This white paper covers the integration of a DeltaV Process System with SquareD Omni6 MCC using Modbus TCP/IP and the Virtual IO Module.

Executive Summary

In continuous and batch process applications the Motor Control Center (MCC) is the integration point for the electrical distribution and process control systems. The MCC is a critical interface point for system design and performance.

Traditionally MCC contained only electromechanical components and all connections were hardwired. Advances in solid-state technology has ushered in a revolution with intelligent motor control devices that can be programmed to do more than just turn a motor on and off. These intelligent motor control devices include variable frequency drivers, solid-state starters, and electronic overload relays. These intelligent motor control devices provide a great deal of data, but transforming these islands of data into useful information presents a major challenge.

Modem communication networks have brought new possibilities for advanced monitoring, diagnostics, and integration with Digital Process Automation Systems. Of the communication networks available, Ethernet offers the greatest opportunity for simplifying wiring, integration with plant information systems for start up and trouble shooting, and efficient integration with the Digital Process Automation System.

This document documents the integration of Emerson’s DeltaV Digital Process Automation System, using PlantWeb Architecture and Technology, with Schneider Electric’s OMNI model 6 MCC system using Transparent Ready Architecture and Technology. These two systems were integrated using the Modbus TCP/IP protocol over Ethernet and RS-485.

The deliverables from this document include integration standards and sample configurations that are free and open source for use on any projects worldwide. These documents can be obtained by request from support@mynah.com and include:

• DeltaV Omni6 Integration White Paper including hardware, software application configuration.
• DeltaV System Configuration Database Export and Graphics (DeltaV FHX and Operate format)
• Sample System Architecture Drawing (Microsoft Visio 2000 format)
• Sample DeltaV Configuration Standards Documents (Microsoft Word format)
• Sample Installation Factory Acceptance Test Report and Installation Qualification Document (Microsoft Word format)

System Description and Architecture

The test system is installed at Experitec’s headquarters in Chesterfield, Missouri, USA. The following system components were used for to test integration between the DeltaV Digital Process Automation System and the OMNI6 Enhanced Motor Control Center (intelligent motor controlling devices) using the Modbus TCP/IP protocol over Ethernet and RS-485.

Schneider Electric Omni6 Motor Control Center

• OMNI Model 6, double section, 20inch MCC configured with an incoming main circuit breaker; PowerLogic Circuit Monitor; (2) ATV58 VFD's; (2) Overload Relay /combination starter (FVNR, FVR); EGX-400; Advantsys I/O; Touchscreen PC; and ATS48.
• The OMNI MCC was configured with a Modbus TCP/IP network over RS-485 and Ethernet connected to hubs with a single port upstream connection to the DeltaV System via the Virtual IO Module.

Omni6 MCC Cabinet

Emerson DeltaV Process Automation System

• DeltaV Process Automation System Software v7.2
• DeltaV ProPlus Engineering/Operations Node on Dell Precision workstation
• DeltaV MD Controller, Power Supply, and 4-Wide Controller Carrier
• MYNAH Technologies Virtual IO Module with Modbus TCP/IP Master Driver License v1.15

DeltaV MD Controller and Virtual IO Module

Modbus TCP/IP Network Layout

Modbus TCP/IP over Ethernet:

The MYNAH Technologies Virtual IO Module provides Modbus TCP/IP connectivity to the Ethernet components in the MCC, and functions as the Modbus Master. It provides the signals from the Modbus TCP/IP to the DeltaV Controller as native DeltaV IO Registers. All Ethernet components were connected to an Ethernet switch mounted in the top MCC bucket. Components connected directly via Ethernet to the switch included:

• PowerLogicCM4000 with ECC21
• Schneider Electric ATV58 VFD
• Powerlogic EGX-400 Gateway
• Schneider Electric Momentum M1E CPU
• Grayhill Touchscreen PC
• Advantys I/O with Ethernet communications Module

Modbus TCP/IP Network Switch and Ethernet/Serial Gateway

RS-485 Modbus:

The Modbus RS-485 Network was connected to Port One on the EGX-400 Gateway. The Virtual IO Module communicated to the Modbus devices via the Ethernet TCP/IP port on the EGX-400 Gateway. Components connected directly via Modbus RS-485 to the EGX-400 included:

• PowerLogicCM4000
• Schneider Electric ATV58 VFD
• FVNR starter unit with Motorlogic Plus SSOL and MLPD display unit.
• FVNR starter unit with Motorlogic Plus SSOL and MMS display unit.
• Powerlogic EGX-400 Gateway
• Soft Starter ATS48

System Hardware Configuration

To follow are the system hardware and network configuration settings for the Modbus TCP/IP network between DeltaV and the Omni6 MCC.

DeltaV Virtual IO Module - Modbus Master

The DeltaV Virtual IO Module was set up as the Modbus Master with the following settings:

Four Modbus TCP/IP Slave devices were installed on P01 of C57 as RTU TCP devices using standard port 502.

Modbus TCP/IP Slave RS485 and Ethernet Devices

RS_485 Modbus:

The RS-485 Network was configured as follows:

• Modbus networking using a trunk/drop line topology
• 19,200 kbaud, 8 data nits, 1 start bit, 1 stop bit
• Modbus RS-485 devices connected to Port 1 of the EGX-400 gateway

Ethernet TCP/IP with Modbus:

The Ethernet Network was configured as follows:

• Ethernet networking using home runs to switch located in EGX-400 Unit
• Data rate set to 10Mbps
• A single Ethernet connection connects to DeltaV via the Virtual IO Module.
• Subnet Mask set to 255.255.255.0
• Gateway/Router IP address set to 0.0.0.0

DeltaV System Software Configuration

The DeltaV “Virtual Serial Cards”, DeltaV Control Modules, and DeltaV Operator Faceplates and Detail displays were configured using the Schneider Electric device communication information as shown below.

