SPS CONTROL SYSTEM

For VECTOR VII DRIVES

USER MANUAL

GE Oil & Gas

Surface Pumping Systems
5500 S.E. 59th Street
Oklahoma City, OK 73135
Tel 405-670-1431
www.geoilandgas.com/artificiallift

Part Number 810520

Revision 2.0
November 2, 2011
Software Version 1.0.0
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SYSTEM OVERVIEW
This SPS System Controller will provide the following basic SPS functions:

Automated Pump Startup Control The Pump Startup Sequence is

automatically controlled based on a limited number of user inputs

I/O Monitoring for System Protection and Control Pump and System
Sensors are monitored and may be configured to shutdown the system
under abnormal operating conditions

Drive Speed and System Control After the Pump Startup Sequence is
complete, the SPS System Controller will control drive speed based on
one of several pre-defined control algorithms. A second PID Loop is
provided for control of auxiliary equipment such as valves.

STANDARD HARDWARE CONFIGURATION

SPS System Controller Mounted Inside of Drive Enclosure:

- Rockwell Automation MicroLogix 1100 Programmable Logic
Controller
- 10 Digital Inputs (120 VAC standard, 24 VDC optional)
6 Digital Outputs (Isolated Relay Contacts 5 to 125 VDC / 5 to
265 VAC)
8 Analog Inputs (4 to 20 ma standard, 0 to 10 VDC optional)
2 Analog Outputs (0 to 10 VDC or 4 to 20 ma)
- Modbus RTU Communications Port Used For Customer (SCADA)
Interface
- Ethernet Communications Port Used as Interface to the Drive
- Real Time Clock Provides Date & Time Information for Event
Logging
- Removable Memory Module Easy Field Upgrades to System
Program

Graphical Operator Interface Mounted on Drive Enclosure Door

- Rockwell Automation PanelView Plus 600
- 5.5 Color Touch Screen Display
- NEMA 4X / IP65 Rated
- Used for Operator Control, Monitoring, and Machine Set Up
- Displayed Values are Scaled and Displayed in Engineering Units

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AUTOMATED PUMP STARTUP CONTROL

The following will describe the startup sequence for general SPS applications.
These steps are sequential.
-

System Start
o A Start command is issued either manually using the start pushbutton provided on the Graphical Operator Interface or via a
customer provided contact closure.

Charge Pump Operation

o Once a Start command is received the Charge Pump Startup
permissives will be checked. After the required Charge Pump
Startup permissives are met, the Charge Pump Run Output will
be activated to start the Charge Pump.
Charge Pump Startup permissives:
Assigned Analog Input point must be <= or >= a
specified value for a specified amount of time.
Assigned Digital Input point must be in its normal
state
o For applications without a Charge Pump the Charge Pump
Startup routine can be disabled

Main Motor Start Sequence

o If the Charge Pump Startup routine is enabled, the Main Motor
Start Sequence will not be executed until the Charge Pump Run
Output is active
o Main Motor Start Permissives:
Assigned Analog Input point must be <= or >= a specified
value for a specified amount of time (generally this input
is Suction Pressure and Suction Pressure must be
greater than a specified value for a specified amount of
time.
Assigned Digital Input point must be in its normal state
o Lube Oil Pump Operation
Once the above permissives are met for Main Motor
Startup, the Lube Pump Start Output is activated, starting
the Lube Oil Pump.
Once Lube Oil Pressure Input point reaches its normal
state, the systems waits for 5 seconds and the Main
Motor is started

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THE FOLLOWING FLOW CHART DEPICTS A TYPICAL SPS SYSTEM STARTUP SEQUENCE.

