system HU 10 nok in new system 11 nat in new system isi HU TERRE RE ETE EE Hi D BYNES SesRa SSSA SSB RE SER e ii i f D Figure 26 Semi improved wiring diagram Much time was spent in improving the wiring diagram in the course of the project period the wiring diagram was made for users to have enough information to set up the power board shown in Appendix A The main aim of the wiring diagram was not only to help with the production of the power board but the safety and for future review and use During the course of documenting the wiring diagram certain important details on the power board and its connections were identified to be an
36. atch panels 7 amp 8 but needed to be changed to suit the set up on the Murdoch campus Since the reconfiguration of addresses total number of I Os and the new Activation Table vi adjustments had to be made to prevent corruption and correct readings from the 6B I O boards After the new 6B I O boards were set up and configured for panels 7 amp 8 adjustments had to be made in the new coding Activation Table vi Specifically the number of I Os had to be configured to fit the exact number of I Os in the loop Figure 22 This was done to prevent corruption of the Patchnames txt file adjustments had to be made to the loop 4 activation table as well in the 2 column True address of the activation table which tells the program the corresponding address for which the activation is to be adjusted Figure 23 The True address column had to be configured for the configuration of the usability of the I Os when setting up loop 4 25 4 Activation Table Activate 1 Deactivate 0 True Adc 152 1 152 2 152 2 152 3 152 3 152 4 152 5 152 6 152 7 152 8 152 9 152 10 Activate Table Activation JAdjust able number of 1 0 in loop exact number required dimension size loop 4 has 62 I O Figure 20 Activation Table Adjustment Figure 21 Activation Table True Address Column Configurations in the normal seque
37. atory facility when it was transferred from Rockingham Another new loop has been set up for the Profibus system and the disabled loop has been reactivated and configured to suit the settings in the Murdoch Campus IC laboratory facility The I O manager allows users to ensure readings and help debug problems in the IC laboratory facility It also allows for the disabling of I Os to cut down on loop time 2 2 Power Board The power boards hold the various protections devices power supplies transformers and thyristors as shown in figure 4 These power boards protect users and equipment from the various high voltages or currents that occur in various situations The power supplies transformers and thyristors provide the necessary voltages and functions for the I O control board and the various equipments which are easily connectable via the patch panel in the IC laboratory facility as shown in figure 5 P UR K T Figure 4 Old power board Figure 5 Patch panel power sockets 16 2 3 I O Control Board The I O control board as shown in figure7 contains the 6B analog and digital isolation devices which allow communication between the server and the various measuring devices located around the IC laboratory facility The various analog and digital read or write devices are connected to a patch panel as shown in figure 6 allowing a flexible implementation of various forms of control systems The I O handles the 6B series devic
38. connectivity into the facility 6 1 Technical Review Profibus DP and PA Profibus DP uses a distributed I O transmission protocol as an open bus system whereas Profibus PA is an extension of Profibus DP being compatible in terms of communication The high powered Profibus DP provides high transmission rates of up to 12MBaud A DP master system can be extended to explosive areas by using DP PA converters where PA runs at a lower baud rate of 31 25K but is capable of intrinsic safety for electrical equipment SIEMENS Bus links 2006 6 2 System Setup in IC laboratory facility The current Profibus system in the IC laboratory facility consists of a PLC 2 I O modules Server using WinCC Clients which are the workstations and the instruments in the field connected to the PLC The PLC has 2 I O modules SIMATIC NET communication processor CP342 5 and 2 DP PA Coupler FDC 157 0 to communicate to the various sensors out in the field The communication processor CP342 5 is designed to attach the PLC to a Profibus Fieldbus system It can act as a DP class 1 master or a slave SIEMENS SIMATIC NET 2006 A class 1 master can communicate actively only with its configured slaves and can communicate passively with a class 2 master Whereas a class 2 master is capable of communicating with class 1 masters the class 1 masters slaves and its own slaves for diagnostic configuration and parameter data exchanging The DP PA coupler acts as a physica
39. d in preparation for it to be wired into the patch panel 3 O Control board Upper Box Ensuring that the control board works includes the connectivity of the PLC and the 6B system There was a need for the configuration of the 6B boards and I O Modules to allow connectivity with the Master IO server program Furthermore the replacement of an incorrectly placed 6B board The board should be configured and ready to be connected to the power board and the patch panel Installation and tidying up of the various components on the I O control board had to be made 4 Profibus PLC This would include the testing of the Profibus equipment which was new to the IC laboratory facility The equipment was ordered and brought in specifically to be connected to the Profibus network 5 WinCC To ensure the connectivity of the PLC which is connected via the use of WinCC and updating the software to suit the new location from where the software is being run from 6 Documentation This part included the IClab website a chad webpage system keeping the CHAD webpage up to date to provide easy access for different level users Technical documents software coding and diagrams will be available on the EngShared server for future users to attain important current information and previous software or information prior to the work done in this project Customised user guides will be made to help future users to configure or even reconstruct sections in the I
40. d convenient for add and removing I Os to the system 7 1 2 Alternation of Labview Coding 7 1 2 1 RS485 2 board functional indicator Currently the program made for this indicator which is suppose to show that the RS485 board is functioning appropriately is useless as it does not actually serve its true purpose Rather it merely turns on the indicator when passing through the start up state drawing a reading from a constant as shown in figure 51 Figure 49 RS485 2 board functional indicator 7 1 2 2 Remapping progress bars loop The remapping progress bars do not actually provide information on actual progress of the remapping state as shown in the red box in figure 52 Rather it merely counts up each time the loop has been run however not every loop has an equal number of I O being remapped into the system The remapping completion state system will have to be adjusted to fit the new progress bars system 51 his Four case structures are used for progress display bar Where each loop rogress bar has its own case structure For each progress bar three cases are epresented remapping normal and empty case In remapping the value of rogress bar increases while in normal case it reaches maximum value and in mpty case it reset it self me Loop One state 200 normal Default Y oop Two Mapping Progress Loop Two State normal Default v oop Three Mapping Progress E
