Sequence of operation IPS 4000 secondary variable speed control File No: 90.96 Date: february 21, 2013 Supersedes: new Date: new
sequence of operation ips 4000 2 list of abbreviations: adj: Field Adjustable ai/ao: Analog Input/Analog Output di/do: Digital Input/Digital Output bas: Building Automation System dp: Differential Pressure Sensor hmi: Human Machine Interface ips 4000 automation system The ips 4000 has one (1) control panel with the following functionality: One ai per zone dp/t/flow transmitter 4-20 ma One ai for dp or Flow transmitter 4-20 ma for pump run-out protection One di per dp switch One di for remote connection for start/stop One di per pump for fault signal One di per vfd for fault signal One d0 for alarm horn (buzzer) One di for alarm silencer One a0 per vfd for speed signal One d0 per pump for status One d0 for pump/motor/vfd alarm One d0 for zone dp/t/fow transmitter alarm One d0 for general system alarm One d0 per vfd automatic bypass One digital communication port for bms One digital communication port for graphical hmi One digital communication port for vfd communication. operation All pumps must be set in auto mode for the plant to work properly. However, any individual pumps can be set to hand or off mode. Any pump in hand or off mode won t be operated by the automatic sequencing of the plant in any mode of operation. Any pump placed in hand mode will start immediately as long as the ips is on. 1 general sequence 1.1 The standard ips 4000 is supplied with a 4" pgd touch Human Machine Interface (hmi). 1.2 When the ips 4000 system is set to local start, the ips will turn on as soon as the ips switch is set to enable. 1.3 During both settings (remote and local start), the ips will turn off when the ips switch is set to off. 1.4 The schematic of the system is displayed on the hmi showing all secondary pumps variables on the screen. 1.5 Monitor single zone differential pressure transmitter (up to 12 transmitters as an option remotely installed by contractor). 1.6 Compare each value to its set-point. The zone that has deviated the most from its set-point shall be set as the controlling zone (see detailed specifications for multizone control). 1.7 pid control algorithm for pump speed control in plc. 1.8 Automatically disable any zone differential pressure signals that are not within limits and alert the operator of a possible transmitter failure. 1.9 Motor speed will be switched to manual at speed set by the operator if all transmitters fail. 1.10 Manual vfd bypass or auto bypass option. 1.11 Manual and automatic alternation of secondary pumps based on hours of operation. 1.12 Alarms shall include transmitters failure, pump/motor/ drive failure, pump fatal alarms, and general system failure. 1.13 Run-out protection on pumps based on dp or flow sensor. 1.14 Three levels of password protection on operator interface. 2 zone sensor control for secondary pumps 2.1 The ips 4000 can operate up to six pumps. One pump can be selected as stand-by. 2.2 When the ips is on, the shall start the lead pump. 2.3 If lead pump fails to start, the next lag pump shall automatically start and an alarm will be displayed showing pump fault. The alarm is sent to the bas as well. 2.4 The ips 4000 shall be capable of alternating the lead and lag variable pumps manually (at hmi), and automatically based on hours of operation. 2.5 The ips can monitor the dp or temperature of up to 12 zones. If there is only one zone enabled, it becomes the active zone. When there are two or more zones and all of them are enabled, the zone with the most negative error becomes the active zone (if all the errors are positive, the zone with the smallest error). The zone dp or temp is referred as zone present value (pv). Each zone has an adjustable setpoint (sp). Zone error is defined as: error = pv - sp. If a zone is disabled, its error will default to 999.9.
ips 4000 sequence of operation 3 2.6 When the system valves control is enabled, the ips 4000 shall obtain the opening (in %) of the system valve with the maximum opening from the bas. The control will modulate the active zone setpoint in order to maintain the system valve with the maximum opening at the system valve opening setpoint (adj.). If the valve s opening is less than the setpoint, reduce the active zone setpoint and vice versa. 2.7 The speed of the pumps is controlled to maintain the active zone differential pressure at setpoint. If the active zone pv is under the setpoint, the speed of the pumps shall increase. If the pv is over the setpoint, the speed shall decrease. 2.8 Automatically disable any zone differential pressure or temperature signals that are not within limits and alert the operator of a possible transmitter failure. Should all sensors fail, the pump speed will be set to 95% (adj.). 2.9 The ips 4000 shall be capable of staging and de-staging pumps based on adjustable bep speeds. If the pump speed is over the bep stage-on speed for the duration of the stage-on delay (adj.), start the next lag pump. Similarly, if the pump speed is under the bep stage-off for the duration of the stage-off delay (adj.), stop the last lag pump. 2.10 The lag pumps shall run for a minimum of 15 minutes (adj.) once started. 2.11 ips 4000 shall have run out (eoc) protection of the pumps using either a dp sensor or a flow meter (user selectable). When the eoc protection is enabled, the ips 4000 will start the next lag pump if the differential pressure from the dp sensor is greater than the eoc dp (adj.) or if the value from the flow meter is greater than the eoc flow (adj.) multiplied by the number of pumps running. If the selected sensor is out of range, disable the eoc protection and display the alarm on the hmi. 2.12 If the pump dp switches are enabled, the ips will use their signals (di) as pump operation confirmation. If the dp switches are not enabled, the vfd feedback is used as pump run confirmation. 