A wealth of diagnostic and equipment health data is included in each Omni6 device. In general, all available information was read into DeltaV “Virtual” serial card registers. In general, the DeltaV Module Control Templates were adapted from the standard DeltaV module library and used the operational parameters as required to adequately control and monitor the device only. The complete DeltaV configuration is available for download on the MYNAH website. The modules included in the sample configuration are open code and can be modified or expanded as required by the user.

ATV58 Variable Frequency Drive

DeltaV Control Template and User Interface complete description is included in the document: Schneider-vA_M_MTR_ATV58.doc.

ATV58 Control Module

The control module executes in the DeltaV controller and provides regulatory control functions for the ATV58 motor control. The name of the module template is MTR8_21A.

ATV58 Motor Control Faceplate

The operator interfaces with the general module parameters using the faceplate. The display name for this template is the standard DL_fp.>

ATV 58 PID Faceplate

The operator interfaces with the general module parameters using the faceplate. The display name for this template is M_PID4_fp.

ATV58 Motor Detail

The specific details and diagnostics of module are on the Detail display. The Detail display consists of eight main tabs (Interlock, Permissive, Process Actions, Force Setpoints, Variables, Alm/Lim, I/O, and Diagnose). The detail display name for MTR8_21_ATV58 is DLSC_dt8.

ATV58 PID Detail

The specific details and diagnostics of module are on the Detail display. The Detail display consists of eight main tabs (Interlock, Permissive, Process Actions, Force Setpoints, Variables, Alm/Lim, I/O, and Diagnose). The detail display name for this template ATV58_VFD_PID is M_pid4_dt.

ATV58 Graphics Dynamo

The Dynamo is an object, link, or group of custom-built objects, such as pumps and motors, stored in a library used to create pictures in the Graphics Studio program. This is the Dynamo for the MTR8_21_ATV58. The Dynamo for the ATV58 resides in a Dynamo Set called Schneider.

FVR and FVNR

DeltaV Control Template and User Interface complete description is included in the document: Schneider-vA_M_MTR_21FVNR.doc.

FVR and FVNR Control Module

The control module executes in the DeltaV controller and provides regulatory control functions for the FVR and FVNR motor control. The name of the module template is MTR8_21A.

FVR and FVNR User Interface

The operator interfaces with the general module parameters using the faceplate. The display name for this template is the standard DL_fp.

FVR and FVNR Motor Detail

The specific details and diagnostics of module are on the Detail display. The Detail display consists of eight main tabs (Interlock, Permissive, Process Actions, Force Setpoints, Variables, Alm/Lim, I/O, and Diagnose). The detail display name for MTR8_21_ATV58 is DLSC_dt8.

FVR and FVNR Graphics Dynamo

The Dynamo is an object, link, or group of custom-built objects, such as pumps and motors, stored in a library used to create pictures in the Graphics Studio program. This is the Dynamo for the MTR8_21_FVNR. The Dynamo for the ATV58 resides in a Dynamo Set called Schneider.

CM4000 Power Monitoring - DeltaV Control Template and User Interface

The CM4000 Power Monitor was configured to monitor Real Total Power, and Current on Phase A, B, and C of the MCC as part of the project. Additional variables are available in the CM4000. A complete list can be found in the product manual.

Any of the variables listed for the CM4000 can be configured as Analog Inputs if desired to allow for standard alarming and faceplate. The Real Total Power variable was configured as an Analog Input as part of this project, to test the alarming functionality.

CM4000 - User Interface and Dynamo

A Dynamo is an object, link, or group of custom-built objects, such as pumps and motors, stored in a library used to create pictures in the Graphics Studio program. This is the Dynamo for the CM4000 used in this project. The Dynamo resides in the Dynamo Set called Schneider.

The Dynamo contains the references for MCC Total Real Power (KW) Analog Input information and the Phase A, B and C Current values from the CM4000.

DeltaV Performance and Load Testing

Data load testing was performed for the installed system. The testing included documentation of the following DeltaV performance parameters:

• DeltaV Controller free time
• DeltaV Controller free memory

Additional Virtual IO Module with the Modbus TCP/IP Driver load testing and performance testing results is found on MYNAH Technologies website at www.mynah.com/products/vim

Data Model and Test Setup

The standard control modules were exercised per the control strategies and the design documents. Changes to the Output DST were monitored and then compared to subsequent changes on the Input DST at the DeltaV Control Module. Please see the following data structure model for the test and communications.

Test Results

Please see the white paper on DeltaV Virtual IO Module Network Performance Testing for complete documentation of Modbus TCP/IP communications IO updates and port scan times benchmarking, on MYNAH Technologies website at www.mynah.com/products/vim

DeltaV Diagnostics were monitored for critical performance data:

• DeltaV Controller Free Time - 97% via DeltaV Diagnostics, with all modules running(total of 19 modules)
• Deltav Controller Free Memory - 15325669 Bytes

Omni6 MCC Device Configuration Reference

Modbus TCP/IP over Ethernet Devices

Definitions