41. e this VI block reads and writes Loop 4 Activation Table alues of modules specified For this port Activate 1 Deactivate 0 Gei R W Status This block reads writes the ste az how if any error occur during operation Configuration in normal loop in IO Manager configuration of selected COM ports have to be ensured to be correct and the maximum number of analog addresses chosen in the Activation table have to exactly be the same The following configurations make reference to the image above e Boxes labelled 1 will have to be configured to the actual serial COM port number e Boxes labelled 2 will have to be configured to the actual serial COM port number minus one Eg COM port 6 a constant of 5 would be used e Box labelled 3 will have to be adjusted to the exact number of maximum analog addresses chosen in the Activation table 12 3 3 Configuration in Remapping loop klo Configuration of the Baud rate and Highest address number will have to be configured in altered The baud rate which is used in the IC laboratory in the Murdoch Campus is 19200 The following configurations make reference to the image above e Box labelled 1 will have to be adjusted if the Baud rate is not 19200 e Boxes labelled 2 will have to be adjusted to the highest possible address number 75 13 Troubleshooting Symptom Module or board does not respond to host Possible Cause T
42. e module at a time with no other modules attached to the backplane during configuration As the power board had not been ready for supplying power an external power sources was used for the configuration of the 6B series devices About 0 5Amps and 5Volts was sufficient to run a couple of analog modules and the digital board however when more modules were added onto the board status indicators on the digital boards started to act up The reasons for the status indicators did not function as per normal after multiple tests were done on the EEPROM the microcontroller and playing around with the number of analog modules on the backplane it was soon noticed that the power levels had dipped below 4 5Volts After placing the desired number of modules the power source with the 41 new setup required 6 1volts and 1 85Amps which is close to the voltage limit of the analog modules of 6 5Volts Devices 1997 Power levels on the external power source had to suit the needs of the 6B I O setup but the power panel will supply 5volts with a larger current to compensate for the lower voltage Interconnections between the various 6B series devices were wired prior to the start of the project It was noticed that these connections were not implemented with the recommended setup Instead the grounds were connected at the end as there is only one shield to allow the connected devices to have a common reference point As terminals 1 and 2 are referenced t
43. eet string index 0 4 g Original Data Stations Arra Array gt Spreadsheet string Create c Headings gt Concentrate strings ic v s Path strip Path gt buiia patr Creates Array for Time Status TS and Loop Indication LI c PATCHNAMES TXT 62 gt Remapping State Selection tc Port a L c Baud Rate 7 c Max Address v loop state r c Max Address s remapping ES T 9 Original Data resting Port Ara c port module Ciears Mapping tables Ic F gt g Status gt loop activity Isi Remapping g Remap loop s Empty Analog Cluster gt Split analog p 14 bands Digi Cluster 3 S I Cluster Initialised Array gt Analog array modifled i gt TAnalog Array gt Tianalog port cluster Module location 7 Error Out checking c F H gt Ig Status gt loop activity gt g Original data in port Original Data ZAU AO Array Normal State Selection s Remapping 9 Remap loop Is Empty g stop loop Es Normal Ec Port Loop Activate Table T port modules Analog Array vou NR ME T Time Status Loop Map System map Loop 3 Map i Remap loop d 5s loop 7 Loop 2 Mag g Remap loop Loop 1 Mag gt Sie d JL Tei loop Loop 4 Maps e gt
44. eries section previously Configuration procedures will be available in a user guide provided in the EngShared folder in Timoshenko also shown in Appendix E 7 5 Proper Housing for the New PA Measuring Equipment As shown in the Profibus testing section the modified add ons only made as temporary testing housing equipment The need for a more experimental friendly housing will be required to be made for these new PA measuring devices The housing should most definitely have some sort of sight glass or a transparent panel for viewing of the level of water in the tank Furthermore the pressure measurement devices should have some sort of tank and housing for the sensor to be placed on the equipment racks 55 8 Conclusion amp Project Experiences The project has run rather smoothly with certain predicted delays in the course of the project The Master I O Labview program has been configured to meet the needs of the new panel and there has been reduction of bugs in the system However it still requires a major redesigning and remaking The I O control board is complete and configured ready to be wired to the patch panel after the two new panels patch panels 7 amp 8 will be available for configuration in the facility With the knowledge learnt in this project and documented future users will be able to set up new panels from scratch with the help of these documents The CHAD website has been updated in several areas and documentation in
45. es which are connected via RS 485 to the server which can then be configured to the users specifications through the use of the 6BWIN software With the use of the Labview program these devices can be used for various purposes and can then be used with the Data Socket system to communicate with the various workstations in the IC laboratory facility The I O control board also provides some protection for the short circuits or over currents through the use of the 6B series devices internal circuitry and various fuses which have been connected to the I O analog ports The I O control board also holds various connections to the control for and supplying from the power board Bei Ba ua I Ras ener ent Bi Figure 6 Patch panel connectors Figure 7 1 0 control board 2 4 Profibus System The new I O control board also contains the PLC as shown in figure 7 which has now been included in order to implement the Profibus system This Profibus network provides for more efficient communication between the server and the various equipments in the field 17 The Profibus system brings variety to the IC laboratory facility Further instrument or communication as part of the Profibus system includes the PA system intrinsic safety system although not required This system may increase in size in the future years as not only is it easier to transfer and rewire it is also faster Further details on the functionality of the Profibus system
