This technical note covers the integration of a DeltaV Process System with SquareD Omni6 MCC using Modbus TCP/IP and the Virtual IO Module.
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:
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.
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:
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:
To follow are the system hardware and network configuration settings for the Modbus TCP/IP network between DeltaV and the Omni6 MCC.
The DeltaV Virtual IO Module was set up as the Modbus Master with the following settings:
Protocol | ModbusTCP |
Virtual DeltaV Modules | 57-60 |
IP Address | 10.10.10.20 |
Hardware Revision | V3.3.2 |
Four Modbus TCP/IP Slave devices were installed on P01 of C57 as RTU TCP devices using standard port 502.
The RS-485 Network was configured as follows:
Modbus Device | Modbus Node Address |
PowerLogicCM4000 | 2 |
FVNR MLPD | 3 |
Schneider Electric ATV58 VFD | 4 |
FVNR MMS | 5 |
ATS48 | 6 |
The Ethernet Network was configured as follows:
Ethernet TCP/IP Device | Ethernet TCP/IP Address |
EGX-400 Gateway | 10.10.10.10 |
PowerLogicCM4000 | 10.10.10.11 |
Schneider Electric ATV58 VFD | 10.10.10.12 |
Advantys I/O | 10.10.10.13 |
Momentum M1E CPU | 10.10.10.14 |
PC Touchscreen | 10.10.10.15 |
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.
DeltaV Control Template and User Interface complete description is included in the document: Schneider-vA_M_MTR_ATV58.doc.
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.
The operator interfaces with the general module parameters using the faceplate. The display name for this template is the standard DL_fp.>
The operator interfaces with the general module parameters using the faceplate. The display name for this template is M_PID4_fp.
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.
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.
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.
DeltaV Control Template and User Interface complete description is included in the document: Schneider-vA_M_MTR_21FVNR.doc.
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.
The operator interfaces with the general module parameters using the faceplate. The display name for this template is the standard DL_fp.
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.
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.
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.
Parameter Name IN | Type | Category | Wired to | Register | Description |
CURR_PH_A | External Ref | I/O | -- | R1000 | MCC Current, Phase A |
CURR_PH_B | External Ref | I/O | -- | R1001 | MCC Current, Phase B |
CURR_PH_C | External Ref | I/O | -- | R1002 | MCC Current, Phase C |
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.
Parameter Name OUT (Displayed) | Type | Category | Input Range | Output Range |
MCC_KW | Floating Pt | I/O | 0-200 |
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.
Data load testing was performed for the installed system. The testing included documentation of the following DeltaV performance parameters:
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
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.
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:
Equipment Description | Altivar ATV58 Drive with Ethernet Modbus TCP/IP communications card. | CM4000 with ECC21 Modbus TCP/IP communications card | Advantys STB Distributed I/O | Momentum M1E CPU | Touchscreen thin client |
Manufacturer | Schneider Electric/Telemecanique | Schneider Electric/Square D Powerlogic | Schneider Electric/Telemecanique | Schneider Electric/Modicon | Grayhill |
Tested with deltaV System? | YES | YES | YES | YES | YES |
Model Name and/or Number | ATV58 with VW3A58310U Card | CM4000 & ECC21 | STB NIP 2212 | 171CCC98020 | 01YY5021-2 |
Configuration Software | DeltaV Explorer and MYNAH Technologies VIMNet Explorer | ||||
Data flow stream exceptions | None | None | None | None | None |
Dip switch configuration | None Required | None Required | None Required | None Required | None Required |
Equipment Description | Ethernet Modbus TCP/IP Gateway | Altivar ATV58 VFD with Modbus RS485 communications | CM4000 with Modbus | Motorlogic Plus SSOLR with Modbus RS485 communications |
Manufacturer | Schneider Electric/ Square D Powerlogic | Schneider Electric /Telemecanique | Schneider Electric /Square D Powerlogic | Schneider Electric /Square D |
Tested with DeltaV System? | YES | YES | YES | YES |
Model Name and/or Number | EGX-400 | ATV58 with VW3A58303U Card | CM4000 | Motor Logic Plus |
Configuration Software | DeltaV Explorer and MYNAH Technologies VIMNet Explorer | |||
Data flow stream exceptions | None | None | None | None |
Dip switch configuration | None Required | Device Address; see ATV58 manual | None Required | None Required |
Equipment Description | Motorlogic Plus MLPD with Modbus RS485 communications | Motorlogic Plus MMS with Modbus RS485 communications | Altivar ATS48 Soft Starter with Modbus RS485 communications | |
Manufacturer | Schneider Electric /Square D | Schneider Electric /Square D | Schneider Electric /Telemecanique | |
Tested with DeltaV System? | YES | YES | YES | |
Model Name and/or Number | Motor Logic Plus with 9999MLPD | Motor Logic Plus with 9999MMS | ATS48 | |
Configuration Software | DeltaV Explorer and MYNAH Technologies VIMNet Explorer | |||
Data flow stream exceptions | None | None | None | |
Dip switch configuration | None Required | None Required | None Required | |
DCS: | Distributed Control System |
EDS: | Electronic Data Sheet |
FAT: | Factory Acceptance Test |
FVNR: | Full Voltage Non-Reversing Motor Starter |
FVR: | Full Voltage Reversing Motor Starter |
IMCC: | Intelligent Motor Control Center |
IQ: | Installation Qualification Protocol |
MLP: | Motor Logic Plus |
ODVA: | Open DeviceNet Vendor Association |
PCS: | Process Control System |
SSOLR: | Solid State Overload Relay |
VFD: | Variable Frequency Drive |
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