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I/O MONITORING SYSTEM PROTECTION AND CONTROL

Digital Inputs 24 Vdc
-

Dedicated Digital Inputs

o Start/Stop Inputs
Momentary Pushbuttons or customer supplied contact
closure to trigger automatic startup sequence
o Local/Remote Inputs
Local Control
Drive Speed is controlled manually through the
drive (Not by PLC)
Automated Pump Startup Sequence Control
remains active
PLC I/O Monitoring and Protection functions
remain active
Remote Control
Drive Speed is controlled by PLC
Automated Pump Startup Sequence Control is
functional
PLC I/O Monitoring and Control is functional
o Lube Pump Pressure Switch Input
Shuts down drive on loss of Lube Pressure

Configurable Digital Inputs

o 8 Programmable Inputs are available for application dependent
functions. Typical Inputs include:
Excessive Vibration Switch
Motor Winding Temperature Switch
Bearing Temperature Switch(s)
Charge Pump Pressure Switch
Charge Pump On / Lube Pump On
Tank Level Switches
External Fault
Emergency Stop
o Each Digital Input is independently configurable:
NO or NC Contact
Enable (Start) Time Delay
Trip Time Delay
Maximum Number of Restart Attempts
Restart Time Delay
o Alarm Action (Alarm or Shutdown)

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Digital (Relay) Outputs

-

Charge Pump Run Output

Lube Pump Run Output
Main Motor Run Output
Three additional programmable outputs are available

Analog Inputs (4 to 20 ma standard, 0 to 10 Vdc optional)

-

Dedicated Analog Inputs

o Suction Pressure
o Discharge Pressure

Configurable Analog Inputs

o 6 Additional Programmable Inputs are available for application
dependent functions. Typical Inputs include:
Thrust Chamber Temperature
Motor Bearing Temperature
Mass Flow

Each Input is independently configurable

o High or Low Threshold Limit
o Enable (Start) Time Delay
o Trip Time Delay
o Maximum Number of Restart Attempts
o Restart Time Delay
o Alarm Action (Bypass or Fault)

Analog Outputs (0 to 10 Vdc standard, 4 to 20 mA optional)

-

2 Programmable Analog Outputs

Typical: Output based on PID Control Algorithm
o Operator Setpoint
o Selected Analog Input

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SYSTEM SETUP

MAIN MENU

On boot the system will display the Main Menu. The main menu is used to
navigate through the system.
If the user is not logged in, the SETUP button will NOT be visible. Access to the
Setup Menu can be restricted only to personnel who have access.
To log into the system, or change the password, press the LOG IN button on the
screen.

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LOG IN

Touch the Password box to open the numeric entry screen and enter the 4 digit
password. From the factory the password is zero. Press the Log In button after
the 4 digit password is entered. You will now be able to enter your own
password. If no password protection is needed, the password can be left at zero.

When the user is logged in the password can then be changed. Press the New
Password box to enter a new 4 digit password and press the UPDATE
PASSWORD button to change.
Press the BACK button to return to the Main Menu.
SETUP MENU
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The Setup Menu is used to access the I/O configuration screens. Press the
DISCRETE I/O button to access the Digital Inputs and Outputs configuration
screens.

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DISCRETE I/O MENU

The Digital I/O setup screens are accessed through the Digital Setup screen.
Press the DIGIN 1 button to configure Digital Input 1. After the Description is
changed in the configuration screen, the button on the Digital Setup screen will
change to show the description of the input.
The Digital Outputs are accessed through either of the Outputs Buttons. All the
digital outputs are configured on one screen.
Press the BACK button to return to the Setup Menu.

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DIGITAL INPUTS SCREEN

Digital inputs 1 thru 4 are user configurable. Digital inputs 0, 5, 6, and 7 are
preconfigured for Start Push Button Input, Lube Pressure Switch, Local/Remote
Switch and Stop Push Button.
Digital inputs 1 through 4 are each configured in their own screen.
Press the Description box to enter a new description for the input. The
description can be up to 16 characters long.
Press the NORMALLY CLOSED/NORMALLY OPEN button to toggle the input
operation between a normally closed input and a normally open input.
The Enable Delay is the amount of time after the system has been placed in
SEQUENCE START that the system waits to evaluate the input for an Alarm or
Shutdown of the system. The enable delay must be set to at least 1 sec to
enable the input in the system.
The Trip Delay is the amount of time after the input changes state before it trips
the alarm or shuts down the system.

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After the main motor has shutdown from this input, the Restart Delay is the
amount of time the system will wait before restarting the main motor. This delay
is in minutes.
The Max Restarts are the number of restarts the system will automatically allow.
After the max restarts have been exceeded the system must be restart by an
operator.
Press the ALARM/SHUTDOWN button to toggle between shutdown of the motor
and alarm only operation of this input.