46. evices runesteinen redene disket 69 1 4 2 Digital DEVICES avsa 72 2 LabView configuration rorornrrnanannnnrnrrrnrnnsnannnnnnvnnnnnnsnannnnnnvnnnssnsrnnnnnnnrnnnssssssnnnnnnrsnnssne 74 2 Importantihotes c endete teen eso te eoa se epe chau pese ee ERR Rene BERE De erede gend 74 2 2 Required information cccsessececccecessensnsececececeesnsaeaeceeeeuseesesaeaecesecesseseaeseeeeeess 74 2 3 Procedures iucunde ERR estet eee Ee Te eot eta iade 74 2 3 1 Activation table configuration rrrrnnnnrorvrnrrnnnnnnnnvnvvnnrrnrnnnnnnvnnvnnsrnsnrnnnnnenn 74 2 3 2 Configuration of Normal loop in IO Manager 75 2 3 3 Configuration in Remapping loop 75 3 TroublesHootihB ce eterne aksessere 76 67 11 Installation amp Configuration of 6B series devices 11 1 Important notes e Information is available in the 6B series devices manual can be found in the C facility 2010 folder e Itis best to configure each 6B series devices before connecting all of the devices as a network as each device has to be configured separately e The 6B backplanes for the analog devices and the 6B Boards both require 5V and 0 3mA e NEVER go above 6 5V this will burn the boards 11 2 Required Information Software e COM port number e Largest address number e 6B WIN software 11 3 Assumed devices used e Analog backplane 6BP16 1 e Analog Input module 6B11 e 500 precision resistor black blocks e Analog Output module 6B21
47. ewly added Profibus PLC The Profibus network Master I O server also communicates to various experimental workstations via Ethernet collecting data in arrays from the various loops and sending and receiving data to the experimental workstations The Data Socket server is the interface between the Labview program and the client workstation The Master I O program basically acts as a middle man for the two different systems 6B system and Profibus network as shown in figure 3 The respective network transfers the data to Master I O through the use of their networking system The data is then manipulated and read or sent to the Data Socket server which holds the data waiting for the workstation Computer Users around the IC laboratory facility Workstations Workstations Data Socket Data Socket Master I O Master I O PC DAQ card WinCC program Analog Digital Card Profibus PLC Field Instruments Field Instruments Figure 3 Master I O as part of the 2 networks The master I O server program is capable of doing multiple configurations such as setting preferences getting port signals Configuration of 6B series hardware and its core sub program the IO Manager The IO Manager sub program deals with the mapping and 15 transfer of data Originally there were 4 main loops in the IO Manager program each handling 2 patch panels in the IC laboratory facility One main loop had been disabled as there were only 6 patch panels usable in the IC labor
48. he RS 485 Ethernet cable may be loose or not connected properly Possible Solution Check the cable connection and review chapter 1 4 The external power supply is not attach or is not supplying power Check the power supply and ensure that the right amount of voltage is coming in no higher than 6 5V You are using an incorrect baud rate Verify that the baud rate is the same for the module board and the host computer default 9600 Module or board is not operating properly The module or board is damaged or malfunctioning Check the EEPROM Software and the processor chip Fix it Or you are in big trouble Vibration or loose Cushion the source of connection vibration and tighten connections Incorrect wiring Review the respective sections Missing or broken wires Replace the wires Overheating Ambient temperature should be less than 60degC unlikely the case IC Lab Facility Murdoch Campus has air conditioning duct running into the I O Control Panels Electrical noise Control electromagnetic interference through better cable shielding and planned ground connections High line resistance Use larger cable size within 22 14 AWG range Yellow and Green LED on 6B series board backplane continuously ON Malfunction of the board backplane or one of the modules Test each board backplane or each modules individually Not enough power supplied to the board backp
49. ical review to help the reader get a better understanding of the various systems around the IC laboratory facility The report also includes documentation on the possible future directions and future recommended directions for the various sections in the IC laboratory facility 1 2 Background Prior to the start of the project there were numerous bugs problems and unwanted programming in the Labview Master I O program The program was also found to be troublesome to use and over complex hence it was desired for the program to be revamped allowing future users to pick up on the program quickly and easily if there was a need for the program to be worked upon A new panel is being built up to meet the growing demand for the need of panels in the Instrumentation and control laboratory The panel would consist of a power board an IO control board two patch panels and an equipment rack The power board which powers the I O control board and the other higher powered devices in the IC laboratory facility had its components laid out in preparation for it to be wired However the wiring diagrams did not have sufficient information for it to be recreated and the previous power board poorly labelled preventing users from easily locating connections The I O control board was supposedly completed and commissioned but was later found to have some major issues wrong Digital I O boards were placed into the panel and SSRs and I O modules had not been
50. ion time Both the 6B11 and 6B21 analog devices have an EEPROM which stores calibration constants as well as configuration information Details on how to configure these 6B series devices is available in a user guide Configurations for the Adding or Removal of 6B series devices available in Appendix E 38 RS 485 Input Connector from previous backplane Figure 38 6BP16 1 Analog backplane Devices 1997 5 1 1 1 1 6B11 Isolated field configurable analog input The 6B11 module is an isolated field configurable analog device which have been configured to 19 2K baud rate to maximise information transmission speed These analog inputs have also been configured to 20mA with 60ms Integration time The use of a microcontroller allows for module output signals to be converted into engineering units as requested by the controller For protection of the controller from the field there is isolation between the field and controller side of the module of 1500Vrms The analog inputs requires a 50 O precision resistor which converts the 20mA current signal to a 1V signal which is readable by the 6B11 as shown in figure 41 The plug in resistor fits into the two pin socket between the module terminals and the screw termination block shown in figure 40 above Do note that as the module s inputs are bipolar a negative value may mean that the user has reversed the high and low inputs on the screw terminal Devices 1997 Figure 39 Process Cur