2.13 Shall the plc loose the pump run feedback (whether dp switch as digital input or vfd signal) the ips will generate a Pump Run Feedback Alarm and lock the pump out of operation until 2.14 The ips will continuously monitor the vfd status, shall the vfd raise its fault signal, the ips will generate a Pump vfd Fault Alarm and lock the pump out of operation until 2.15 Shall the plc loose communication with a pump vfd (due to loose or broken wire, vfd not properly configured or powered off), the ips will generate a Pump Communication Alarm and lock the pump out of operation until 2.16 The pump auto bypass can be enabled or disabled. If it is enabled, when a pump fails (due to no run feedback, vfd fault or communication), the ips will determine if there is another pump available to replace the faulty pump. If there is no pump available, a digital output will mechanically bypass the vfd and energize the pump motor directly. All pumps running at that moment will be bypassed. The bypass condition will remain until manually reset at the hmi. 3 sensorless control for secondary pumps 3.1 The ips 4000 can operate up to six pumps. One pump can be selected as stand-by. 3.2 When the operator selects sensorless control, the hmi hides the zone setup screens and shows the sensorless control setup screen with the following additional adjustable parameters: Design Head, Design Flow, Zero Flow Head, Head bep, Flow bep, Dead Band, Sensorless Map Adjustment Factor. 3.3 The ips 4000 reads Head and Flow from each vfd, in addition to current, power, and speed feedback. 3.4 When the ips is turned On all the duty pumps are started. 3.5 The ips calculates the total flow (Q) as the addition of the flow read from each running pump. The IPS uses the head read from the lead pump as the system head (H). 3.6 The pump speed and best efficiency staging points are controlled by embedded Armstrong algorithm to maintain the operation point (system head & flow) on the system control curve. 3.7 The lag pumps shall run for a minimum of 15 minutes (adjustable) once started. 3.8 If eoc is enabled, use Q instead of flow sensor. 3.9 The control monitors the flow of each running pump and if it deviates more than 20% off the average the system will issue an alarm. 3.10 If the pump dp switches are enabled, the ips will use their signals (di) as pump operation confirmation. If the dp switches are not enabled, the vfd feedback is used as pump run confirmation. 3.11 Shall the plc loose the pump run feedback (whether dp switch as digital input or vfd signal) the ips will generate a Pump Run Feedback Alarm and lock the pump out of operation until
sequence of operation ips 4000 4 3.12 The ips will continuously monitor the vfd status, shall the vfd raise its fault signal, the ips will generate a Pump vfd Fault Alarm and lock the pump out of operation until 3.13 Shall the plc loose communication with a pump vfd (due to loose or broken wire, vfd not properly configured or powered off), the ips will generate a Pump Communication Alarm and lock the pump out of operation until 3.14 The pump auto bypass can be enabled or disabled. If it is enabled, when a pump fails (due to no run feedback, vfd fault or communication), the ips will determine if there is another pump available to replace the faulty pump. If there is no pump available, a digital output will mechanically bypass the vfd and energize the pump motor directly. All pumps running at that moment will be bypassed. 5.2 alarm screens a Alarms with time stamp b Alarm help c Alarm history d Diagnostic indicating status (ok or bad) of plc, memory, network and communication e hmi and plc software version 5.3 setup screens (three levels of access) a Level 0 - No password, allows view only access b Level 1 - Allows modification of all parameters, except pump pid and bas setup. Allows restoring previously saved values c Level 2 - Allows modification of all parameters. Allows saving and restoring of all parameters 4 temperature control of modulating valve 4.1 If the temperature control is enabled, the ips 4000 will use one of the zone sensor analog inputs for a temperature sensor, and pump four analog output to control the modulating valve. 4.2 The valve position is controlled by pid to maintain the temperature at a setpoint specified by the user. 4.3 The valve output is selectable between 0-10 VDC or 2-10 VDC. 5 hmi screens 5.1 operator screens a Source of control: Local or remote b ips status: On/off c System overview graphic. This display adjusts to the selected configuration (i.e. number of pumps, piping configuration, number of zones) d Pump information: Running/Off/Alarm, hoa, Duty 1, Duty 2, Stand-by, etc. e Pump vfd information: Speed, amps, power, volts ac f All enabled zones present value, set-point, error and indication of which one is the active zone g Pump hours of operation 6 bas 6.1 The ips 4000 shall be capable of serial communication with the bas with any of the following protocols: Modbus RTU, BACnet MS/TP, BACnet IP, BACnet Ethernet and LonWorks. 6.2 The following points will be available through all protocols: a Remote Start/Stop b ips On/Off status c Pump information: Running/Off/Alarm, hoa, Duty 1, Duty 2, Stand-by, etc. d Pump vfd information: Speed, Amps, power, volts ac, Flow and Head. e All zones present value, setpoint and error. f Pump hours of operation. 6.3 The ips has the following signals available as hard wired: a Remote Start/Stop (di). b Pump alarm (do). c Sensor alarm (do). d General alarm (do).
ips 4000 sequence of operation 5
toronto 23 bertrand avenue toronto, ontario canada m1l 2p3 +1 416 755 2291 buffalo 93 east avenue north tonawanda, new york u.s.a. 14120-6594 +1 716 693 8813 birmingham heywood wharf, mucklow hill halesowen, west midlands united kingdom b62 8dj +44 (0) 8444 145 145 manchester wenlock way manchester united kingdom m12 5jl +44 (0) 8444 145 145 bangalore #59, first floor, 3rd main margosa road, malleswaram bangalore, india 560 003 +91 (0) 80 4906 3555 shanghai no. 1619 hu hang road, xi du township feng xian district, shanghai p.r.c. 201401 +86 21 3756 6696 armstrong integrated established 1934 armstrongintegrated.com tm