DIGITAL OUTPUTS SCREEN

The Charge Pump and Lube Pump are preconfigured and operate with
permissives as stated in the Automated Startup flow chart. Outputs 3 and 4
operate with permissives which are evaluated after the system is placed in
SEQUENCE START.
Press the >=/<= Button to toggle between a less than or greater than comparison
to the selected analog input. Press the Analog # box to select an analog input for
comparison. Set the Analog # to zero to disable the comparison function.
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Press the Discrete # box to select a digital input to trigger the digital output.
Select the Seconds box to set the amount of time after the system has been in
SEQUENCE START mode before evaluating the trigger input.

ANALOG INPUTS SCREEN

The system has 8 user configurable analog inputs. Select the analog input you
want to configure from the Analog Inputs Menu.
Once the description has been changed in the setup screen, the button in the
Analog Inputs menu will change to show the description of the input.

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ANALOG INPUT CONFIGURATION SCREEN

Press the Description box to enter a new description for the input. The
description can be up to 16 characters long. Press the Units box to enter the
units for the input.
The Span and Offset are used to set the zero and span for the input. Set the
Span to the number equivalent to a 20 mA signal level. Set the Offset to the
number equivalent to 4 mA. These numbers can then be adjusted up or down if
needed to adjust the signal to match the actual process being measured.
The Lo Limit and Hi Limit are the comparison values for the analog input to
trigger a system shutdown or alarm. The limit must be greater than zero to
enable the comparison.
The Enable Delay is the amount of time after the system has been placed in
SEQUENCE START that the system waits to evaluate the input for an Alarm or
Shutdown of the system.
The Trip Delay is the amount of time after the input has exceeded the limit
before it trips the alarm or shuts down the system.

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After the main motor has shutdown from this input, the Restart Delay is the
amount of time the system will wait before restarting the main motor. This delay
is in minutes.
The Max Restarts are the number of restarts the system will automatically allow.
After the max restarts have been exceeded the system must be restart by an
operator.
Press the ALARM/SHUTDOWN button to toggle between shutdown of the motor
and alarm only operation of this input.

ANALOG OUTPUT CONFIGURATION SCREEN

The system has two, 0-10 Vdc analog outputs. Analog output 1 is preconfigured
for drive speed. The level of the output is copied over Ethernet to the speed
reference of the P7 drive. If a different drive is used, the analog output should be
wired to the analog input on the drive to control the drive speed.

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The outputs can be preset to a defined value by selecting the MANUAL

checkbox. The value is set in percent of full scale, 0 being 0 Vdc and 100 being
10 Vdc. Set the desired signal level in the OUTPUT ADJUST box.
To configure an output to be evaluated through the PID loop, an analog input
must be defined in the INPUT # box. Set the Setpoint in the SETPOINT box. It
must also be set in the 0-100% range.
To set up the PID loop to operate in reverse acting mode, (increasing analog
input causes the output to increase), select the REVERSE ACTING box.
Press the TUNE button to access the tuning parameters for the PID loops.

PID TUNING SCREEN

Use the PID tuning screen to change the P, I and D terms of the PID loops. The
deadband for the feedback analog input can also be changed from this screen.

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PUMP CONTROL SCREEN

The Pump Control screen is used to place the system into and out of
SEQUENCE START mode.
Press the START button to enable SEQUENCE START. Digital Input 0 is also
dedicated to a remote START pushbutton. Wire a momentary pushbutton into
DIGIN 0 to implement a remote start.
Press the STOP button to take the system out of SEQUENCE START mode.
Digital input 7 is also dedicated to a remote STOP pushbutton. Wire a
momentary pushbutton into DIGIN 7 to implement a remote stop.
When the max restarts for any input has been exceeded, use the RESTART
button to reset the system.
When an input has tripped a shutdown of the main motor, the indicator above the
buttons will display AWAITING RESTART. A timer will appear above the Reset
button displaying the time since shutdown, and the number directly above the
Reset button will display the number of shutdowns the system has experienced.
The display will also indicate if the max restarts for any input have been
exceeded.
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RUN SCREEN

The RUN screen is used to monitor the system.