51. l link between the Profibus DP and Profibus PA networks It is possible to connect up to five FDC157 0 DP PA couplers which may be configured differently With the use of an active field distributor AFD the network is set 45 up for ring redundancy and with the use of an active field splitter the net work is setup for coupler redundancy shown in the figure46 SIEMENS Bus links 2006 In the case of the IC laboratory facility there is a standalone DP PA coupler which daisy chains to the devices in the field Operator station or engineering station with parameter assignment tool Higher ranking layer Industrial Ethernet Local parameter assignment DP master b T E tool 2 DP PA coupler DP PA coupler DP divo Foc 157 0 FDC 157 0 Lowest layer field devices PROFIBUS PA Lag i H Figure 43 DP PA coupler in a system SIEMENS Bus links 2006 6 3 Termination Termination for signal wires is important in order to prevent signal reflections on the Profibus PA or DP cable Wrong or missing cable terminations may result in transmission errors or even completely losing communication link Termination for the two different Profibus cables requires different termination The Profibus DP uses active termination whereas PA uses a passive termination The Profibus DP termination requires a 5V source two 3900 resistors and a 2200 resistor connecting as shown in Figure 47 below Termination on PA requires a 1
52. lane Check power terminals of the board backplane closest to the Ethernet cable connections from the server computer Green LED goes You may have blown fuse F1 Replace with little off fuse251 500 5A for 6BP16 1 back planes Replace with little fuse 251 500 1 A for 6B50 1 76 Symptom 6B21 analog output module responds to all commands but readback indicates that no current following When using search option in 6B Win software doesn t recognise any devices TIMEOUT error occurs when using 6B Win Possible Cause The current loop is open host access Some multispeed computers cannot 6B WIN using diskette Memory resident programs may interfere with communication with the 6B series devices Address or Baud rate have been altered and are not recognised by 6B WIN Possible Solution Check wiring Use 6B WIN from the hard disk Run 6B WIN while other programs are not running Eg Master I O Power cycle the 6B devices and search for the devices under the appropriate baud rate 77
53. lows users to be able to create a control system with its various analog inputs outputs and digital inputs outputs I O This allows users to design and implement various control systems designs and algorithms with the use of a client based Labview program The IC lab has a number of connection panels wired to a master I O server which in turn is connected via Ethernet cabling to client workstations The panels allow for a variety of instruments to be used and with the use of analog digital connections readings and signals can be received or sent to the connected instruments as shown in figures 1 and 2 The server is connected to the patch panels via an RS485 network based on Analog Devices 6B Series I O modules and Solid State Relays to connect with higher powered devices Also with the use of the WinCC program the server is connected through RS232 to a PLC which in turn connects to the instrument on the Profibus network From the Master I O Server using the Lab View and Data Socket software users on client workstations are able to control the panel I Os ere E E D Figure 1 IC laboratory facility front panel Figure 2 IC laboratory facility back panel 14 2 1 Master I O The Master I O is a Labview program which acts as the server program for the whole IC laboratory facility reading various I Os via the national instruments RS485 serial communication COM3 6 to 6B series modules and COM1 which is linked to the n
54. ly redesigned and the need for revamping This is due to the continual small improvements and additions to the program have now made it very complicated and difficult to understand More information in the documentation and ideas for the revamping of the Labview program are contained in the Future Direction section 27 4 Power Board The power board has been designed to power the I O board in the box above the power board and sends power to power sockets to power equipment such as pumps heaters and measuring devices that need the high AC voltage Components for the power board had already been bought based on the previous boards and had to be assembled and wired in preparation for the powering of the panel The power sockets have yet to be wired and commission due to the patch panel not being ready for the panel 4 1 Wiring Diagram The original wiring diagram prior to the construction of the IC laboratory facility was a single line diagram It had some information on the wiring diagram shown in Figure 27 However there was little information on how each component was to be connected which made it very difficult for the uniquely wiring up of the power board many assumptions would have to be made upon using the single line diagram HH Dues er IS So S Po OG EARTH LEAKAGE PROTECTED it Figure 25 Single line diagram til oi II Ll Hoe PH od E S SUME ED mimm Prior to the st
55. m the server is at times calling for COM port 5 as a constant as shown in figure 54 The users will have to look into certain sub vi programs to make alterations to fit the new true COM ports being used in the higher level loop Figure 52 COM port numbers 53 7 2 1 O Control Board Wiring Diagram Even though it is assumed there will not be any changes to the I O control board having a better I O control board diagram will be useful for the future should the need arise Currently the wiring diagrams for the I O control board is quite vague when trying to relate to the planned layout drawing Documentation of how the labelling code has been made would help create some sense in the way the labelling has been done The current labelling on the I O control board does not provide any indication on how the system is to be wired to the patch panel In addition having five A3 pages of wiring diagram can be very troublesome to follow and hard to understand 7 3 Patch Panel and Power Board The patch panel which has yet to be created is an important section to follow up after this project John Boulton is the person to contact as he will be sending the metal plates to be specifically punched to fit the power switches sockets and I O connection sockets Using information on the power wiring diagram will help with the wiring and isolation of the power sockets and switches Information on the I O connection sockets will have to made based
56. ments in the field The power board is currently being constructed within this project and required a new and clearer wiring diagram to help with the construction of the power board With the help of the new wiring diagram the reduction of wiring mistakes and failures provided safety for both the constructor and future users With the introduction of the new panel a Profibus network has also been introduced to the IC laboratory facility The Profibus network provides a demonstration of alternative industrial communication system Contrast to the established system it has a faster transmission rate less wiring and intrinsic safety Table of Contents 1 uge UL et 8 1 1 Background eege ee eege deene 8 12 Scope OF RE DOM c saue 8 13 Objective EE 9 1 4 Relateg Mot E 10 1 5 Assumptions Constraints and Risks cccscscccceceesesesseaeeeeeceseessaeeeeeeseessesneaeens 11 1 6 D finitions nd Acronyms aaaaresarsseedd kameraet 12 1 7 Structure of the Report 12 The Instrumentation and Control Laboratory Facility eese 14 2 1 Master 1 O cccccsccscccccecsscssscccsccesessesscccecsscsssescescesascesseeeeecscsseesceseensensessceseessenseues 15 2 2 dd ru c haan 16 2 3 O Control Board 17 2 4 ProfibUs System eege 17 Labview Program Master UO 19 3 1 Activation Tablevi sussebass riaa 19 3 2 Patchinnames t
57. n and testing computer was not the main server computer 6 5 Testing Prior to the start of the project pressure levels of the new pressure sensors were shown to change in the IO Manager when air was blown into the pressure sensor However the new measuring equipment had yet to be tested out for experimental purposes This simple containment structures were built to encase the measurement equipment John Boulton a technician was brought into help construct these simple modified add ons for usage in the IC laboratory facility shown in figures 49 and 50 below Figure 47 Level sensor in PVC container Figure 48 pressure sensor with resized tube fitting The pressure sensor was fitted with tubing and a resized cap to fit onto a level tank in the IC laboratory facility The Level sensor was encased in a PVC tube which was sealed on both ends with an opening on the top with a screw on fitting for the level sensor The PVC tube 48 was fitted with taps and fittings to use the cold water supply in the IC laboratory facility With the new setup the measuring devices were again tested to show additional levels of readings on both workstations and from the server However these instruments would require calibration as the results from the testing of the equipment showed that the level sensor could not go below 30 and the pressure sensor was at 3 to the IC laboratory facility s atmospheric pressure 6 6 Profibus System Conclusion The Profibu
58. nce loop were also made for setting up of loop 4 where COM ports had to be configured differently due to the change of COM port number when the IC laboratory facility was brought shifted The initialisation Activation Table vi Read Write vi and loop info vi COM port constants had to be changed to fit the existing COM port 6 as shown in figure 24 below circled in red The green circled constant in figure 24 shows the number that needs to be changed for the fitting of analog devices to be read and sent for the patchnames txt file this will have to be altered to the maximum number of analog addresses present in particular loop of IO Manager FN E Loop la mri a io status 3 7 f oop Four tme pel status 3 dee Loop Four state remapping a EST is case is normal operation case For To here the following functions are done l Add Remove modules this VI block a f modules into current list of used modi icdule will not be read or written to ar Figure 22 Various COM port settings In the remapping sequence changes in Maximum number of I Os had to be adjusted as well in order to allow IO Manager to read the addresses which were originally no higher 26 than 150 This maximum number of addresses is now configured to 200 to allow readings of loop 4 which have I O addresses of 151 to 192 shown in figure 25 152 20 ES7 Do
59. nt on how the patch panels are to be made More discussion on what needs to be done will be discussed in the Future Direction section 35 Figure 36 Power box Multi core cables have been used and labelled for the wires that are leading to the patch panel power sockets for clear indication of where they should go and to make the power box cleaner to also allow future users make it easier to follow the wiring Figure 38 Multiple checks on the wiring of the power board have been cross referenced to the updated wiring diagram and previous power boards in order to help prevent any event of failure due to wiring issues As the patch panel could not be made in time before the end of the project period cabling could only be done in preparation for the patch panel Cables have been labelled and information on how they are to be wired has been stated in the legend Further details on what needs to be done will be discussed in the Future Direction section 4 4 Power Board Conclusion The new power board is currently near completion with minor adjustments and wiring to the patch panel left to be done The board can then be checked in conjunction with the new wiring diagrams and can be connected to the mains for testing The new component changes will hopefully provide more flexibility in new control systems 36 5 I O Control Board The I O control board is set up to provide control of the relay section for the power board as well a
60. ntrol and computer systems Due to the numerous aspects within the project of upgrading the IC laboratory facility the report will be broken up into four major components The Labview Server program Power board Input Output IO control board and the Profibus system A small introduction on the IC laboratory facility will be provided before the four major sections to give the reader a feel on how the IC laboratory facility runs as a whole The four major sections will then start with a brief introduction and within each section documentation on the background and problems will be discussed Following this discussion a report on what was done and the reasoning behind these actions then review s of results or overlooked issues and how 12 each of them was addressed Technical reviews will be interlaced amongst the various sections of the report to help readers understand the capabilities of the numerous different components in the IC lab facility without having to remember all the technical details at the start of the report A conclusion will end each major section to provide a small review on that section This document as a whole will end with a discussion of the possible future directions of the Instrumentation and Control IC Laboratory 13 2 The Instrumentation and Control Laboratory Facility The Instrumentation and control IC laboratory facility is a multi purpose SCADA supervisory control and data acquisition system which al
61. o the initialised size of the blank array created each time the finishing vi starts This array size should only include the total number of I O addresses and this does not include the Timestamp data shown in figure 18 With the wrong number of I O addresses the starting point for the Timestamp data would be formatted accordingly 23 E PATCHNAMES Notepad Tile Edt Format View Help iae originsl_ Data Figure 15 Corrupted Patchnames txt Figure 16 Blank Array Initialisation Size This new version of the Master I O program was made available to the 2 and 3 year engineering students who often used the IC laboratory facility Intriguingly corruptions occurred again Looking at the patchnames txt file there were missing I O addresses and incomplete usability data Testing on operations of shutting down and starting up were done and when the IO Manager was shut down during the remapping phase remapping incomplete corruptions for the patchnames txt file reoccurred This problem was solved by reading a separate text file with fixed data and replacing the missing data in the patchnames txt file each time IO Manager would start up However it was decided that doing so would prolong the already long waiting time of loading the IO Manager and would be tackled in a different manner It was decided to have a large indicator to be shown next to the stop button on the IO Manager interface to warn users not to stop the