Across the top of the screen is the status of the main motor, the charge pump,
and the lube oil pump. The drive output speed is also displayed in Hz.
The analog inputs are displayed in the center of the screen. Only four can be
displayed at a time. Press the AIN 1-4 button to toggle between analog inputs 14 and 4-8.
The status of the digital inputs and digital outputs are shown below the analog
inputs. The description of the inputs is displayed in a green or red box for On
and Off status.
The levels of the analog outputs are displayed at the bottom of the screen. The
levels are displayed as 0 to 100%.

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DIAGNOSTICS SCREEN

The I/O can also be monitored from the Diagnostics screen. Like the Run screen
the analog input and output values are displayed, and the status of the digital
inputs and outputs are indicated by a red or green pilot indicator.
The digital inputs are displayed from left to right: Start PB, Digin1, Digin2, Digin3,
Digin4, Press Switch, Local/Remote and Stop PB.
The digital outputs are displayed from left to right: Charge Pump, Lube Pump,
Dout3, Dout4 and Main Motor.

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DRIVE STATUS SCREEN

The drive status screen displays the information read from the drive over the
Ethernet link. If the RUN indicator displays NO COMMS, the PLC and the Drive
are not communicating over the Ethernet link.
The CURRENT FAULT AND PREVIOUS FAULT will display the last two faults in
the drives fault cue.

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ALARMS SCREEN

The Alarms screen displays alarm messages and diagnostic messages. Press
the ALARM/DIAG button to toggle between the alarm messages and the
diagnostic messages. Press the up and down arrows to move through the pages
of messages.
The system will display the last 500 messages and discard the oldest after
reaching 500.

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SYSTEM WIRING

The system I/O is wired into the PLC through the terminal block PLC TB. 24 Vdc
is available on the power terminal block for loop powered instruments.

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Digital inputs are wired in on terminals 1 thru 8. Inputs are 24 Vdc ONLY, DO
NOT wire in a 120VAC signal, you will burn out the input. Interposing relays
must be used for 120 VAC digital inputs.
Terminal 1 - momentary START PB input.
Terminal 2 Digin 1
Terminal 3 Digin 2
Terminal 4 Digin 3
Terminal 5 Digin 4
Terminal 6 Lube Pressure Switch
Terminal 7 maintained Local/Remote Switch
Terminal 8 momentary STOP PB input

Digital Outputs are wired into terminals 9 thru 20. Outputs are relay contacts.
They can be either AC or DC loads. Each output has a common and an output
terminal. Relay contacts are rated for 3 amps max. Use interposing relays for
any large loads.
Terminal 9 and 10 Charge Pump
Terminal 11 and 12 Lube Pump
Terminal 13 and 14 Dout 3
Terminal 15 and 16 Dout 4
Terminal 17 and 18 Main Motor
Terminal 19 and 20 Not used future expansion

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Because of the potentially high current surges that occur when switching
inductive load devices, such as motor starters and solenoids, the use of some
type of surge suppression to protect and extend the operating life of the
controllers output contacts is required. Switching inductive loads without surge
suppression can significantly reduce the life expectancy of relay contacts. By
adding a suppression device directly across the coil of an inductive device, you
prolong the life of the output or relay contacts. You also reduce the effects of
voltage transients and electrical noise from radiating into adjacent systems.
The following diagram shows an output with a suppression device. We
recommend that you locate the suppression device as close as possible to the
load device.

If the outputs are dc, we recommend that you use a 1N4004 diode for surge
suppression, as shown below. For inductive dc load devices, a diode is suitable.
A 1N4004 diode is acceptable for most applications. These surge suppression
circuits connect directly across the load device.

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Analog inputs are wired into terminals 21 thru 36. Analog input signals are 4 to
20 mA.
Terminal 21 and 22 Analog input 1
Terminal 23 and 24 Analog input 2
Terminal 25 and 26 Analog input 3
Terminal 27 and 28 Analog input 4
Terminal 29 and 30 Analog input 5
Terminal 31 and 32 Analog input 6
Terminal 33 and 34 Analog input 7
Terminal 35 and 36 Analog input 8

The analog outputs are wired into terminals 37 thru 40. Analog output signals
are 0-10 Vdc.
Terminal 37 and 38 Analog output 1
Terminal 39 and 40 Analog output 2

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