62. o the left ground terminal and terminals 3 and 4 are referenced to the right ground terminal shown in figure 44 below by commoning all the grounds transmission of data is possible Other Drops To Host or Recommended Wiring Impimented Wiring Figure 41 Interconnection wiring Devices 1997 The 6BWin program allowed for the configuration and testing of the analog and digital devices as such this program was used as a tool for basic commissioning tests As these devices would be used by a higher level program IO Manager vi the Labview program was 42 setup and configured to allow the usage of the new 6B configured devices Readings and current changes were shown in the process of testing and the 6B series devices 5 2 Other Components Several other components have been added onto the I O control board in order to have the panel to ready for powering and wiring connections to the patch panel As shown at the grey terminals in Figure 45 below where analog terminal connection AA 1C to AB 12C have been commoned 16 fuses 0 1A were placed in line for the analog I O devices for protection shown in Figure 45 as black fuse holders down from the 32 fuses in the older panels The reduction in numbers of fuses placed into the I O board was due mainly to the reduction in the number of analog I O modules and sockets in the new panels compared with the old Most of the time no more than four of each type of analog input or outputs were
63. onductor sizes were 1mm Figure 36 Most parts of the power board run at a no higher than 16Amps Power drawn from the main switch board is less than what is actually available 25Amps Hence wire sizes from the main switch to the protection devices can be adjusted to suit the load of no higher than 16Amps with 9Amps to spare which can go to a sub power circuit if the need arises 34 Figure 34 Conductor Sizes Figure 35 Earth amp Neutral Bars Certain Neutral wires are in orange and light blue colours These however are not in the standard of AS NZS3000 and should be black in colour Figure 37 This was due to cable sizes not being available and would not have been able to be bought and shipped in time for the end of the project Hence it was decided to use these colours as a temporary wire to give a clear indication of where the neutral wire will have to run before the shipping of the new multi core cables arrive Apart from these wires the power board itself is complete However the power board cannot be cleared for powering up as grounding for the box emergency stop buttons main switch and isolation of multi core cable leading to the patch panel is not yet complete These issues are to be resolved by John Boulton as grounding of the box requires unique clamps to secure the earth lines main switch and emergency stop buttons require drilling of the power box or cutting of thick metal and isolation of multi core cable is depende
64. placed nor configured for the panel The PLC had just been installed and programmed into the network and had not been tested 1 3 Objectives The project would help the IC laboratory facility move towards an ultimate goal of having a new panel up and running The project was aimed towards the upgrade of the IC laboratory facility with the addition of a PLC into the new panel which is being set up in the IC laboratory facility Areas have been left open for upgrades and work to be done The upgrade would include both hardware and software improvements to the IC laboratory facility the following areas were to be worked upon 1 Labview Master I O There is a need for the improvement and debugging of the Labview program Master I O which needed to be corrected and improved upon It was a desired aim for the Labview program to be revamped Due to the lack of time and the due to the complexity of the Labview program significant documentation for the Labview program was made in preparation for future users to be able to easily revamp the Master I O program 2 Power Board Bottom Box There was a need to generate a new wiring diagram which would improve and replace the previous wiring diagrams allowing users to easily understand and be able to set up the power board This included gathering and preparation of the correct documents for the new hardware and size types of wires for the power board following this the wiring of the power boar
65. precision resistors at the 2 pin terminals below the module terminals for analog input devices shown in figure 3 Power the board and ensure that there is sufficient power 5V at the power terminals of the board closest to the Ethernet cable 71 11 7 Digital Devices e Iw TUE The following procedures should be followed when configuring the analog devices Connect the Ethernet cable to the digital board you are configuring as shown in section 1 4 Switch the configuration jumper to common pins C amp B Ensure that no other devices are connected to the board this may cause bugs Power the board at points GND and 5V as shown in figure 4 RS 485 Input Connector from previous backplane RS 485 Output Connector 50 Pin to next backplane al subsequent Connector backplanes must be RS 485 interface only Figure 59 6B50 1 digital board 5 Open the Sixb program 6B WIN this leads you to a screen for COM port selection select the COM port that you are connecting the device s to as shown below 6B WIN SELECT COM PORT x DEE r COM 2 COM 3 COM 4 Ey Folders EZ 2 manlDesktop SBWIN be PE M 3 BK Com4 com 4cg COMA4BK Com5 com_5 cfg COM_5_BK 5 B A S B amp s com 6 g COM 6 BK Com7 comJ cfg COM7 EK Comp COM 8 BK connection cvi cvi cviz devs Doft devs 1 dfg COM 6 COM 7 COM 8 CANCEL HELP
66. r 4 6 interface coiere o bo spi T est a ETEEN 19 Figure 11 Activation Table Interface kA 20 Figure 12 Activation Table connected to Activation Table vi in loop system 21 Figure 13 Test point readings cci cient ecce etaed ear rta re de cann a eere Pe agna eR DER dca des 22 Figure 14 Normal procedure corruption eese enne nnne ener nnns nns 22 Figure 15 Jumbled sequence of combining data 23 Figure 16 Murdoch Campus Adjusted Sequence rrnnrorrrrrrrsrannnnnnrvnnrrrsrnnannvnvrnnrrrsrannnnnnrsnnssne 23 Figure 17 Corrupted Patchnames Cvt 24 Figure 18 Blank Array Initialisation Size 24 Figure 19 Remapping warning indicator eese 24 Figure 20 Path toRubbieb Dt 25 Figure 21 Patbtobatchnames Dt 25 Figure 22 Activation Table Adjustment sess nins 26 Figure 23 Activation Table True Address Column 26 Figure 24 Various COM port settings eene n nnne nnns 26 Figure 25 Maximum number of Addresses sessi nnns 27 Figure 26 loop 4 configured oatchnames Cvt 27 Figure 27 Single line diagram sesenta nenne nnns 28 Figure 28 Semi improved wiring diagram cccccccessessssecececesesseseaeceseesseesesesaeeeeeessesseseaeees 29 Figure 29 Implementation of Isolation Switch 29 Figure 30 Old Thyristor DAC 315 C naa a G 32 Figure 31 New Thyristor IDAC2161 a aaa 32 Figure 32 Control modes and wave form of the Thyristors Shimaden
67. rent Inputs Devices 1997 39 The I O modules in the previous panels have an integration time of 50ms which may not be as desirable due to possible interferences with the power line frequencies in Australia These integration times will have to be altered as further discussed in the Future Direction section 5 1 1 1 2 6B21 Isolated field configurable analog output The 6B isolated configurable analog output devices have been configured to 0 to 20mA and 19 2k baud rate to maximise information transmission rate The slew rates for these analog modules are set to immediate The output range for these modules is selectable between 0 to 20mA and 4 to 20mA with a digitally controlled isolated current loop output to a resolution of 12bits The 6B21 module provides output protection of 240Vrms and 1500Vrms protection for the controller Devices 1997 Additional protection is available from the current flow being read back by an on board isolated voltage to frequency converter whose frequency is proportional to the loop current Devices 1997 This frequency signal is read back to a microcontroller through an optical isolator where the frequency signal is scaled and returned to the host computer Devices 1997 5 1 1 2 Digital The 6B series digital system in the IC laboratory facility utilises two 6B50 1 boards per I O cabinet 2 panels which are connectable via a 50 pin ribbon cable to two 24 slotted SSR racks One is for inputs and
68. ristors in the previously set up power boards have basic features of zero voltage switching adjustable power supply and current capacity of 20 100 Amperes shown in figure 30 The new Thyristors have same features as the old one convenient mode settings zero voltage switching or phase angel control soft start slow rise and slow fall function as shown in figure 31 below 31 Figure 28 Old Thyristor PAC 15 C Figure 29 New Thyristor PAC 16 4 2 1 1 Technical Review Control Modes Thyristors use different control modes producing different wave forms Information on the different types of control modes are documented in figure 32 The main advantage of zero voltage switching control which is currently used in the old control board set up is the lower cost due to the fewer Silicon controlled rectifier SCR and having less noise as compared with the phase angle controlled Thyristors In the case of the IC laboratory facility zero voltage switching control mode is being used and as such on the new Thyristors when they are powered Moving Coil Heating Ele Output Wave Form Deflection ment Capacity 10 Output 50 Output Continuous Very Small A yx Phase Angle Control P Low Output Zero voltage Large Deflection Smell Ay Arr o A Aw NAN AN Ay Ay Av ran pea si 1 cycle ON and 9 1 cycle ON and 1cycle 9 cycle ON and 1 Conia cycle OFF OFF continuously cycle
69. s System is ready to be used However having plugs and socket will provide more practicality and convenience to student users The Profibus PA instruments will also require better containers for the storage of liquids and pressured gas liquids for usage in control systems set up by the users in the IC laboratory facility These instruments will also require some calibration before usage in a proper control system 49 7 Future Directions The future directions of this project are important to the completion of the total upgrading of the IC laboratory facility as there are many viable options and possible improvements to help the IC laboratory facility run at its full capacity The following sections will cover several recommendations for future directions to be taken under serious consideration with regards to the upgrade and development of the IC laboratory facility 7 1 Revamping Labview server program The revamping of the Labview server program is still a major concern of the upgrading of the IC laboratory facility Due to the prioritisation of getting the 4 panel up and running the program has gained some minor upgrades and debugging however a total review and revamping of the program is required Block diagrams on the Labview program have been created to help future users quickly grasp the major ideas of how the Master I O server program functions The block diagrams are shown in the appendix C 4 pages and will be available in the EngSh
70. s input and out signal connection to the patch panel In the beginning the I O control board was assumed to have the correct components clearly assembled onto the board However during the process of commissioning the I O control board and configured it for the Labview program IO Manager certain components were found to be incorrectly placed and wired Thus additional work had to be done to get the board ready for connected into the power board for running 5 1 6B System The Analog Devices 6B product family consists of backplanes digital boards and analog modules which allow for direct communication between the server and the different I Os in the field The 6B system is used to deal with remote I O removing the need to use point to point wiring directly to the server computer The 6B devices use a serial communication specifically RS 485 to communicate between 6B devices In the IC laboratory facility these communication lines are wired using cables which are plugs into a RS485 serial card in the computer shown in figure 39 Where the Labview program can use this RS485 serial card for communication to the I Os and 6BWin software allows for easy configuration of the various 6B series I O devices Figure 37 4 RS485 serial card 37 5 1 1 6B Series I O Devices The 6B series I O devices are highly configurable as they contain internal circuitry using microcontrollers and EEPROM to communicate with similar devices Up to 255 I O channels
71. seaaeess 52 Figure 54 COM port numbers isisi a S a E 53 Figure 55 New patch panel location back 55 Figure 56 New patch panel location front 55 Figure 1 6BP16 1 analog backolanel 68 Figure 2 6B50 1 digital Board meoin a a AN 68 Figure 5 Interdevice connecthon 69 Figure 3 6BP16 1 analog backolanel 70 Figure 4 6B50 1 digital board tarse iiron K A E NA NO EEES Si 72 1 Introduction The Instrumentation and control IC laboratory facility on the Murdoch Campus has been undergoing constant upgrade to provide student users with usability and to increased capability of the Instrumentation and control laboratory This document will discuss the various topics with regards to the project allowing readers to view the direction and improvements the project had made during the course of time The document will also explain in detail the technical aspects of the project The approach of the various problems improvements assumptions reasoning and analysis of the results from the actions that had been taken on each area of the project will hopefully give readers a clear understanding on how the project unfolded 1 1 Scope of Report The report will encompass any improvements and knowledge attained as the project unfolded The report will discuss the various objectives that were developed as the project progressed The report covers four main areas Labview programming Power board I O control board and the Profibus System There will be a techn
72. the other for outputs Similar to the other analog devices used in the IC laboratory facility the 6B50 1 digital board communicates using RS 485 to the next board or backplane in the network Similarly the digital I O boards use a configuration jumper shown in figure 43 where if placed on pins A and B configuration of the board is available and if placed on pins C and B only parameters such as input range data format and integration time are available for change The 2 LEDS CR1 and CR2 shown in figure 43 present on the board show the communication status where CR 1 provides information on transmission and CR2 flashes with the on board clock A fuse F1 on figure 43 helps to 40 protect the board from damage caused by short circuits and the shunt diode provides power reversal protection to the board Devices 1997 RS 485 Input Connector RS 485 Output Connector 50 Pin to next backplane all subsequent Connector backplanes must be RS 485 interface only Figure 40 6B50 1 Digital Board Devices 1997 5 1 2 Setting Up and Testing Details on configuration procedures are explained in the user guide However notable results and undocumented issues will be discussed in this section Upon configuration of the analog board it was noticed that additional modules placed in non configurable sections of the analog backplane produced interference with the configurable port It will be advised in the user guide to only configure on
73. this VI Or else this will lead to corruption of the PATCHNAMES txt File Address Ang Patch Name Set Value Actual Value Units Dig Patch State Com Avail Usability 175 as vs 180 180 181 181 182 182 183 183 192 192 193 193 194 194 195 195 The list of addresses in the True Address Column and the address header column in the Activation Table for the loop being configured contains the added I O address For the 6B digital board the digital address should be from 1 to 23 in the address columns 74 12 3 2 Configuration of Normal loop in IO Manager 1 Eja gt E GEN ka E ini 1 Quay a E ing this loop CO ALC system erte Four time ms Ia 3 3 j i e E A Loop Four state I 3 Tis case is normal operation case For Toop one here the Following Functions are done 1 Add Remove modules this VI block allows tl f modules into current list of used modules in jodule will not be read or written to and will E iber of modules in this port is 1 PATCHNAMES file change the this constant number of analogue madules is o eliminate the spaces at the end ort array Read Writ
74. un a SEARCH to ensure that all connected devices are present Any other issues review the Troubleshoot section 11 6 Analog devices The following procedures should be followed when configuring the analog devices 1 Ensuring that the Ethernet cable has been connected between the backplane and the server computer see 1 4 for connection information Take out the configuration jumper Place the analog module that is to be configured in the far left terminal next to the Configuration Jumper shown in Figure 3 Ensure that no other modules are on the board this may cause bugs Power the analog backplane at GND and 45V as shown in figure 3 69 RS 485 Input Connector v Data 1o et backplane af etur SuDtequen backplares must be RS 485 intertace only Figure 58 6BP16 1 analog backplane 6 Open the Sixb program 6B WIN this leads you to a screen for COM port selection select the COM port that you are connecting the device s to as shown below B WIN SELECT COM PORT x EEE pue ar Be L n Com4 com4 dg COM 4BK np comS fg COM_S_BK a x e rj fs ei PA amp Sa Fal Lay Lay Lay om 6 com6 cfg COM6BK Com7 com7 g COM7_BK Com8 a AN 3 A z amp E a COM 8 BK connection cvi cvi cvi2 devs_O cfg dee L cfg m s 2g devs_a cia ders Acht d r
75. uo 50 ue uw and neutral ba have bee wed c e right of tre bur he pewer bos orandan no when LAam 18 re r he top ofthe patch panel aid 30A and 108 wa at the of the panch pune DESIGNED MURDOCH UNIVERSITY INSTRUMENTATION AND d IG ICE LAB ELECTRICAL PANEL WIRING DRAWING NUMBER 701339E LEGEND 60 10 4 Appendix C Master I O Block Diagrams Part 1 4 Available Electronically Open Master I O VI Legend T Starting point in page CT Sequence Local RS gt Er mate peter gv global variable Inside vi Sequence Structure iv local variable i indicator v visibility ctri control d delay Sequence 0 i sequence state of sequence Leit gt i AT RS485 2 board Brings up Ver Title screen gt ver gt El c Tltle ctr Title 2500ms wait Sequence 3 Master Screen is brought up a number of options are available to be chosen c F v Error Code Set Preferences Get ports IO Manager Configuration loop and Shutdown Appended Path i v Brings up Prefs Screen to be adjusted Sequence 1 ctrl Set Preferences Open Datalog Prefs path in c Current vis Path gt Strip Path Strip path gt Build Path d x Tj PrefeType d EM tei Config Relative Path H al d te Prefs T Deg cese Fie 5 Relative Path ES e Ls P lt i a isi lt ree Return Closes Prefs screen a PrefsType e T Prefsrype Records 7 S g
76. xt Corruption iere cerdo et trei oia ko ed eo dne e aces 21 3 3 Read Write Previous I O Listings enhn 25 3 4 Setting up Loop 4d cucine needs RES aES EE AEN ebe AEE EEN 25 3 5 Labview Conclusion eeecceeeseceesceceeaceceeeeeesaeeeeaaeceeeeeceaeeeeaaeeeeaeeseeeeeaeeseaaeeneaeeees 27 Power Board essi 28 4 1 Wiring Diagram iiie estote Leeda este idee eani EEGEN aa 28 4 2 Components Changes sss nnnn inanes nennt rasa nass esee nena n nis 31 4 2 1 New NN NEE 31 4 2 2 New 24VDC Power Supplies 33 4 2 3 Transformer 5 Primary Circuit Breaker Current Rating 33 4 3 Wiring Up the Power Board 34 4 4 Power Board Conchusion enne nnne nennen nnne nent 36 110 Control BOal d eine Ec or etr LED eee De DE EIL DNI DI SLE CILE 37 51 OB System oet p Er E NR pe eee 37 5 1 1 6B Series I O Devices oo ccecccesssssssccecceececsssenececceecesseseneceesecceesesenteeeesecees 38 5 1 2 Setting Up and Testing i oot tee tex cede eade REENEN 41 5 2 Other eeler 43 5 3 1 0 Control Board Conchusion eee nme enne ens 44 6 10 Hiel le 45 6 1 Technical Review Profibus DP and PA 45 6 2 System Setup in IC laboratory facility eese 45 6 3 Termination EE 46 6 4 NIE Explorer utei t tete te enn ape lee a eds 47 6 5 Ln ACID 48 6 6 Profibus System Conchuslon esses ennemis nnns 49 Future Directions ce t iet te te estt rte ie e cot irt Nettstedet 50 7
77. yone who may have to construct the board or indentify possible issues These important details are as listed below 1 1 9A amp 1 9B are multi core wires that are used to connect the power supply board with the patch panel s power connections There will be an isolation switch between these wires and the actual power supply socket Figure 29 i Power Control Board Patch Panel AC Isolator Switch Figure 27 Implementation of Isolation Switch 29 10 11 24VDC drawn for the relay coils is taken from the control board s 24VDC coming from T4 Power Supply 4 There is a reduction to four 240VAC sockets for the new patch panels 2010 11 09 instead of the original six 240VAC sockets Thyristors A amp B are running straight from the mains They use the circuit breakers on the power board as Thyristors used in the power board do not have over current are not connected via the Earth Leakage Circuit Breaker ELCB this may be due to the sensitivity of ELCB being able to detect tiny amounts of current changes in the Thyristors circuitry which is likely to occur each time the Thyristors is set to a different voltage Thyristors A is controlled by the ESA DO 04 and Thyristors B is controlled by ESB DO 04 110VAC power sockets are named C B1 4 on the patch panel and will use a yellow power socket cap 240VAC Sockets will use a blue power socket cap and will be labelled ESA DO 06 to ESA DO 12 or ESB DO 06 to ESB DO 12

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